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Quick Reference Guide
General Information 1 j
Periodic Maintenance 2 j
Fuel System 3 j
Cooling System 4 j
Engine Top End 5 j
Lubrication System 6 j
Camshaft/Crankshaft 7 j
Starter System 8 j
Electrical System 9 j
Troubleshooting 10 j
This quick reference guide will assist
you in locating a desired topic or procedure.
•Bend the pages back to match the
black tab of the desired chapter number with the black tab on the edge at
each table of contents page.
•Refer to the sectional table of contents
for the exact pages to locate the specific topic required.
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FH451V, FH500V, FH531V
FH541V, FH580V, FH601V
FH641V, FH661V, FH680V
FH721V
4-Stroke Air-Cooled V-Twin Gasoline Engine
Service Manual
All rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise,
without the prior written permission of Quality Division/Consumer Products & Machinery Company/Kawasaki
Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible
care has been taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation
to make such changes to products manufactured previously.
All information contained in this publication is based on the latest product information available at the time
of publication. Illustrations and photographs in this publication are intended for reference use only and may
not depict actual model component parts.
© 2006 Kawasaki Heavy Industries, Ltd. 1 Edition (1):Mar. 31, 2006 (K)
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LIST OF ABBREVIATIONS
A ampere(s) lb pound(s)
ABDC after bottom dead center m meter(s)
AC alternating current min minute(s)
ATDC after top dead center N newton(s)
BBDC before bottom dead center Pa pascal(s)
BDC
BTDC before top dead center psi pound(s) per square inch
°C degree(s) Celsius r revolution
DC direct current rpm revolution(s) per minute
F farad(s) TDC top dead center
°F degree(s) Fahrenheit TIR total indicator reading
ft foot, feet
g gram(s) W watt(s)
h hour(s) Ω ohm(s)
L liter(s)
bottom dead center
PS
V
horsepower
volt(s)
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EMISSION CONTROL INFORMATION
To protect the environment in which we all live, Kawasaki has incorporated crankcase emission
(1) and exhaust emission (2) control systems (EM) in compliance with applicable regulations of
the United States Environmental Protection Agency and California Air Resources Board.
1. Crankcase Emission Control System
A sealed-type crankcase emission control system is used to eliminate blow-by gases. The
blow-by gases are led to the breather chamber through the crankcase. Then, it is led to the air
cleaner.
Oil is separated from the gases while passing through the inside of the breather chamber from
the crankcase, and then returned back to the bottom of crankcase.
2. Exhaust Emission Control System
The exhaust emission control system applied to this engine consists of a carburetor and an
ignition system having optimum ignition timing characteristics.
The carburetor has been calibrated to provide lean air/fuel mixture characteristics and opti-
mum fuel economy with a suitable air cleaner and exhaust system.
TAMPERING WITH EMISSION CONTROL SYSTEM PROHIBITED
Federal law and California State law prohibits the following acts or the causing thereof: (1) the
removal or rendering inoperative by any person other than for purposes of maintenance, repair,
or replacement, of any device or element of design incorporated into any new engine for the
purpose of emission control prior to its sale or delivery to the ultimate purchaser or while it is in
use, or (2) the use of the engine after such device or element of design has been removed or
rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below:
Do not tamper with the original emission related part:
Carburetor and internal parts
•
Spark plugs
•
Magneto or electronic ignition system
•
Fuel filter element
•
Air cleaner elements
•
Crankcase
•
Cylinder heads
•
Breather chamber and internal parts
•
Inlet pipe and tube
•
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Foreword
This manual is designed primarily for use by
trained mechanics in a properly equipped shop.
However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and
repair work. A basic knowledge of mechanics,
the proper use of tools, and workshop procedures must be understood in order to carry out
maintenance and repair satisfactorily. Whenever the owner has insufficient experience or
doubts as to his ability to do the work, all adjustments, maintenance, and repair should be
carried out only by qualified mechanics.
In order to perform the work efficiently and
to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures
before starting work, and then do the work carefully in a clean area. Whenever special tools or
equipment are specified, do not use makeshift
tools or equipment. Precision measurements
can only be made if the proper instruments are
used, and the use of substitute tools may adversely affect safe operation.
To get the longest life out of your engine:
Follow the Periodic Maintenance Chart in the
•
Service Manual.
Be alert for problems and non-scheduled
•
maintenance.
Use proper tools and genuine Kawasaki en-
•
gine parts. Genuine parts provided as spare
parts are listed in the Parts Catalog.
Follow the procedures in this manual care-
•
fully. Don’t take shortcuts.
Remember to keep complete records of main-
•
tenance and repair with dates and any new
parts installed.
How to Use This Manual
In preparing this manual, we divided the product into its major systems. These systems became the manual’s chapters. All information
for a particular system from adjustment through
disassembly and inspection is located in a single chapter.
The Quick Reference Guide shows you all
of the product’s system and assists in l ocating
their chapters. Each chapter in turn has its own
comprehensive Table of Contents.
The Periodic Maintenance Chart is located
in the General Information chapter. The chart
gives a time schedule for required maintenance
operations.
If you w ant spark plug information, for example, go to the Periodic Maintenance Chart first.
The chart tells you how frequently to clean and
gap the plug. Next, use the Quick Reference
Guide to locate the Electrical System chapter.
Then, use the Table of Contents on the first
page of the chapter to find the Spark Plug section.
Whenever you see these WARNING and
CAUTION symbols, heed their instructions!
Always follow safe operating and maintenance
practices.
WARNING
This warning symbol identifies special
instructions or procedures which, if not
correctly followed, could result in per-
sonal injury, or loss of life.
CAUTION
This caution symbol identifies special
instructions or procedures which, if not
strictly observed, could result in dam-
age to or destruction of equipment.
This manual contains four more symbols (in
addition to WARNING and CAUTION) which will
help you distinguish different types of information.
NOTE
This note symbol indicates points of par-
○
ticular interest for more efficient and con-
venient operation.
Indicates a procedural step or work to be
•
done.
Indicates a procedural sub-step or how to do
○
the work of the procedural step it follows. It
also precedes the text of a WARNING, CAU-
TION, or NOTE.
Indicates a conditional step or what action to
take based on the results of the test or inspec-
tion in the procedural step or sub-step it fol-
lows.
In most chapters an exploded view illustration
of the system components follows the Table of
Contents. In these illustrations you will find the
instructions indicating which parts require specified tightening torque, oil, grease or a locking
agent during assembly.
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GENERAL INFORMATION 1-1
General Information
Table of Contents
Before Servicing ..................................................................................................................... 1-2
Model Identification................................................................................................................. 1-4
General Specifications............................................................................................................ 1-7
1
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1-2 GENERAL INFORMATION
Before Servicing
Before starting to service the engine, carefully read the applicable section to eliminate unnecessary
work. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever necessary. Nevertheless, even a detailed account has limitations, a certain amount
of basic knowledge is required for successful work.
Especially note the following:
(1) Dirt
Before removal and disassembly, clean the engine. Any dirt entering the engine, carburetor, or
other parts, will work as an abrasive and shorten the life of engine. For the same reason, before
installing a new part, clean off any dust or metal filings.
(2) Battery Ground
Remove the ground (–) lead from the battery before performing any disassembly operations on
the equipment. This prevents:
(a)the possibility of accidentally turning the engine over while partially disassembled.
(b)sparks at electrical connections which will occur when they are disconnected.
(c) damage to electrical parts.
(3) Tightening Sequence
Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes
and tighten them to a snug fit. Then tighten them evenly, in a staggered sequence. This is to
avoid distortion of the part and/or causing gas or oil leakage. Conversely when loosening the
bolts, nuts, or screws, first loosen all of them by about a quarter of a turn and then remove them.
Where there is a tightening sequence indication in this Service Manual, the bolts, nuts, or screws
must be tightened in the order and method indicated.
(4) Torque
When torque values are given in this Service Manual, use them. Either too little or too much
torque may lead to serious damage. Use a good quality, reliable torque wrench.
(5) Force
Common sense should dictate how much force is necessary in assembly and disassembly. If
a part seems especially difficult to remove or install, stop and examine what may be causing the
problem. Whenever tapping is necessary, tap lightly using a wooden or plastic-faced mallet. Use
an impact driver for screws (particularly for the removal of screws held by a locking agent) in order
to avoid damaging the heads.
(6) Edges
Watch for sharp edges, especially during major engine disassembly and assembly. Protect your
hands with gloves or a piece of thick cloth when lifting the engine or turning it over.
(7) High-Flash Point Solvent
A high-flash point solvent is recommended to reduce fire danger. A commercial solvent commonly available in North America is Standard solvent (generic name). Always follow manufacturer
and container directions regarding the use of any solvent.
(8) Gasket, O-Ring
Do not reuse a gasket or O-ring once it has been in service. The mating surfaces around the
gasket should be free of foreign material and perfectly smooth to avoid oil or compression leaks.
(9) Liquid Gasket, Non-Permanent Locking Agent
Follow manufacturer’s directions for c leaning and preparing surfaces where these compounds
will be used. Apply sparingly. Excessive amounts may block engine oil passages and cause
serious damage. An example of a non-permanent locking agent commonly available in North
America is Loctite Lock’n Seal (Blue).
(10)Press
A part installed using a press or driver, such as a journal, should first be coated with oil on its
outer or inner circumference so that it will go into place smoothly.
(11)Ball Bearing
When installing a ball bearing, the bearing race which is affected by friction should be pushed
by a suitable driver. This prevents severe stress on the balls and races, and prevents races and
balls from being dented. Press a ball bearing until it stops at the stop in the hole or on the shaft.
(12)Oil Seal and Grease Seal
Replace any oil or grease seals that were removed with new ones, as removal generally damages seals.
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GENERAL INFORMATION 1-3
Before Servicing
When pressing in a seal which has manufacturer’s marks, press it in with the marks facing out.
Seals should be pressed into place using a suitable driver, which contacts evenly with the side of
seal, until the face of the seal is even with the end of the hole.
(13)Seal Guide
A seal guide is required for certain oil or grease seals during installation to avoid damage to
the seal lips. Before a shaft passes through a seal, apply a little oil, preferably high temperature
grease on the lips to reduce rubber to metal friction.
(14)Circlip, R etaining Ring
Replace any circlips and retaining rings that were removed with new ones, as removal weakens
and deforms them. When installing circlips and retaining rings, take care to compress or expand
them only enough to install them and no more.
(15)Cotter Pin
Replace any cotter pins that were removed with new ones, as removal deforms and breaks
them.
(16)Lubrication
Engine wear is generally at its maximum while the engine is warming up and before all the
rubbing surfaces have an adequate lubricative film. During assembly, oil or grease (whichever
is more suitable) should be applied to any rubbing surface which has lost its lubricative film. Old
grease and dirty oil should be cleaned off. Deteriorated grease has lost its lubricative quality and
may contain abrasive foreign particles.
Don’t use just any oil or grease. Some oils and greases in particular should be used only in
certain applications and may be harmful if used in an application for which they are not intended.
This manual makes reference to molybdenum disulfide grease (MoS2) in the assembly of certain
engine parts. Always check manufacturer recommendations before using such special lubricants.
(17)Electrical Wires
All the electrical wires are either single-color or two-color and, with only a few exceptions, must
be connected to wires of the same color. On any of the two-color wires there is a greater amount
of one color and a lesser amount of a second color, so a two-color wire is identified by first the
primary color and then the secondary color. For example, a yellow wire with thin red stripes is
referred to as a “yellow/red” wire; it would be a “red/yellow” wire if the colors were reversed to
make red the main color.
(18)Replacement Parts
When there is a replacement instruction, replace these parts with new ones every time they are
removed. There replacement parts will be damaged or lose their original function once removed.
(19)Inspection
When parts have been disassembled, visually inspect these parts for the following conditions
or other damage. If there is any doubt as to the condition of them, replace them with new ones.
Abrasion Crack Hardening Warp
Bent Dent Scratch Wear
Color change
(20)Specifications
Specification terms are defined as follows:
“Standards” show dimensions or performances which brand-new parts or systems have.
“Service Limits” indicate the usable limits. If the measurement shows excessive wear or deteriorated performance, replace the damaged parts.
Deterioration
Seizure
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1-4 GENERAL INFORMATION
Model Identification
Electric Starter Model-FH500V
Recoil Starter Model-FH500V
Cylinder Number Designation:
No.1 Cylinder is the left-hand cylinder viewed from the air cleaner.
No.2 Cylinder is the right-hand cylinder viewed from the air cleaner.
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GENERAL INFORMATION 1-5
Model Identification
Electric Starter Model-FH580V
Electric Starter Model-FH680V
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1-6 GENERAL INFORMATION
Model Identification
Heavy Duty Air Cleaner Type
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GENERAL INFORMATION 1-7
General Specifications
Item
Type Forced air-cooled, vertical shaft, OHV, 4-stroke gasoline engine.
Cylinder Layout 90 V-Twin
Bore × Stroke
Displacement 494 mL (30.1 cu. in.) 585 mL (35.6 cu. in.) 675 mL (41.19 cu. in.)
Direction of Rotation Counterclockwise facing the PTO shaft
Compression Release Automatic compression release
Low Idle Speed 1 550 rpm
High Idle Speed
Ignition System Transistorized-fly wheel magneto
RFI Per Canada and U.S.A. requirements
Starting System Electric starter and/or recoil starter
Charging System 12 V - 13 amps with regulator
Spark Plug CHAMPION RCJ8Y NGK BPR4ES
Carburetor Float type, fixed main jet Float type, fixed main jet, two
Fuel Pump Diaphragm type pulse pump
Air Cleaner Dual stage element, dry type/Heavy duty type
Governor Flyweight all speed governor
Lubrication System Pressure feed by positive displacement pump
Oil Filter Cartridge type full flow filter
Oil Pressure Switch ON-OFF switch (Option)
Oil Capacity (when
engine is completely
dry)
Cooling System Forced air cooling by fan
Dimensions
(L×W×H)
Electric Starter Model
Recoil Starter Model 425 mm × 359 mm ×
Dry Weight
Electric Starter Model 34 kg (75 lbs) 34 kg (75 lbs) 40.5kg(89.3lbs)
Recoil Starter Model 32 kg (71 lbs) 32 kg (71 lbs)
FH451V, FH500V,
FH531V
68 mm × 68 mm
(2.68in.×2.68in.)
3 600 rpm
1.8 L (1.9 US-qt)
425 mm × 359 mm ×
324 mm
(16.7 in. × 14.1 in. ×
12.8 in.)
361 mm
(16.7 in. × 14.1 in. ×
14.2 in.)
FH541V, FH580V
74 mm × 68 mm
(2.91 in. × 2.68 in.)
425 mm × 359 mm ×
324 mm
(16.7 in. × 14.1 in. ×
12.8 in.)
425 mm × 359 mm ×
361 mm
(16.7 in. × 14.1 in. ×
14.2 in.)
FH601V, FH641V,
FH661V, FH680V
75.2 mm × 76 mm
(2.96 in. × 2.99 in.)
barrel
458 mm × 430 mm × 381 mm
(18.0 in. × 16.9 in. × 15.0 in.)
–
–
FH721V
1.9 L
(2.0 US-qt)
41.2 kg
(90.8 lbs)
Specifications are subject to change without notice.
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PERIODIC MAINTENANCE 2-1
Periodic Maintenance
Table of Contents
Periodic Maintenance Chart ................................................................................................... 2-2
Torque and Locking Agent...................................................................................................... 2-4
Specifications ......................................................................................................................... 2-9
Special Tools .......................................................................................................................... 2-10
Periodic Maintenance Procedures.......................................................................................... 2-11
Fuel System ......................................................................................................................... 2-11
Low Idle Speed Adjustment .............................................................................................. 2-11
High Idle Speed Adjustment ............................................................................................. 2-11
Fuel System Cleanliness Inspection ................................................................................. 2-13
Element Cleaning and Inspection ..................................................................................... 2-13
Housing (Cap and Body) Inspection ................................................................................. 2-15
Engine Top End ................................................................................................................... 2-15
Cylinder Head Cleaning and Inspection............................................................................ 2-15
Valve Clearance Inspection .............................................................................................. 2-16
Valve Clearance Adjustment............................................................................................. 2-17
Valve Seat Inspection ....................................................................................................... 2-17
Valve Seat Repair ............................................................................................................. 2-18
Lubrication System .............................................................................................................. 2-20
Oil Level Inspection........................................................................................................... 2-20
Oil Change........................................................................................................................ 2-21
Oil Filter Replacement ...................................................................................................... 2-22
Oil Cooler Cleaning........................................................................................................... 2-22
Electrical System ................................................................................................................. 2-22
Spark Plug Cleaning and Inspection ................................................................................. 2-22
Spark Plug Gap Inspection ............................................................................................... 2-22
2
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2-2 PERIODIC MAINTENANCE
Periodic Maintenance Chart
To ensure satisfactory operation over an extended period of time, any engine requires normal maintenance regular intervals. The Periodic Maintenance Chart below shows periodic inspection and
maintenance items and suitable intervals. The bullet mark (
should be performed at that interval.
Some adjustments require the use of special tools or other equipment. An electronic tachometer
will facilitate setting idle and running speeds.
FH451V, FH500V, FH531V, FH541V, FH580V
OPERATION
Daily
Check and clean air inlet
screen
First
8hr.
Every
25 hr.
•
) designates that the c orresponding item
•
INTERVAL
Every
50 hr.
Every
100
hr.
Every
200
hr.
Every
250
hr.
Every
300
hr.
Every
500
hr.
Check and add engine oil
Check for fuel and oil leakage
Check for loose or lost nuts
and screws
Check battery electrolyte level
Clean air cleaner foam element
(1)
Clean air cleaner paper
element (1)
Clean cylinder and cylinder
head fins (1)
Tighten nut and sc
Change engine oil
Clean and re-gap spark plugs
Change oil filter
Change air cleaner paper
element (1)
Replace air cleaner element
(Heavy duty air cleaner model)
(1)
Check and adjust valve
♦
clearance
Clean and lap valve seating
♦
surface
rews
•
•
•
•
•
•
•
•
• •
•
•
•
•
•
•
♦
Clean combustion chambers
(1): Service more frequently under dusty conditions.
♦: These items must be performed with the proper tools. See your authorized Kawasaki Engine
Dealer for service, unless you have the proper equipment and mechanical proficiency.
•
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PERIODIC MAINTENANCE 2-3
Periodic Maintenance Chart
FH601V, FH641V, FH661V, FH680V, FH721V
INTERVAL
OPERATION
Check and clean air inlet
screen
Daily
•
First
8hr.
Every
25 hr.
Every
50 hr.
Every
100
hr.
Every
200
hr.
Every
250
hr.
Every
300
hr.
Every
500
hr.
Check and add engine oil
Check for fuel and oil leakage
Check for loose or lost nuts
and screws
Check battery electrolyte level
Clean air cleaner foam element
(1)
Clean air cleaner paper
element (1)
Replace air cleaner paper
element (1)
Replace air cleaner primary
element (Heavy duty air
cleaner model) (1)
Check air cleaner secondary
element (Heavy duty air
cleaner model) (1)
Replace air cleaner secondary
element (Heavy duty air
cleaner model) (1)
Clean cylinder and cylinder
head fins (1)
•
•
•
•
•
•
•
•
•
•
•
Tighten nut and screws
Change engine oil
Clean and re-gap spark plugs
Check and clean oil cooler fins
(FH721V model)
Change oil filter
Check and adjust valve
♦
clearance
Clean and lap valve seating
♦
surface
♦Clean combustion chambers
(1): Service more frequently under dusty conditions.
♦: These items must be performed with the proper tools. See your authorized Kawasaki Engine
Dealer for service, unless you have the proper equipment and mechanical proficiency.
• •
•
•
•
•
•
•
•
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2-4 PERIODIC MAINTENANCE
Torque and Locking Agent
The following tables lists the tightening torque for the major fasteners, and the parts requiring use
of a non-permanent locking agent or liquid gasket.
Letters used in the “Remarks” column mean:
L : Apply a non-permanent locking agent to the threads.
M : Apply a molybdenum disulfide lubricant (grease or oil) to the threads, seated surface, or washer.
O: Apply oil to the threads, seated s urface, or washer.
S: Tighten the fasteners following the specified sequence.
SS: Apply silicone sealant.
FH451V, FH500V, FH531V, FH541V, FH580V
FH451V, FH500V, FH531V,
Fastener
Fuel System
Carburetor (FH451V, FH500V, FH531V)
Choke Valve Screw
Throttle Valve Screws 1.0 0.1 9in·lb
Pilot Jet 1.7 0.17 15 in·lb
Main Jet 0.7 0.07 6in·lb
Main Air Jet 0.7 0.07 6in·lb
Main Nozzle 2.0 0.20 17 in·lb
Pilot Air Jet 0.7 0.07 6in·lb
Drain Screw 1.3 0.13 11 i n ·l b
Ground Lead Screw (Carburetor Side) 3.4 0.35 30 in·lb
Fuel Shut Off Solenoid Valve
Float Bowl Mounting Bolt 8.8 0.90 78 in·lb
Carburetor (FH541V, FH580V)
Throttle Valve Screws
Main Jet 2.3 0.23 20 in·lb
Fuel Shut off Solenoid Valve 4.5 0.46 40 in·lb
Float Chamber Mounting Screw
Governor Arm Clamp Nut 7.8 0.80 69 in·lb
Governor Shaft Plate Screws 2.0 0.20 18 in·lb
Holder Plate Nuts (Air Cleaner, Carburetor
Mounting)
Inlet Manifold Mounting Bolts 5.9 0.60 52 in·lb
Air Cleaner Body Mounting Screws 3.4 0.35 30 in·lb
Air Cleaner Body Bracket Bolts (Heavy Duty
Air Cleaner Type)
Air Cleaner Body Bracket Nuts (Heavy Duty
Air Cleaner Type)
Control Panel Mounting Bolts 5.9 0.60 52 in·lb
Cooling System
Engine Shroud Bolt (M8) 15 1.5 11
Engine Shroud Bolts (M6) 5.9 0.60 52 in·lb
Plug Bolt (Engine Shroud)
Plug Screw (Engine Shroud) 3.4 0.35 30 in·lb
FH541V, FH580V
Torque
N·m kgf·m ft·lb
0.7 0.07 6in·lb
6.9 0.70 61 in·lb
0.7 0.07 6in·lb L
4.5 0.46 40 in·lb
5.9 0.60 52 in·lb
5.9 0.60 52 in·lb
9.8 1.0 87 in·lb
5.9 0.60 52 in·lb
Remarks
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PERIODIC MAINTENANCE 2-5
Torque and Locking Agent
FH451V, FH500V, FH531V,
Fastener
Engine Top End
Cylinder Head Bolts
Valve Clearance Lock Screws 6.9 0.70 61 in·lb
Connecting Rod Big End Cap Bolts 5.9 0.60 52 in·lb O
(FH541V, FH580V) 9.8 1.0 87 in·lb O
Rocker Arm Bolts 28 2.8 20
Rocker Cover Mounting Bolts 5.9 0.60 52 in·lb
Exhaust Pipe Flange Nuts 15 1.5 11
Spark Plugs 22 2.2 16
Lubrication System
Engine Drain Plugs (Plastic) 6.9 0.70 61 in·lb
Engine Drain Plug (Metal) 20 2.0 14.5
Engine Drain Plug Joint (Plastic)
Engine Drain Plug Joint (Metal)
Oil Pressure Switch 9.8 1.0 87 in·lb SS
Oil Passage Plug 3.9 0.40 35 in·lb
Oil Pump Cover Plate Mounting Bolts 5.9 0.60 52 in·lb
Oil Filter in the text ← ←
Camshaft/Crankshaft
Crankcase Cover Bolts
Breather Chamber Cover Bolts 5.9 0.60 52 in·lb
Electrical System
Stator Coil Screws 3.4 0.35 30 in·lb
Flywheel Bolt 56 5.7 41
Fan Housing Bolts 5.9 0.60 52 in·lb
Screen Bolts
Regulator Screws 3.4 0.35 30 in·lb
Ignition Coil Bolts (Studs) 7.8 0.80 69 in·lb
Ignition Coil Bolts (Bolts) 5.9 0.60 52 in·lb
Starter Motor Mounting Bolts 15 1.5 11
Recoil Starter Mounting Nuts
Recoil Starter Retainer Screw
Spark Plugs 22 2.2 16
FH541V, FH580V
Torque
N·m kgf·m ft·lb
25 2.6 19.0
17 1.7 12.0
39 4.0 29
25 2.6 19.0
5.9 0.60 52 in·lb
5.9 0.60 52 in·lb
7.8 0.80 69 in·lb
Remarks
S
S
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2-6 PERIODIC MAINTENANCE
Torque and Locking Agent
The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and
nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the
values are for use with dry solvent-cleaned threads.
Basic Torque for General Fasteners
Threads dia
(mm)
4 2.0 0.20 17 in·lb
5 3.4 0.35 30 in·lb
6 5.9 0.60 52 in·lb
8 15 1.5 11
N·m kgf·m ft·lb
Torque
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PERIODIC MAINTENANCE 2-7
Torque and Locking Agent
The following tables lists the tightening torque for the major fasteners, and the parts requiring use
of a non-permanent locking agent or liquid gasket.
Letters used in the “Remarks” column mean:
L: Apply a non-permanent locking agent to the threads.
M: Apply a molybdenum disulfide lubricant (grease or oil) to the threads, seated surface, or washer.
O: Apply oil to the threads, seated surface, or washer.
S: Tighten the fasteners following the specified sequence.
SS: Apply silicone sealant.
FH601V, FH641V, FH661V, FH680V, FH721V
FH601V, FH641V, FH661V,
Fasteners
Fuel System
Choke Valve Screw 1.0 0.10 8.9 in·lb L
Throttle Valve Screws 1.0 0.10 8.9 in·lb L
Pilot Jet – – –
Main Jet – – -
Main Jet, Plug 19 1.9 14
Main Nozzle – – –
Main Air Jet – – –
Pilot Air Jet – – –
Drain Screw (Carburetor) 2.0 0.20 18 in·lb
Ground Lead Screw (Carburetor Side) – – –
Fuel Shut Off Solenoid Valve (Carburetor)
Float Bowl Mounting Screw (Carburetor)
Governor Arm Clamp Nut 7.8 0.80 69 in·lb
Governor Shaft Plate Screws 2.0 0.20 18 in·lb
Inlet Pipe Mounting Bolts and Nuts 5.9 0.60 52 in·lb
Inlet Manifold Mounting Bolts 5.9 0.60 52 in·lb
Air Cleaner Body Mounting Screws – – –
Air Cleaner Body Bracket Bolts (Heavy Duty
Air Cleaner Type)
Air Cleaner Body Bracket Nuts (Heavy Duty
Air Cleaner Type)
Control Panel Mounting Bolts 5.9 0.60 52 in·lb
Cooling System
Engine Shroud Bolt (M8) 15 1.5 11
Engine Shroud Bolts (M6) 5.9 0.60 52 in·lb
Plug Bolt (Engine Shroud)
Plug Screw (Engine Shroud)
Engine Top End
Cylinder Head Bolts
Valve Clearance Lock Screws
Connecting Rod Big End Cap Bolts
(For M7 × P1.0 screw thread spec.)
FH680V, FH721V
Torque
N·m
20 2.0 15
3.9 0.40 35 in·lb
5.9 0.60 52 in·lb
9.8 1.0 87 in·lb
– – –
3.4 0.35 30 in·lb
25 2.6 19
6.9 0.70 61 in·lb
21 2.1 15
kgf·m ft·lb
Remarks
S
O
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2-8 PERIODIC MAINTENANCE
Torque and Locking Agent
FH601V, FH641V, FH661V,
Fasteners
Connecting Rod Big End Cap Bolts
(For M6 × P1.0 screw thread spec.)
Rocker Arm Bolts 28 2.8 20
Rocker Cover Mounting Bolts 5.9 0.60 52 in·lb
Exhaust Pipe Flange Nuts 15 1.5 11
Spark Plugs 22 2.2 16
Lubrication System
Engine Drain Plugs (Plastic) 6.9 0.70 61 in·lb
Engine Drain Plug (Metal) 20 2.0 14.5
Engine Drain Plug Joint (Plastic)
Engine Drain Plug Joint (Metal) 39 4.0 29
Oil Pressure Switch 9.8 1.0 87 in·lb SS
Oil Passage Plug 3.9 0.40 35 in·lb
Oil Pump Cover Plate Mounting Bolts 5.9 0.60 52 in·lb
Oil Filter in the text ← ←
Oil Cooler Mounting Joint (FH721V)
Camshaft/Crankshaft
Crankcase Cover Bolts 25 2.6 19.0 S
Breather Chamber Cover Bolts 5.9 0.60 52 in·lb
Electrical System
Stator Coil Screws 3.4 0.35 30 in·lb
Flywheel Bolt 56 5.7 41
Fan Housing Bolts 5.9 0.60 52 in·lb
Screen Bolts 5.9 0.60 52 in·lb
Regulator Screws 3.4 0.35 30 in·lb
Ignition Coil Bolts (Studs) 7.8 0.80 69 in·lb
Ignition Coil Bolts (Bolts) 5.9 0.60 52 in·lb
Starter Motor Mounting Bolts
Recoil Starter Mounting N uts – – –
Recoil Starter Retainer Screw – – –
Spark Plugs 22 2.2 16
FH680V, FH721V
Torque
N·m kgf·m ft·lb
9.8 1.0 87 in·lb
17 1.7 12
44 4.5 33
15 1.5 11
Remarks
O
The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and
nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the
values are for use with dry solvent-cleaned threads.
Basic Torque for General Fasteners
Threads dia
(mm)
4 2.0 0.20 17 in·lb
5 3.4 0.35 30 in·lb
6 5.9 0.60 52 in·lb
8 15 1.5 11
N·m
Torque
kgf·m ft·lb
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PERIODIC MAINTENANCE 2-9
Specifications
Item Standard
Fuel System
Idle Speed: (1)
Low Idle Speed 1 550 r/min (rpm)
High Idle Speed 3 600 r/min (rpm)
Air Cleaner:
Type Dual stage filtration system
Pre-cleaner Foam element
Second-stage cleaner
Type Heavy duty type
Cleaner
Pre-cleaner – – Primary element
Second-stage cleaner – – Secondary element
Engine Top End
Valve Clearance:
Inlet, Exhaust 0.10 ∼ 0.15 mm (0.004 ∼ 0.006 in.)
Valve Seating Surface Angle:
Inlet, Exhaust
Valve Seating Surface Width:
Inlet, Exhaust 0.6 ∼ 0.9 mm (0.024 ∼ 0.035 in.)
Lubrication System
Engine Oil:
Type
Viscosity
Capacity 1.5 L (1.6 US qt) (When the oil filter is not removed)
Level Operating range (grid area) on dipstick
Electrical System
Spark Plug CHAMPION RCJ8Y, NGK BPR4ES
Spark Plug Gap 0.75 mm (0.030 in.)
Paper element
FH451V, FH500V,
FH531V
– Paper element –
45°
SF,SG,SH,SJorSLclass
SAE 40, SAE 30, SAE 10W-30/SAE 10W-40, or SAE 5W-20
1.7 L (1.8 US qt) (When the oil filter is removed) except FH721
1.8 L (1.9 US qt) (When the oil filter is removed) FH721
FH541V, FH580V
FH601V, FH641V,
FH661V, FH680V,
FH721V
Item Service Limit
Engine Top End
Cylinder Head Warp 0.05 mm (0.002 in.)
(1) Idle speeds may vary depending on each equipment. Refer to the equipment specification.
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2-10 PERIODIC MAINTENANCE
Special Tools
Valve Seat Cutter, 45° - 35:
57001-1116
Valve Seat Cutter, 32° - 30:
57001-1120
Valve Seat Cutter Holder Bar:
57001-1128
Valve Seat Cutter, 32° - 33:
57001-1199
Oil Filter Wrench:
57001-1249
Valve Seat Cutter Holder, 6:
57001-1360
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PERIODIC MAINTENANCE 2-11
Periodic Maintenance Procedures
Fuel System
NOTE
High and low idle speeds may vary depending on the
○
equipment on which the engine is used. Refer to the
equipment specification.
Low Idle Speed Adjustment
Disconnect all possible external loads from the engine.
•
Start and warm up the engine thoroughly.
•
WARNING
Always keep your hands clear of the moving parts.
Move the throttle lever at a dash to the idle position, and
•
hold the throttle lever on the carburetor in closed position
(turn the governor arm clockwise all the way) and adjust
the low idle speed screw [A] until the engine idles at specified speed.
For FH601V, FH641V, FH661V, FH680V, FH721V model;
•
adjust the low idle speed screw [C] with Phillips Head
Screwdriver [D] until the engine idles at specified speed.
Low Idle Speed (Carburetor idle rpm)
1450rpm
Release the throttle lever and adjust the low idle speed
•
set screw [A] on the control plate to obtain the specified
governor low idle speed.
Low Idle Speed (Governor idle rpm)
1550rpm
High Idle Speed Adjustment
NOTE
High idle speed adjustment should be made after the
○
low idle speed adjustment is performed.
CAUTION
Do not adjust high idle speed with the air cleaner
removed.
Start and warm up the engine thoroughly.
•
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2-12 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
WARNING
Always keep your hands clear of the moving parts.
Move the throttle lever at a dash to the high idle position
•
and match the lever hole position with the panel hole by
inserting 6 mm dia. pin or bolt [A].
Loosen two M6 control panel mounting bolts [B] enough
•
to move the control panel assembly.
Carefully move the control panel assembly right side [C]
•
up or down to obtain the specified high idle speed.
High Idle Speed
3600rpm
Tighten the M6 Mounting bolts.
•
Torque - Control P anel Mounting Bolts: 5.9 N·m (0.60
kgf·m, 52 in·lb)
Remove the 6 mm dia. pin or bolt.
•
Check the high idle speed, and readjust the high idle
•
speed if necessary.
CAUTION
Be sure to make the low idle speed and high idle
speed respectively correspond to those of the
equipment.
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PERIODIC MAINTENANCE 2-13
Periodic Maintenance Procedures
Fuel System Cleanline ss Inspection
WARNING
Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition
switch OFF. Do not smoke. Make sure the area is
well ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.
Remove the air cleaner (see Air Cleaner Body Removal).
•
Place a suitable container [A] under the drain screw (B)
•
on the carburetor.
Turn out the drain screw a few turns to drain the carbu-
•
retor and check if water or dirt has accumulated in the
carburetor.
For FH541V, FH580V model; remove the float bowl to
•
drain the carburetor and check if water or dirt has accumulated in the carburetor.
Tighten the drain screw.
•
Torque - [FH451V, FH500V, FH531V]
Drain Screw: 1.3 N·m (0.13 kgf·m, 11 in·lb)
[FH601V, FH641V, FH661V, FH680V, FH721V]
Drain Screw: 2.0 N·m (0.20 kgf·m, 18 in·lb)
For FH541V, FH580V model; tighten the solenoid valve
•
or float bowl mounting screw.
Torque - Solenoid Valve: 4.5 N·m (0.46 kgf·m, 40 in·lb)
Float Bowl Mounting Screw: 4.5 N·m (0.46 kgf·m,
40 in·lb)
If any water or dirt is found, clean the carburetor (see
•
Carburetor Cleaning) and fuel tank. And check the fuel
filter.
Element Cleaning and Inspection
Standard Type
FH451V, FH500V, FH531V, FH541V, FH580V Models
NOTE
In dusty areas, clean the elements more frequently than
○
the recommended intervals.
WARNING
Because of the danger of highly flammable liquids,
do not use gasoline or a low-flash point solvent to
clean the element.
Remove the foam element and the paper element.
•
Clean the foam element [A] in a bath of detergent and
•
water, and dry the element by air thoroughly before installation.
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2-14 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Clean the paper element [A] by tapping it gently on a flat
•
surface to remove dust. If the element is very dirty, re-
place it with a new one.
CAUTION
Do not use compressed air to clean the paper ele-
ment. Do not oil the paper element or the foam ele-
ment.
FH601V, FH641V, FH661V, FH680V, FH721V Models
Remove the foam and paper elements (see Air Cleaner
•
Element Removal).
Clean the foam element [A] in a bath of detergent and
•
water, and let the element air-dry thoroughly.
Clean the paper element [B] by tapping it gently on a flat
•
surface to remove dust. If the element is very dirty, re-
place it with a new one.
Heavy Duty Air Cleaner Type
For FH541V and FH580V Models
This air cleaner element is not recommended to be
cleaned, and the air cleaner element should be replaced
with a new one at the maintenance time as shown in the
maintenance chart.
NOTE
Operating in dusty condition may r equire more frequent
○
maintenance than above.
Remove the element (see Element Removal in the Fuel
•
System chapter).
Replace the element [A] every 250 hrs.
•
CAUTION
Do not wash air cleaner element. Do not oil air
cleaner element. Do not use pressurized air to clean
air cleaner element.
FH601V, FH641V, FH661V, FH680V, FH721V Models
Air cleaner elements are not recommended to be cleaned,
and each air cleaner element should be replaced with new
ones at the maintenance time as shown in the maintenance
chart.
NOTE
Operating in dusty condition may r equire more frequent
○
maintenance than above.
Remove the elements (see Element Removal in the Fuel
•
System chapter).
Replace the primary element [A] every 250 hrs.
•
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PERIODIC MAINTENANCE 2-15
Periodic Maintenance Procedures
Replace the secondary element [A] with a new one if dirty
•
when primary element is checked.
Replace the secondary element every 500 hrs.
•
CAUTION
Do not wash air cleaner elements. Do not oil air
cleaner elements. Do not use pressurized air to
clean air cleaner elements.
Housing (Cap and Body) Inspection
Clean the housing with detergent and water and dry the
•
housing thoroughly.
Check the housing for deformation or other damage.
•
Seal the housing well and permit only filtered air to reach
○
the carburetor.
If the housing is damaged, replace the housing with a new
one.
Check that no foreign material obstructs the air passage.
•
Engine Top End
Cylinder Head Cleaning and Inspection
Scrape the carbon deposits from the cylinder head and
•
the exhaust port with a suitable tool [A].
To avoid gouging, use scrapers that material will not dam-
•
age the cylinder head and the exhaust pipe.
Clean the head in a bath of high-flash point solvent and
•
dry it with compressed air.
WARNING
Clean the cylinder head in a well ventilated area,
and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. D o not use gasoline or a
low-flash point solvent to clean the cylinder head.
A fire or explosion could result.
Lay a straight edge [A] across the mating surface of the
•
cylinder head at several different points, and measure
the warp by inserting a thickness gauge [B] between the
straight edge and the cylinder head.
If the warp exceeds the service limit, repair the mating
surface. Replace the cylinder head with a new one if the
mating surface is badly damaged or warped.
Cylinder Head Warp
Service Limit: 0.05 mm (0.002 in.)
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2-16 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Check the cylinder head for cracks or other damage.
•
Cracks not visible to the eye may be detected by coating
•
the suspected area with mixture of 25% kerosene and
75% light engine oil.
Wipe the area dry and immediately apply a coating of zinc
•
oxide dissolved in wood alcohol. If a crack is present, the
coating will become discolored at the detected area.
If a crack is present in the cylinder head, replace it with a
•
new one.
Inspect the mating surface for burrs or nicks.
•
Clean and inspect the rocker arm where it touches the
•
push rod and the valve stem.
If the contact points [A] are worn or damaged, replace the
rocker arm with a new one.
Valve Clearance Inspection
NOTE
Check the valve clearance when the engine is cold (at
○
room temperature).
Remove the rocker cover (see Cylinder Head Removal).
•
Place the piston at the top dead center (TDC) of the com-
•
pression stroke by turning the crankshaft clockwise facing
the flywheel.
No.1 Cylinder:
The left projection [A] on the flywheel is faced with the
○
right leg [B] on the #1 ignition coil [C] as shown in the
figure.
Check the inlet and exhaust valves are closed completely,
○
if they are not closed, turn the flywheel one turn (360°)
clockwise and face the left projection with the right leg
again.
No.2 Cylinder:
The left projection [A] on the flywheel is faced with the
○
right leg [B] on the #2 ignition coil [C] as shown in the
figure. Follow No.1 Cylinder alignment.
Check the valve clearance.
•
Using a thickness gauge [A], measure the valve clearance
○
between the rocker arm [B] and the valve stem end.
If the valve clearance is no correct, adjust it.
Valve Clearance (when cold)
Inlet, Exhaust
0.10 ∼ 0.15 mm (0.004 ∼ 0.006 in.)
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PERIODIC MAINTENANCE 2-17
Periodic Maintenance Procedures
Valve Clearance Adjustment
Since valve repairs change the valve clearance, adjust
•
the valve clearance as specified.
Assemble the cylinder head and install the cylinder head
•
assembly on the block (see Cylinder Head Installation).
Turn the crankshaft in proper direction until the piston is at
•
the TDC of the compression stroke (as described above).
Loosen the lock screws [A] and the valve clearance ad-
•
justing nuts [B].
Insert a 0.10 mm (0.04 in.) thickness gauge [C] between
•
the rocker arm and valve stem. Tighten the adjusting
nut until the thickness gauge begins to bind between the
rocker arm and valve stem end. Sweep the thickness
gauge during this adjustment.
Valve Clearance (when cold)
Inlet, Exhaust:
Holding the adjusting nut with a spanner, tighten the lock
•
screw to the specified torque.
Torque - Valve Clearance Lock Screws: 6.9 N·m (0.70
kgf·m, 61 in·lb)
Do not overtighten the valve clearance lock screws.
•
After the valve clearance adjustment, measure the valve
•
clearance again. Readjust the valve clearance if necessary.
0.10 ∼ 0.15 mm (0.004 ∼0.006 in.)
Valve Seat Inspection
Remove the valve (see Valve Mechanism Removal/Instal-
•
lation).
Inspect the valve seats for damage.
•
If the seats are warped or distorted beyond reconditioning, replace the cylinder head with a new one.
Pitted or worn valve seats can be refaced. Lap the v alves
•
to the seats after refacing.
Coat the valve seat with machinist’s dye.
•
Push the valve into the guide.
•
Rotate the valve against the seat with a lapping tool.
•
Pull the valve out, and check the seating pattern on the
•
valve head. It must be the correct width [A] and even all
the way around.
NOTE
The valve stem and guide must be in good condition or
○
this check will not be valid.
If the valve seating pattern is not correct, repair the seat.
Valve Seating Surface Width (STD)
[FH451V, FH500V, FH531V, FH541V, FH580V]
Inlet, Exhaust
[FH601V, FH641V, FH661V, FH680V, FH721V]
Inlet
Exhaust
0.6 ∼ 0.9 mm (0.024 ∼ 0.035 in.)
0.8 ∼ 1.4 mm (0.03 ∼ 0.05 in.)
1.1 ∼ 1.6 mm (0.04 ∼ 0.06 in.)
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2-18 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Valve Seat Repair
Follow the manufacture’s instructions for use of valve seat
•
cutters
Special Tools
Inlet Valve:
57001-1116
Valve Seat Cutter 45° -
Valve Seat Cutter 32° -
Exhaust Valve:
Valve Seat Cutter 45° -
Valve Seat Cutter 32° -
Valve Seat Cutter Holder
Valve Seat Cutter Holder Bar:
If the manufacture’s instructions are not available, use the
following procedure.
Seat Cutter Operating Cares
1. This valve seat cutter is designed only for valve seat re-
pair. Do not use the valve seat cutter for other purpose.
2. Do not drop or hit the valve seat cutter, or the diamond
particles may fall off.
3. Be sure to apply engine oil to the valve seat cutter before
grinding the seat surface. Also wash off ground particles
sticking to the cutter with washing oil.
35
57001-1199
33
57001-1187
30
57001-1120
30
6 57001-1360
57001-1128
NOTE
Do not use a wire brush to remove the metal particles
○
from the cutter. It will take off the diamond particles.
4. Setting the valve seat cutter holder [A] in position, op-
erate the cutter [B] with one hand [C]. Do not apply too
much force to the diamond portion.
NOTE
Prior to grinding, apply oil to the cutter, and during the
○
operation wash off any ground particles sticking to the
cutter with washing oil.
5. After use, wash the cutter with washing oil and apply thin
layer of engine oil before storing.
Marks Stamped on the Cutter
The marks stamped on the back of the cutter represent the
following.
1
32° Cutter angle [A]
37.5
KS8B Manufactured lot number
Cutter number, selected from 1 to 12
Cutter diameter [B]
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PERIODIC MAINTENANCE 2-19
Periodic Maintenance Procedures
Operating Procedures
Clean the seat area carefully.
•
Recondition the valve seats with the valve seat cutters
•
(45°, 32°) and lap the valves.
Check the seats for good contact all the way around with
•
machinist’s dye.
Measure the seat width [A]. If it is greater than the STD
•
width, reface the seating surface.
If the valve seating pattern is not correct, repair the seat.
•
Coat the seat with machinist’s dye.
•
Fit a 45° cutter [A] to the holder and slide it into the valve
•
guide.
Resurface the valve seat with a 45° cutter, removing only
○
enough material to produce a smooth and concentric
seat.
CAUTION
Do not grind the seat too much. Overgrinding will
reduce valve clearance by sinking the valve into the
head. If the valve sinks too far into the head, it will
be impossible to adjust the clearance, and the cylinder head must be replaced. Do not turn the cutter
counterclockwise or drop it against the seat, or it
will be dulled.
Use a 32° seat cutter [A] to narrow the seat width to the
•
STD width.
Turn the seat cutter one turn at a time while pressing down
○
very lightly. Check the seat width after each turn.
CAUTION
The 32° cutter removes material very quickly.
Check the seat width frequently to prevent over
grinding.
NOTE
Keep the seat width as close as possible to the STD
○
width.
Make a light contact on the valve seat with the 45° cutter
•
to remove any possible burrs at the edge of the seat.
After resurfacing the seat, inspect for even valve seating.
•
Apply a machinist’s dye to the valve face, insert the
○
valve, and snap it closed against the seat several times.
The valve surface should show good contact all the way
around. Be sure the valve seat is centered on the valve
face. The position of the valve in the seat is evident after
lapping the valve.
If the seat does not make proper contact, lap the valve
into seat with a vacuum cap tool.
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2-20 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Coat the valve face sparingly with a fine lapping com-
•
pound.
Use the vacuum cap tool [A], to grip the top of the valve
•
[B]. Rotate the valve in a circular motion to lap the valve
to the seat.
Lift the valve slightly from the seat every 8 to 10 strokes,
•
continue lapping operation until a uniform ring appears
around entire surface of the valve face.
When lapping is completed, wash all parts in solvent to
•
remove lapping compound. Dry the parts thoroughly.
Note the position of the lapping mark on the valve face.
•
The lapping mark should appear on or near the center of
the valve face.
When the engine is assembled, be sure to adjust the valve
•
clearances (see Valve Clearance Adjustment).
Lubrication System
Oil Level Inspection
Place the engine on a level surface.
•
Remove the oil filler cap [A] and wipe its dipstick [B] with
•
a clean cloth.
Insert the dipstick into tube [C] w ithout screwing it in, then
•
check the oil level.
The oil level should be the operating range [A] (grid area)
•
on the dipstick [D].
If the oil level is “ADD” range [B], add enough engine oil
to bring oil level to the operating range [A].
CAUTION
Do not add more oil above the operating range. Ex-
cess oil w ill cause a smoking condition.
Use the same type and make of oil that is already in the
○
engine.
NOTE
If the engine oil type and make are unknown, use any
○
brand of the specified oil to top up the level in preference
to running the engine with the oil level low. Then at your
earliest convenience, change the oil completely.
If the oil level is “FULL” range [C], drain the excess oil by
loosening the drain plug.
Oil Level Gauge: Before 2002/2 produce model [E]
Oil Level Gauge: On and after 2002/2 produce model [F]
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PERIODIC MAINTENANCE 2-21
Periodic Maintenance Procedures
Oil Change
Change the oil after first 8 hours of operation. Thereafter
•
change oil every 100 hours of operation.
Start and warm up the engine to drain the oil easily.
•
Stop the engine.
•
Place the engine on a level surface.
•
Place a suitable container under the engine.
•
Remove the oil drain plug [A] and drain the oil.
•
WARNING
Be careful of hot oil when draining. It may be hot
enough to burn you severely.
Check the O-ring [B] at the oil drain plug for damage. Re-
•
place the O-ring with a new one if it is damaged.
If the oil drain plug joint is removed, tighten it.
Torque - Oil Drain Plug Joint (Plastic) :17 N·m (1.7 kgf·m,
12.0 ft·lb)
Oil Drain Plug Joint (Metal) :39 N ·m (4.0 kgf·m, 29
ft·lb)
Install the oil drain plug with the O-ring and tighten it.
•
Torque - Oil Drain Plug (Plastic) : 6.9 N·m (0.70 kgf·m, 61
in·lb)
Oil Drain Plug (Metal) : 20 N·m (2.0 kgf·m, 14.5
ft·lb)
Remove the oil filler cap and pour in the specified type
•
and the amount of oil.
Engine Oil :
Grade: SF, SG, SH, SJ or SL Class
Viscosity:
Capacity: [When the oil filter is not removed]
Check the O-ring [A] on the oil filler cap for damage. Re-
•
place the O-ring with a new one if it is damaged.
When checking the oil level, do not turn oil filler cap on
threads.
Some increase in oil consumption may be expected
○
when a multi grade engine oil (10W-30/10W-40, 5W-20)
is used. Check the oil level more frequently than recommended interval.
SAE40, SAE30, SAE10W-30/SAE10W-40,
or SAE5W-20
1.5 L (1.6 US qt)
[When the oil filter is removed]
1.7 L (1.8 US qt) ··· except FH721V
1.8 L (1.9 US qt) ··· FH721V
NOTE
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2-22 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Oil Filter Replacement
Drain the engine oil (see Oil Change).
•
Remove the oil filter [A] with the oil filter wrench [B] or
•
strap wrench.
Special Tool - Oil Filter Wrench: 57001-1249
When unscrewing the oil filter, place a suitable container
○
beneath the oil drip tray to receive oil from the oil filter and
oil passages in the engine.
Replace the oil filter [A] with a new one.
•
Apply light film of engine oil to the seal [B].
•
Install the oil filter.
•
Turn the filter until the seal contacts mounting surface [C]
○
of the engine. Then turn the filter BY HAND (S) 3/4 turn
more.
Run the engine at slow idle speed for 2 minutes.
•
While running the engine, check for oil leaks around it.
○
Stop the engine and check the oil level (see Oil Level
•
Inspection).
Oil Cooler Cleaning
Clean dirt off the outside fins with brush or with com-
•
pressed air.
Electrical System
Spark Plug Cleaning a nd Inspection
Carefully pull the plug cap from the spark plug, and re-
•
move the spark plug.
If the plug is oily or has carbon built up on it, clean the
plug using a high-flash point solvent and a wire brush or
other suitable tools.
If the spark plug electrodes are corroded or damaged, or
if the insulator is cracked replace the plug with a new one.
Use the standard spark plug or its equivalent.
Insulator [A]
Center Electrode [B]
Plug Gap [C]
Side Electrode [D]
Spark Plug G ap Inspection
Measure the gap with a wire-type thickness gauge.
•
If the gap is not correct, carefully bend the side electrode
with a s uitable tool to obtain the correct gap.
Spark Plug Gap
Standard: 0.75 mm (0.030 in.)
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FUEL SYSTEM 3-1
Fuel System
Table of Contents
Exploded View........................................................................................................................ 3-2
Specifications ......................................................................................................................... 3-14
Governor Link Mechanism...................................................................................................... 3-15
Control Panel Assembly Removal .................................................................................... 3-15
Control Panel Assembly Installation ................................................................................. 3-15
Governor Arm Removal .................................................................................................... 3-15
Governor Arm Installation ................................................................................................. 3-16
Governor Assembly Removal ........................................................................................... 3-16
Governor Assembly Installation ........................................................................................ 3-17
Governor Assembly Inspection ......................................................................................... 3-17
Governor Shaft Removal .................................................................................................. 3-17
Governor Shaft Installation ............................................................................................... 3-17
Carburetor .............................................................................................................................. 3-18
Fuel and Air Flow .............................................................................................................. 3-18
Fuel Shut Off Solenoid Valve (Electric Starter Model) ...................................................... 3-20
Low Idle Speed Adjustment .............................................................................................. 3-20
High Idle Speed Adjustment ............................................................................................. 3-20
High Altitude Operation..................................................................................................... 3-20
Main Jet Replacement ...................................................................................................... 3-20
Fuel System Cleanliness Inspection ................................................................................. 3-21
Carburetor Removal.......................................................................................................... 3-21
Carburetor Installation....................................................................................................... 3-22
Carburetor Disassembly/Assembly-FH451V, FH500V, FH531V....................................... 3-24
Carburetor Disassembly/Assembly-FH541V, FH580V ..................................................... 3-25
Carburetor Disassembly/Assembly-FH601V, FH641V, FH661V, FH680V, FH721V ......... 3-26
Carburetor Disassembly/Assembly-FH680V and FH721V Late Models........................... 3-27
Carburetor Cleaning.......................................................................................................... 3-29
Carburetor Inspection ....................................................................................................... 3-30
Fuel Shut Off Solenoid Valve Test (Electric Starter Model)............................................... 3-31
Inlet Manifold .......................................................................................................................... 3-32
Inlet Manifold Removal ..................................................................................................... 3-32
Inlet Manifold Installation .................................................................................................. 3-32
Inlet Manifold Inspection ................................................................................................... 3-33
Fuel Pump, Fuel Filter ............................................................................................................ 3-34
Fuel Pump Inspection ....................................................................................................... 3-34
Fuel Filter Inspection......................................................................................................... 3-34
Air Cleaner (Standard Type)................................................................................................... 3-35
Element Removal.............................................................................................................. 3-35
Element Removal.............................................................................................................. 3-35
Element Installation ........................................................................................................... 3-35
Element Cleaning and Inspection ..................................................................................... 3-35
Air Cleaner Body Removal................................................................................................ 3-35
Air Cleaner Body Installation............................................................................................. 3-36
Air Cleaner (Heavy Duty Type)............................................................................................... 3-38
Element Removal.............................................................................................................. 3-38
Element Installation ........................................................................................................... 3-38
Element Cleaning and Inspection ..................................................................................... 3-38
Air Cleaner Body Removal................................................................................................ 3-39
Air Cleaner Body Installation............................................................................................. 3-40
Housing (Cap and Body) Inspection ................................................................................. 3-41
3
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3-2 FUEL SYSTEM
Exploded View
[FH451V, FH500V, FH531V]
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FUEL SYSTEM 3-3
Exploded View
[FH451V, FH500V, FH531V]
1. Pilot Screw
2. Pilot Air Jet
3. Main Air Jet
4. Main Jet
5. Pilot Jet
6. Solenoid Valve
7. Out Vent Tube (Before 2003/5 Product model)
T1: 0.7 N·m (0.07 kgf·m, 6 in·lb)
T2: 1.0 N·m (0.10 kgf·m, 9 in·lb)
T3: 1.3 N·m (0.13 kgf·m, 11 in·lb)
T4: 1.7 N·m (0.17 kgf·m, 15 in·lb)
T5: 2.0 N·m (0.20 kgf·m, 17 in·lb)
T6: 3.4 N·m (0.35 kgf·m, 30 in·lb)
T7: 5.9 N·m (0.60 kgf·m, 52 in·lb)
T8: 6.9 N·m (0.70 kgf·m, 61 in·lb)
T9: 8.8 N·m (0.90 kgf·m, 78 in·lb)
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3-4 FUEL SYSTEM
Exploded View
[FH541V, FH580V]
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FUEL SYSTEM 3-5
Exploded View
[FH541V, FH580V]
1. Pilot Screw
2. Main Jet
3. Solenoid Valve
T1: 0.7 N·m (0.07 kgf·m, 6 in·lb)
T2: 2.3 N·m (0.23 kgf·m, 20 in·lb)
T3: 4.5 N·m (0.46 kgf·m, 40 in·lb)
T4: 3.4 N·m (0.35 kgf·m, 30 in·lb)
T5: 5.9 N·m (0.60 kgf·m, 52 in·lb)
L: Apply non-permanent locking agent.
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3-6 FUEL SYSTEM
Exploded View
[Heavy Duty Air Cleaner Type]
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FUEL SYSTEM 3-7
Exploded View
[Heavy Duty Air Cleaner Type]
1. Pilot Screw
2. Main Jet
3. Solenoid Valve
T1: 0.7 N·m (0.07 kgf·m, 6 in·lb)
T2: 2.3 N·m (0.23 kgf·m, 20 in·lb)
T3: 4.5 N·m (0.46 kgf·m, 40 in·lb)
T4: 5.9 N·m (0.60 kgf·m, 52 in·lb)
T5: 9.8 N·m (1.0 kgf·m, 87 in·lb)
L: Apply non-permanent locking agent.
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3-8 FUEL SYSTEM
Exploded View
[FH601V, FH641V, FH661V, FH680V, FH721V]
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FUEL SYSTEM 3-9
Exploded View
[FH601V, FH641V, FH661V, FH680V, FH721V]
1. Pilot Screw
2. Pilot Air Jet
3. Main Air Jet
4. Main Jet
5. Pilot Jet
6. Solenoid Valve
7. Out Vent Tube (Before 2003/5 Product model)
T1: 1.0 N·m (0.10 kgf·m, 9 in·lb)
T2: 3.9 N·m (0.40 kgf·m, 35 in·lb)
T3: 2.0 N·m (0.20 kgf·m, 18 in·lb)
T4: 19 N·m (1.9 kgf·m, 14 ft·lb)
T5: 20 N·m (2.0 kgf·m, 15 ft·lb)
T6: 5.9 N·m (0.60 kgf·m, 52 in·lb)
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3-10 FUEL SYSTEM
Exploded View
[Heavy Duty Air Cleaner Type]
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FUEL SYSTEM 3-11
Exploded View
[Heavy Duty Air Cleaner Type]
1. Main Jet
2. Pilot Screw
3. Solenoid Valve
R: Replacement Parts
T1: 1.0 N·m (0.10 kgf·m, 9 in·lb)
T2: 3.9 N·m (0.40 kgf·m, 35 in·lb)
T3: 2.0 N·m (0.20 kgf·m, 18 in·lb)
T4: 2.5 N·m (0.25 kgf·m, 22 in·lb)
T5: 6.9 N·m (0.70 kgf·m, 61 in·lb)
T6: 9.8 N·m (1.0 kgf·m, 87 in·lb)
T7: 5.9 N·m (0.60 kgf·m, 52 in·lb)
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3-12 FUEL SYSTEM
Exploded View
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FUEL SYSTEM 3-13
Exploded View
[FH451V, FH500V, FH531V]
T1: 5.9 N·m (0.60 kgf·m , 52 in·lb)
T2: 2.0 N·m (0.20 kgf·m , 17 in·lb)
T3: 7.8 N·m (0.80 kgf·m , 69 in·lb)
[FH541V, FH580V]
T1: 5.9 N·m (0.60 kgf·m , 52 in·lb)
T2: 2.0 N·m (0.20 kgf·m , 17 in·lb)
T3: 7.8 N·m (0.80 kgf·m , 69 in·lb)
[FH601V, FH641V, FH661V, FH680V, FH721V]
T1: 5.9 N·m (0.60 kgf·m , 52 in·lb)
T2: 2.0 N·m (0.20 kgf·m , 17 in·lb)
T3: 7.8 N·m (0.80 kgf·m , 69 in·lb)
A: Separate Choke Type
B: Associate Choke Type
O: Apply engine oil.
1. Fuel Tube for FH680V Late Model
2. Fuel Tube for FH680V Early Model
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3-14 FUEL SYSTEM
Specifications
Standard
Item
Carburetor
Specifications:
Make/Type MIKUNI B24T1 ← Walbro LMF ← Nikki 621266
Throttle Bore Diameter
Venturi Diameter
Main Jet (MJ) #125 #116.3 #100 #105 L: #122, R: #128
Pilot jet (PJ) #48.8 #43.8 #48 #50 L: #46, R: #44
Main air jet (MAJ) 1.7 1.4 #150 #110 1.7, * 1.6
Pilot air jet (PAJ) 1.2 0.8 #170 #140 1.1, * 1.4
Pilot Air Screw Turns out
(PS) (Idle Mixture Screw
Turns Out)
Float Level Float parallel to carburetor body
Idle Speed: (1)
Low Idle Speed 1 550 r/min (rpm)
High Idle Speed 3 600 r/min (rpm)
Air Cleaner:
Standard Model:
Type
Pre-cleaner Foam element
Second-stage cleaner Paper element
Heavy Duty Model:
Type – – Heavy duty type
Cleaner – – Paper element –
Pre-cleaner – – – – Primary element
Second-stage cleaner
Fuel:
Fuel Requirement Unleaded regular grade gasoline
Fuel Pump:
Type Pulse-diaphragm pump
Governor:
Type Flyweight all speed governor
FH451V,
FH500V
24 mm (0.94 in.)
16 mm (0.63 in.)
21/4 13/8 21/2 17/8 L: 2 1/4, R: 1 1/4
Dual stage filtration system
– – – –
FH531V FH541V FH580V
← ← ←
18 mm
(0.71 in.)
16 mm
(0.63 in.)
18 mm
(0.71 in.)
FH601V, FH641V,
FH661V, FH680V,
FH721V
26 mm (1.02 in.)
21 mm (0.83 in.)
*18 mm (0.71 in.)
*L: #104, R: #108
*#52
*L:3,R:21/4
Secondary
element
(1) Idle speeds may vary depending on each equipment. Refer to the equipment specification.
*: For FH680V and FH721V Late Models
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FUEL SYSTEM 3-15
Governor Link Mechanism
Control Panel Assembly Removal
Remove:
•
Air Cleaner (see Air Cleaner Body Removal)
Air Cleaner Mount Bracket Bolts [A]
Air Cleaner Mount Bracket [B]
Ground Lead (Electric Starter Model)
Control Panel Mounting Bolts [C]
Remove the control panel assembly [A] while unhooking
•
the governor spring [B] end loop at the panel bracket.
Clear the choke link rod lower end [C] from the choke
•
lever.
Control Panel Assembly Installation
Before installing the control panel assembly, check to see
•
that the choke lever [A] and engine speed control lever [B]
move smoothly in all directions.
If any part is worn or damaged, replace the control panel
assembly with a new one.
After installation, adjust the low idle speed and high idle
•
speed to the specifications (see Low Idle Speed and High
Idle Speed adjustment in the Periodic Maintenance chapter).
For separate choke type; the control panel assembly is
•
as shown in the figure.
Governor Arm Removal
Remove:
•
Control Panel Assembly
Loosen the clamp nut [A] and take off the governor arm
•
[B].
Unhook the throttle link rod spring [C] end loop and clear
•
the throttle link rod lower end [D].
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3-16 FUEL SYSTEM
Governor Link Mechanism
For FH541V, FH580V model; the governor arm is as
•
shown in the figure.
Governor Arm Installation
Install the governor arm [A] onto the governor shaft [B]
•
temporarily.
Be sure the link spring [C] around the throttle link rod [D]
•
is in place and that it pulls the governor arm and throttle
lever [E] each other.
Loosen the clamp nut [F] on the governor arm enough to
•
move the governor shaft.
Turn the top end of the governor arm counterclockwise
•
to fully open the carburetor [G] throttle valve and hold it
there.
Turn the governor shaft counterclockwise fully to the end
•
of its travel.
Tighten the clamp nut.
•
Torque - Governor Arm Clamp Nut: 7.8 N·m (0.80 kgf·m, 69
in·lb)
Be sure the governor shaft extension from the governor
•
arm is approximately 7 mm (0.3 in) [H] as shown in the
figure.
Install the control panel assembly, and connect the gov-
•
ernor arm with the governor spring.
Governor Assembly Removal
Remove the crankcase cover (see Camshaft/Crankshaft
•
chapter).
Remove the push rod (see Engine Top End chapter).
•
Remove the camshaft [A].
•
Remove:
•
Washer [A]
Snap Ring [B]
Sleeve [C]
Governor Plate [D]
Snap Ring [B]
Steel Balls [E]
Ball Guide [F]
Ball Plate [G]
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FUEL SYSTEM 3-17
Governor Link Mechanism
Governor Assembly Installation
Fit the snap ring [A] into the groove securely.
•
Turn the governor plate by hand and check that the steel
•
balls and governor plate move freely.
Governor Assembly Inspection
Visually check all governor parts for wear or damage.
○
If any parts are worm or damaged, replace them with new
ones.
Governor Shaft Removal
Split the crankcase (see Camshaft/Crankcase chapter).
•
Unscrew the governor shaft plate screws [A], and pull out
•
the governor shaft [B].
NOTE
Remove the governor shaft only if the replacement of
○
the governor shaft is necessary.
Replace the oil seal with a new one only if the lip shows
•
signs of leakage or it has been damaged.
Assemble the oil seal [A]. Be sure that the seal lip must
•
face the inside of the engine.
Press in the oil seal 0 ∼ 1.0 mm (0.04 in.) [B] flush or
•
below the crankcase cover surface [C].
Governor Shaft Installation
Apply engine oil to the governor shaft.
•
Insert the governor shaft into the crankcase.
•
Install the governor shaft plate [A] to the shaft [B] as
•
shown in the figure.
Torque - Governor S haft Plate Screws: 2.0 N·m (0.20 kgf·m,
17 in·lb)
Check that the governor shaft moves freely in its operating
•
range.
NOTE
If the oil seal is removed, install the governor shaft first,
○
then install the oil seal.
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3-18 FUEL SYSTEM
Carburetor
Fuel and Air Flow
The main system of the carburetor consists of the main jet [A], valve seat [B] main nozzle [C], and
the main air passage [D] (main air jet [E]). The main system meters fuel to the engine during moderate
to heavy load conditions. Fuel flows through the main jet and into the main nozzle, where it is joined
by air from the main air passage (main air jet). The resulting mixture flows out of the main nozzle end
into the carburetor bore, where it is atomized by the high speed air flow, and carried into the engine.
Main Fuel Flow →
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FUEL SYSTEM 3-19
Carburetor
The pilot system includes the pilot jet [F], pilot screw [G] (Idle mixture screw), pilot air jet [H], pilot
outlet [I], and the bypass holes [J]. The pilot system meters the fuel/air mixture while the engine is
idling and running under a light load. Under these conditions there is very little a ir flow through the
carburetor bore; so little that it is not enough to draw fuel through the main system of the carburetor
and to atomize it. Instead, the fuel is drawn through the pilot system, since the nearly closed throttle
valve [K] causes high speed air flow through the pilot outlet and bypass holes (even at low engine
speed).
Fuel flow in the pilot system is metered by the pilot jet. Air for better atomization is admitted via the
pilot air jet in the mouth of the carburetor. The fuel/air mixture passes into the bore of the carburetor
side stream of the throttle valve through the bypass holes and pilot outlet. While the throttle valve is
almost closed, it covers the small bypass holes opening into the bore from the pilot system. As the
throttle valve begins to open, it uncovers the bypass holes, allowing more fuel/air mixture to flow. The
extra flow is needed because the engine starts to run faster as the throttle is opened. The pilot screw
controls the amount of fuel/air mixture allowed through the pilot outlet, but does not meter the bypass
holes. A moderate amount of air comes in around the throttle valve at an idle, so adjusting the pilot
screw changes the fuel/air ratio. Turning the pilot screw (idle mixture screw) out (counterclockwise)
enriches the mixture; turning it in (clockwise) leans the mixture.
Pilot Fuel Flow ⇒
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3-20 FUEL SYSTEM
Carburetor
Fuel Shut Off Solenoid Valve (Electric Starter Model)
To avoid after firing when stopping the engine, a solenoid
actuated fuel shut off solenoid valve [A] is installed in the
carburetor bowl. The valve shuts off the fuel supply to the
valve seat [B] simultaneously when the switch key turned
to the “OFF” position.
The valve opens automatically when the switch key is
turned to the “Run” position.
Low Idle Speed Adjustment
Refer to the Low Idle Speed Adjustment in the Periodic
•
Maintenance chapter.
High Idle Speed Adjustment
Refer to the High Idle Speed Adjustment in the Periodic
•
Maintenance chapter.
High Altitude Operation
At high altitude, the standard carburetor air-fuel mixture
will be excessively rich. Performance will decrease, and
fuel consumption will increase. High altitude performance
can be improved by installing a smaller diameter main-jet in
the carburetor and adjusting the idle speed.
NOTE
The main jet high altitude kits are available for the equip-
○
ment used in the high altitude. The main jet numbers
are stamped on the ends of the main jets.
High Altitude Main Jet
Main Jet No.
FH601V
Altitude
0 ∼ 1 000 m (0 ∼ 3000ft) #125 #116.3 #100 #105 L: #122 R: #128 L: #104 R: #108
1000∼ 2000m(3000∼ 6 000 ft) #122.5 #113.8 #98 #100 L: #119 R: #125 L: #101 R: #105
2 000 m (6 000 ft) and higher #120 #111.3 #96 #98 L:# 116 R: #122 L: #98 R: #102
FH451V
FH500V
FH531V FH541V FH580V
FH641V
FH680V
FH661V
FH721V
FH680V and
FH721V Late
Models
Main Jet Replacement
Place the engine (equipment) on a level surface.
•
Close the fuel shut off valve in the equipment.
•
Drain the fuel in the carburetor completely by unscrewing
•
the drain screw at the bottom of the float chamber.
Remove the carburetor (see Carburetor Removal).
•
Unscrew the float chamber bolt [A] and take off the float
•
bowl [B].
For Electric Starter model, unscrew the solenoid valve
•
and take off the valve and gasket.
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FUEL SYSTEM 3-21
Carburetor
Using a proper standard tip screwdriver, carefully replace
•
the main jet (A) with a new one for expected altitude.
Tighten the main jet to the specified torque (see Carbure-
•
tor Disassembly Assembly Notes).
Install the float chamber, gasket and float bowl bolt.
•
For Electric Stater model, install the float chamber, gasket
•
and solenoid valve.
For FH601V, FH641V, FH661V, FH680V, FH721V model;
•
note the following.
Remove the carburetor (see Carburetor Removal).
○
Unscrew the main jet plugs [C] and take off the main jet
○
plugs and gaskets.
Make sure that “L” [L] or “R” [R] mark on the float shows
○
the main jet position.
Using a proper standard tip screwdriver, carefully replace
○
the main jet [D] with a new one for expected altitude.
Tighten the main jet to the specified torque (see Carbure-
○
tor Disassembly/Assembly).
Install the gasket and the main jet plug.
○
Torque - Main Jet Plug: 19 N·m (1.9 kgf·m, 14 ft·lb)
Fuel System Cleanline ss Inspection
Refer to the Fuel System Cleanliness Inspection in the
•
Periodic Maintenance chapter.
Carburetor Removal
WARNING
Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition
switch OFF. Do not smoke. Make sure the area is
well ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.
move:
Re
•
Air Cleaner and Related Parts (see Air Cleaner Body)
Turn the fuel shut off valve to the OFF position.
•
Drain the carburetor.
•
Disconnect the fuel tube at the fuel inlet joint [A] of the
•
carburetor.
For Electric Starter model, disconnect the solenoid valve
•
lead terminal and remove the ground terminal.
Unhook the throttle link spring [B] at the throttle s haft lever
•
top end [C] with a long nose plier.
Unhook the throttle [D] and choke link rods [E] at the top
•
ends of their arms while pulling off the carburetor.
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3-22 FUEL SYSTEM
Carburetor
For FH541V, FH580V model; see the figure.
•
For FH601V, FH641V, FH661V, FH680V, FH721V model;
•
note the following.
Unhook the throttle link spring [B] at the link clip [F] with
○
a long nose plier.
Unhook the link clip [F] and remove the throttle link rod
○
[D] and choke link rods [E] at the ends of their arms while
pulling off the carburetor.
Carburetor Installation
Clean the mating surfaces of the carburetor and inlet man-
•
ifold, and fit the new gaskets.
Install the inlet manifold, the new gaskets, the insulator,
•
the carburetor, the new gasket and the inlet pipe in the
sequence as shown.
For FH451V, FH500V, FH531 model;
•
Inlet Manifold [A]
Gaskets [B]
Insulator [C]
Carburetor [D]
Gasket [E]
Stud Bolt [F]
For FH541V, FH580V model;
•
Inlet Manifold [A]
Gaskets [B]
Insulator [C]
Carburetor [D]
Gasket [E]
Stud Bolt [F]
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FUEL SYSTEM 3-23
Carburetor
For FH601V, FH641V, FH661V, FH680V, FH721V model;
•
Inlet Manifold [A]
Gaskets [B]
Insulator [C]
Carburetor [D]
Gasket [E]
Install the air cleaner (see Air Cleaner Body Installation).
•
Take care not to bend the throttle link rod and choke link
•
rods during installation. Make sure that the link spring
around the throttle link rod is in place and that it pulls the
governor arm and carburetor throttle shaft lever toward
each other.
Be sure that the fuel tube clip ends [A] face horizontal
•
direction.
WARNING
Improper installation of the fuel inlet hose clamp
can result in gasoline leakage and potential fire hazard.
Be sure the clip ends of the hose clamp face in a
horizontal direction. In a vertical position (see illustration), the clip ends [A] can come into contact
with the inlet pipe and become loose.
Adjust:
•
Carburetor Pilot Screw
Idle Speed
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3-24 FUEL SYSTEM
Carburetor
Carburetor Disassembly/Assembly-FH451V, FH500V, FH531V
Refer to the illustration for disassembly and assembly.
•
There are several passage plugs (Ball plugs) in the car-
•
buretor body. Do not remove them.
Before disassembly, mark the out side of choke valve and
•
throttle valves for assembling them.
Replace the pilot screw with a new one if necessary in
•
accordance with the following procedure.
Carefully mark the position of the pilot screw limiter on
○
the carburetor body so that it can be installed and set to
its original position later.
Remove the limiter. Be careful not to turn the pilot screw
○
at this point.
Turn the pilot screw clockwise and count the number of
○
turns until screw is gently seated in the pilot passage.
Record the number of turns needed to close the screw.
Turn out the pilot screw to replace it with a new one.
○
Install the new pilot screw until the screw is gently
○
seated. Then open the screw the same number of turns
as recorded prior to removal.
Align the limiter with the mark on the carburetor body to
○
install, taking care not to turn the pilot screw.
Install the choke valve and throttle valve on the shaft as
•
the outside mark of them facing outside.
Drive the float pin into the carburetor body. The big diam-
•
eter side of the float pin must face the engine flange side.
The fuel inlet valve seat is pressed into the carburetor
•
body and is not replaceable.
Assemble carburetor parts with recommended tightening
•
torque (see Exploded View).
1. Limiter
2. Pilot Screw
3. Spring
4. Low Idle Speed
Screw
5. Spring
6. Seal
7. Ring
8. Throttle Shaft
9. Throttle Valve
10. Screws
11. Pilot Jet
12. Screw
13. Choke Valve
14. Choke Shaft
15. Spring
16. Collar
17. Main jet
18. Float
19. Main Nozzle
20. Valve Seat
21. Float Bowl
22. Gasket
23. Bolt (Other than Solenoid
Valve Type)
24. Gasket
25. Solenoid Valve (Electric
Starter Model)
26. Drain Screw
27. Gasket
28. Float Pin
29. Snap Ring
30. Float Valve
31. Main Air Jet
32. Air Jet
33. Washer
34. E Type Circlip
35. Cap
36. Ground Lead (Electric
Starter Model)
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FUEL SYSTEM 3-25
Carburetor
Carburetor Disassembly/Assembly-FH541V, FH580V
Refer to the illustration for disassembly and assembly.
•
There are several passage plugs (Ball plugs) in the car-
•
buretor body. Do not remove them.
Before disassembly, mark the out side of choke valve and
•
throttle valves for assembling them.
Replace the pilot screw with a new one if necessary in
•
accordance with the following procedure.
Carefully mark the position of the pilot screw limiter on
○
the carburetor body so that it can be installed and set to
its original position later.
Remove the limiter. Be careful not to turn the pilot s crew
○
at this point.
Turn the pilot screw clockwise and count the number of
○
turns until screw is gently seated in the pilot passage.
Record the number of turns needed to close the screw.
Turn out the pilot screw to replace it with a new one.
○
Install the new pilot screw until the screw is gently
○
seated. Then open the screw the same number of turns
as recorded prior to removal.
Align the limiter with the mark on the carburetor body to
○
install, taking care not to turn the pilot screw.
Install the choke valve and throttle valve on the shaft as
•
the outside mark of them facing outside.
Drive the float pin into the carburetor body. The big diam-
•
eter side of the float pin must face the choke value side.
Assemble carburetor parts with recommended tightening
•
torque (see Exploded View).
1. Limiter
2. Pilot Screw
3. Spring
4. Spacer
5. Low Idle Speed Screw
6. Spring
7. Screws
8. Throttle Valve
9. Throttle Shaft
10. Dust Seal
11. Choke Valve
12. Choke Shaft
13. Dust Seal
14. Solenoid Valve (Electric Starter Model)
15. Gasket
16. Float Bowl
17. Gasket
18. Float Pin
19. Float
20. Main Jet
21. Main Nozzle
22. Float Valve
23. Gasket
24. Screw (Other than Solenoid Valve Type)
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3-26 FUEL SYSTEM
Carburetor
Carburetor Disassembly/Assembly-FH601V,
FH641V, FH661V, FH680V, FH721V
Refer to the illustration for disassembly and assembly.
•
There are several passage plugs (Ball plugs) in the car-
•
buretor body. Do not remove them.
Before disassembly, mark the out side of choke valve and
•
throttle valves for assembling them.
1. Plug Pilot Screw
2. Pilot Screw
3. Low Idle Speed Screw
4. Spring
5. Seal
6. Collar
7. Throttle Valve
8. Screws
9. Throttle Shaft
10. Choke Valve
11. Choke Shaft
12. Seal
13. Float Valve
14. Float Pin
15. Float
16. Gasket
17. Float Bowl
18. Screw
19. Clamp
20. Plug M ain Jet
21. Gasket
22. Main J et: L
23. Main Jet: R
24. Slow Jet
25. Drain Screw
26. Spring
27. Gasket
28. Solenoid Valve
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FUEL SYSTEM 3-27
Carburetor
Carburetor Disassembly/Assembly-FH680V and FH721V Late Models
Refer to the illustration for disassembly and assembly.
•
There are several passage plugs (Ball plugs) in the car-
•
buretor body. Do not remove them.
Before disassembly, mark the out side of choke valve and
•
throttle valves for assembling them.
1. Plug Pilot Screw
2. Pilot Screw
3. Gasket
4. Cover Plate
5. Screws
6. Low Idle Speed Screw
7. Spring
8. Seal
9. Collar
10. Throttle Valve
11. Screws
12. Throttle Shaft
13. Choke Valve
14. Choke Shaft
15. Seal
16. Main Jet (L)
17. Main Jet (R)
18. O-rings
19. Gasket
20. O-ring
21. Spacer
22. Pin
23. Float Valve
24. Float
25. O-ring
26. Gasket
27. Screws
28. Gasket
29. Solenoid Valve
30. Drain Screw
31. Spring
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3-28 FUEL SYSTEM
Carburetor
Replace the pilot screw [A] with a new one if necessary in
•
accordance with the following procedure.
Remove the pilot screw plug [B] (material: Stainless steel)
○
as follows: Punch a hole in the plug and pry it out with an
awl or other suitable tool.
Turn in the pilot screw and count the number of turns until
○
it seats fully but not tightly, then remove the screw. This is
to set the screw to its original position when assembling.
Turn in the new pilot screw [A] fully but not tightly, then
○
back it out the same number of turns counted during disassembly.
Install a new pilot screw plug [B] in the pilot screw hole by
○
pressing with the rod [C], and apply a small amount of a
bonding agent [D] around the plug to fix the plug.
Install the choke valve and throttle valve on the shaft as
•
the outside mark of them facing outside, and apply a small
amount of a bonding agent to the valve screw threads.
CAUTION
Do not apply too much bonding agent to the valve.
Screws themselves may be fixed.
Drive the float pin into the carburetor body. The big side
•
of the float pin must face the throttle shaft lever side.
The fuel inlet valve seat is pressed into the carburetor
•
body and is not replacable.
Assemble carburetor parts with specified tightening
•
torque (see Exploded View).
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FUEL SYSTEM 3-29
Carburetor
Carburetor Cleaning
WARNING
Clean the carburetor in a well ventilated area, and
take care that there is no sparks or flame anywhere
near the working area; this includes any appliance
with a pilot light. Because of the danger of highly
flammable liquids, do not use gasoline or low-flash
point solvents to clean the carburetors.
CAUTION
Do not use compressed air on an assembled carburetor, or the floats may be crushed by the pressure.
Remove as many rubber or plastic parts as possible from the carburetor before cleaning the carburetor with a cleaning solution. This will prevent from
damage or deterioration of the parts.
The carburetor body has plastic parts that cannot be removed. Do not use a strong carburetor
cleaning solution which could attack these parts;
instead, use a mild high-flash point cleaning solution safe for plastic parts.
Do not use wire or any other hard instrument to
clean carburetor parts, especially jets, as they may
be damaged.
Disassemble the carburetor.
•
Immerse all the carburetor metal parts in a carburetor
•
cleaning solution and clean them.
Rinse the parts in water and dry them with compressed
•
air.
Do not use rags or paper to dry parts. Lint may plug the
•
holes or passages.
Blow air through the holes and fuel passages with the
•
compressed air. All holes must be open.
Assemble the carburetor.
•
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3-30 FUEL SYSTEM
Carburetor
Carburetor Inspection
WARNING
Gasoline is extremely flammable and can be explosive under certain. Turn the ignition switch OFF. Do
not smoke. Make sure the area is well ventilated
and free from any source of flame or sparks; this
includes any appliance with a pilot light.
Inspect the carburetor body for damage. Flange sealing
•
surfaces should be smooth and free of burns and nicks.
Replace the gasket with a new one if necessary.
Turn the throttle and choke shafts to check that the throttle
•
and choke butterfly valves move smoothly.
If the valves do not move smoothly, replace the carburetor
body and/or throttle shaft and choke shaft assembly with
new ones.
Check the gasket on the carburetor body.
•
If the gasket is not in good condition, replace it with a new
one.
Check the other parts of the carburetor for any wear or
•
damage. Replace the part with a new one if necessary.
Clean and check the float level as follows.
•
CAUTION
Do not push do wn on the float during float level
checking.
With the float [A] assembly installed onto the carburetor
•
body [B], hold the carburetor upside down at eye level.
Gently support the float with a finger and bring it down
slowly so that the float arm tab [C] just touches the float
valve [D]. The float lower surface [E] should be parallel
with the c arburetor body mating surfaces [F].
If the float position is not correct, replace the float with a
new one.
Inspect the float valve for excessive wear or damage. The
•
tip should be smooth, without any grooves, scratches, or
tears. The rod at the other end of the needle should move
smoothly when pushed in and released.
If either the needle or the seat is worn or damaged, replace the float assembly and carburetor body as a set with
a new one.
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FUEL SYSTEM 3-31
Carburetor
Inspect the tapered portion [A] of the pilot screw [B] for
•
wear or damage.
If the pilot screw is worn or damaged on the taper portion,
replace it with a new one.
Check the spring condition, replace it with a new one if
•
necessary.
For FH601V, FH641V, FH661V, FH680V, FH721V model;
•
the pilot screw is as shown in the figure.
Fuel Shut Off Solenoid Valve Test (Electric Starter Model)
Unscrew the fuel shut off valve and remove the valve.
•
Connect a 12 VDC source to the solenoid as shown in the
•
figure.
If the actuated solenoid plunger (Needle Valve) does not
pop out when the Test Voltage is applied, replace it with
a new one.
NOTE
If necessary, push the plunger slightly for the plunger to
○
withdraw.
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3-32 FUEL SYSTEM
Inlet Manifold
Inlet Manifold Removal
Remove:
•
Air Cleaner (see Air Cleaner Body Removal)
Engine Upper Cover
Cut off the band [A] and release the harness and/or lead
•
from the inlet manifold.
Unscrew the manifold mounting bolts [B].
•
Then lifting up the inlet manifold middle section [A] then
•
pull out the inlet manifold from the carburetor [B] as shown
in the figure.
Inlet Manifold Installation
Replace the inlet manifold gaskets with new ones.
•
Clean the mating surfaces of the cylinders and inlet man-
•
ifolds and fit new gaskets [A].
[B] D istance (FH451V, FH500V, FH531V): 6 mm (0.24
in.)
[B] Distance (FH541V, FH580V): 0 mm (0 in.)
[B] Distance (FH601V, FH641V, FH661V, FH680V,
FH721V): 12 mm (0.47 in.)
Clean the mating surfaces of the carburetor and inlet man-
•
ifolds and install the new gaskets [A] and insulator [B] in
the sequence as shown in the figure.
Install the inlet manifold.
•
Tighten the mounting bolts.
•
Torque - Inlet Manifold Mounting Bolts: 5.9 N·m (0.60
kgf·m, 52 in·lb)
Install and tighten the band [A] around the manifold [B]
•
and the lead [C] and/or the harness [D].
Position the lead and/or the harness on top of the manifold
○
as shown in the figure.
Cut the excessive band off.
•
Install the other removed parts in the reverse order of the
•
disassembly.
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FUEL SYSTEM 3-33
Inlet Manifold
Inlet Manifold Inspection
Inspect the inlet manifold for cracks or porous casting.
•
Cracks not visible to the eye may be detected by using a
•
metal crack detection system (Visual color check: commonly found at automotive parts stores).
If a crack is present in the inlet manifold, replace it with a
new one.
Inspect the gasket surfaces for burns and nicks.
•
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3-34 FUEL SYSTEM
Fuel Pump, Fuel Filter
The fuel pump cannot be disassembled. If any damage
of the pump is noticed replace it with a new one.
Fuel Pump Inspection
Check the vent hole [A] and the filter [B] for plugging or
•
clogging.
If the vent hole and the filter are plugged or clogged, remove the foreign material from them.
Fuel Flow Test:
WARNING
Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition
switch OFF. Do not smoke. Make sure the area is
well ventilated and free from any source of flame
or sparks; this includes any appliance with a pilot
light.
Disconnect the fuel pump outlet nozzle from the tube.
•
Connect a suitable hose [A] to the outlet nozzle.
•
Run the lower end of the hose into a container.
•
Start the engine. Check the fuel flow.
•
If fuel flow is none or little, replace the fuel pump with a
new one.
Check the tubes and the fuel filter for clogging or damage.
Replace the clogged or damaged tubes of fuel filter with
new ones.
Fuel Filter Inspection
Visually inspect the fuel filter [A].
•
If the filter is clear with no signs of dirt or other contamination, replacement of the fuel filter is not necessary.
If the filter is dark or looks dirty, replace it with a new one.
Also check the rest of the fuel system for contamination.
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FUEL SYSTEM 3-35
Air Cleaner (Standard Type)
Element Removal
FH451V, FH500V, FH531V, FH541V, FH580V
Pull the hooks [A] to outside and remove the air cleaner
•
cover [B].
Remove:
•
Wing Bolt [A]
Foam Element [B]
Paper Element [C]
Element Removal
FH601V, FH641V, FH661V, FH680V, FH721V
Remove
•
Air Cleaner Case Nut
Air Cleaner Case
Wing Nut [A]
Foam Element [B]
Paper Element [C]
Element Installation
Install the element correctly on the air cleaner body.
•
Be sure to install the paper element into the air cleaner
•
body.
Be sure to install the foam element on the paper element.
•
Element Cleaning and Inspection
Refer to the Element Cleaning and Inspection in the Pe-
•
riodic Maintenance chapter.
Air Cleaner Bod y Removal
FH451V, FH500V, FH531V, FH541V, FH580V
Remove the elements (see Element Removal).
•
Remove the air cleaner body mounting screws [A], the
•
holder plate nuts [B] and the holder plate [C].
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3-36 FUEL SYSTEM
Air Cleaner (Standard Type)
Pull the breather tube [A] off the pipe at the back of the
•
body, and remove the air cleaner body [B].
FH601V, FH641V, FH661V, FH680V, FH721V
Remove the element (see Element Removal).
•
Remove the clamp [A], and pull off the breather tube [B].
•
Loosen the nuts [C] and remove the solenoid valve lead
•
[D].
Unscrew the bolts [E] and remove the inlet pipe [F].
•
Air Cleaner Body Installation
FH451V, FH500V, FH531V, FH541V, FH580V
Connect the breather tube from the crankcase to the pipe
•
at the back of the air cleaner body.
Tighten the holder plate nuts and the air cleaner body
•
mounting screws.
Torque - Holder Plate Nuts: 5 .9 N·m (0.60 kgf·m, 52 in·lb)
Air Cleaner Body Mounting Screws 3.4 N·m (0.35
kgf·m, 30 in·lb)
FH601V, FH641V, FH661V, FH680V, FH721V
Replace the inlet pipe gaskets with new ones.
•
Clean the mating surfaces of the carburetor and the inlet
•
pipe.
Install the inlet pipe and solenoid valve lead.
•
Tighten the mounting bolts and nuts.
•
Torque - Inlet Pipe Mounting Bolts and N uts: 5.9 N·m (0.60
kgf·m, 52 in·lb)
Install the sleeve on the inlet pipe.
•
Press in the sleeve [A] to the inlet pipe [B] fixing the groove
•
[C] to the projection [D] as shown in the figure.
Connect the breather tube to the pipe at the inlet pipe and
•
clip it with a clamp.
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FUEL SYSTEM 3-37
Air Cleaner (Standard Type)
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3-38 FUEL SYSTEM
Air Cleaner (Heavy Duty Type)
Element Removal
Unhook the two retaining clamps [A] and remove the cap
•
[B] from the air cleaner body.
Remove:
•
Primary Element [A]
Secondary Element [B]
For FH541V, FH580V
Remove:
•
Element [A]
Element Installation
Slide the secondary element and primary element into
•
place in the air cleaner body.
Install the cap [A] direction as shown.
•
Mark [B]
Upside [C]
Fasten the two retaining clamps [D].
•
For FH541V, FH580V
Slide the element into place in the air cleaner body.
•
Install the cap [A] direction as shown.
•
Mark [B]
Upside [C]
15° [D]
Fasten the two retaining clamps [E].
•
Element Cleaning and Inspection
Refer to the Element Cleaning and Inspection in the Pe-
•
riodic Maintenance chapter.
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FUEL SYSTEM 3-39
Air Cleaner (Heavy Duty Type)
Air Cleaner Bod y Removal
Remove the air cleaner elements (see Element Re-
•
moval).
Loosen the clamps [A], and remove the inlet hose [B].
•
Remove the bolt [C].
•
Take out the air cleaner body [D] from the arrow side [E]
•
in the figure.
Air Cleaner Body Bracket Bolts [F]
Air Cleaner Body Bracket [G]
For FH541V,FH580V
Clamps [A]
Inlet Hose [B]
Bolt [C]
Air Cleaner Body [D]
Arrow Side [E]
Air Cleaner Body Bracket Bolts [F]
Air Cleaner Body Bracket [G]
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3-40 FUEL SYSTEM
Air Cleaner (Heavy Duty Type)
Air Cleaner Body Installation
Install the air cleaner body bracket with the bolts to the
•
specified torque.
Torque - Air Cleaner Body Bracket Bolts: 5.9 N·m (0.60
kgf·m, 52 in·lb)
Set the air c leaner body [A] onto the bracket so that the
•
air inlet duct [B] is facing upward.
Install the inlet hose [C], and position the clamps [D] pinch
•
heads as shown.
Install the air cleaner body clamp bolt [A] as shown and
•
tighten it.
Collar [B]
Spring [C]
Nut [D]
Install the air cleaner elements (see Element Installation).
•
Install the cap as shown.
•
For FH541V,FH580V
Air Cleaner Body [A]
Air Inlet Duct [B]
Inlet Hose [C]
Clamps [D]
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FUEL SYSTEM 3-41
Air Cleaner (Heavy Duty Type)
Air Cleaner Body Clamp Bolt [A]
Collar [B]
Spring [C]
Nut [D]
15° [E]
Housing (Cap and Body) Inspection
Refer to the Housing (Cap and Body) Inspection in the
•
Periodic Maintenance chapter.
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COOLING SYSTEM 4-1
Cooling System
Table of Contents
Exploded View........................................................................................................................ 4-2
Cooling Fan ............................................................................................................................ 4-4
Cooling Fan Removal ....................................................................................................... 4-4
Cooling Fan Installation .................................................................................................... 4-4
Cooling Fan Inspection ..................................................................................................... 4-4
Screen Clearance Adjustment .......................................................................................... 4-4
4
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4-2 COOLING SYSTEM
Exploded View
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COOLING SYSTEM 4-3
Exploded View
[FH451V, FH500V, FH531V]
T1: 3.9 N·m (0.40 kgf·m, 35 in·lb)
T2: 5.9 N·m (0.60 kgf·m, 52 in·lb)
T3: 17 N·m (1.7 kgf·m, 12.0 ft·lb)
T4: 56 N·m (5.7 kgf·m, 41 ft·lb)
T5: 7.8 N·m (0.80 kgf·m, 69 in·lb)
[FH541V, FH580V]
T1: 3.9 N·m (0.40 kgf·m, 35 in·lb)
T2: 5.9 N·m (0.60 kgf·m, 52 in·lb)
T3: 17 N·m (1.7 kgf·m, 12.0 ft·lb)
T4: 56 N·m (5.7 kgf·m, 41 ft·lb)
T5: 7.8 N·m (0.80 kgf·m, 69 in·lb)
[FH601V, FH641V, FH661V, FH680V, FH721V]
T1: 3.9 N·m (0.40 kgf·m, 35 in·lb)
T2: 5.9 N·m (0.60 kgf·m, 52 in·lb)
T3: 17 N·m (1.7 kgf·m, 12.0 ft·lb)
T4: 56 N·m (5.7 kgf·m, 41 ft·lb)
T5: 7.8 N·m (0.80 kgf·m, 69 in·lb)
1. Stud (Before 2002/4 Product Model)
2. Stud (On and after 2002/5 Product Model)
3. Cooling Fan (Late Model)
4. Cooling Fan (Early Model)
A: Recoil Starter Model
B: Electric Starter Model
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4-4 COOLING SYSTEM
Cooling Fan
Cooling Fan Removal
Refer to the Flywheel Removal in Electrical System chap-
•
ter.
Cooling Fan Installation
Refer to the Flywheel Installation in Electrical System
•
chapter.
Cooling Fan Inspection
Visually inspect the blades [A] in the cooling fan [B].
•
If they have any crack, warp or damage, replace the cooling fan with a new one.
If any mud or dust have stuck to the cooling fan, clean it.
Wash the cooling fan in detergent and water.
•
CAUTION
Do not clean the cooling fan in oil solvent. It may
be damage by oil solvent.
Screen Clearance Adjustment
Check the clearance between the screen [A] and the fan
•
housing [B]. If the clearance is less than 1 mm (0.04 in.),
add proper number of the spacer [C] between the screen
and the bracket comp [D] to adjust the clearance [G] 1 ∼
3 mm (0.04 ∼ 0.12 in.).
Screws [F]
Clearance 1 ∼ 3mm(0.04∼ 0.12 in.) [G]
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ENGINE TOP END 5-1
Engine Top End
Table of Contents
Exploded View........................................................................................................................ 5-2
Specifications ......................................................................................................................... 5-6
Cylinder Head ......................................................................................................................... 5-9
Compression Measurement.............................................................................................. 5-9
Cylinder Head Assembly Removal ................................................................................... 5-10
Cylinder Head Assembly Installation ................................................................................ 5-10
Push Rod Removal ........................................................................................................... 5-11
Push Rod Installation ........................................................................................................ 5-11
Push Rod Inspection......................................................................................................... 5-12
Valve Mechanism Removal/Installation ............................................................................ 5-12
Valves ..................................................................................................................................... 5-13
Cylinder Head Cleaning and Inspection............................................................................ 5-13
Valve Clearance Inspection .............................................................................................. 5-13
Valve Clearance Adjustment............................................................................................. 5-13
Valve Seat Inspection ....................................................................................................... 5-13
Valve Seat Repair ............................................................................................................. 5-13
Valve Head Thickness ...................................................................................................... 5-13
Valve Stem Runout ........................................................................................................... 5-13
Valve Stem Diameter ........................................................................................................ 5-13
Valve Guide Inside Diameter ............................................................................................ 5-14
Valve Spring Inspection .................................................................................................... 5-14
Cylinder, Piston....................................................................................................................... 5-15
Piston Removal................................................................................................................. 5-15
Piston Installation..............................................................................................................5-16
Piston/Cylinder Seizure..................................................................................................... 5-18
Piston Cleaning................................................................................................................. 5-19
Piston Ring and Ring Groove Wear.................................................................................. 5-19
Piston Ring End Gap ........................................................................................................ 5-20
Piston Pin, Piston Pin Hole, and Connecting Rod Wear................................................... 5-20
Piston Diameter ................................................................................................................ 5-21
Cylinder Inside Diameter................................................................................................... 5-21
Cylinder Boring and Honing .............................................................................................. 5-22
Muffler/Exhaust Pipe Installation ............................................................................................ 5-24
Muffler/Exhaust Pipe Removal.......................................................................................... 5-24
Muffler/Exhaust Pipe Installation....................................................................................... 5-24
Inspection.......................................................................................................................... 5-25
5
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5-2 ENGINE TOP END
Exploded View
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ENGINE TOP END 5-3
Exploded View
[FH451V, FH500V, FH531V]
T1: 5.9 N·m (0.60 kgf·m, 52 in·lb)
T2: 6.9 N·m (0.70 kgf·m, 61 in·lb)
T3: 25 N·m (2.6 kgf·m, 19.5 ft·lb)
T4: 28 N·m (2.8 kgf·m, 20 ft·lb)
T5: 22 N·m (2.2 kgf·m, 16 ft·lb)
[FH541V, FH580V]
T1: 9.8 N·m (1.0 kgf·m, 87 in·lb)
T2: 6.9 N·m (0.70 kgf·m, 61 in·lb)
T3: 25 N·m (2.6 kgf·m, 19.5 ft·lb)
T4: 28 N·m (2.8 kgf·m, 20 ft·lb)
T5: 22 N·m (2.2 kgf·m, 16 ft·lb)
[FH601V, FH641V, FH661V, FH680V, FH721V]
T1: 21 N·m (2.1 kgf·m, 15 ft·lb)
(For M7 × P1.0 screw thread spec.)
T1: 9.8 N·m (1.0 kgf·m, 87 in·lb)
(For M6 × P1.0 screw thread spec.)
T2: 6.9 N·m (0.70 kgf·m, 61 in·lb)
T3: 25 N·m (2.6 kgf·m, 19.5 ft·lb)
T4: 28 N·m (2.8 kgf·m, 20 ft·lb)
T5: 22 N·m (2.25 kgf·m, 16 ft·lb)
G: Apply grease.
O: Apply engine oil.
S: Follow the specified tightening sequence.
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5-4 ENGINE TOP END
Exploded View
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ENGINE TOP END 5-5
Exploded View
[FH451V, FH500V, FH531V]
T2: 15 N·m (1.5 kgf·m, 11.0 ft·lb)
[FH541V, FH580V]
T2: 15 N·m (1.5 kgf·m, 11.0 ft·lb)
[FH601V, FH641V, FH661V, FH680V, FH721V]
T2: 15 N·m (1.5 kgf·m, 11.0 ft·lb)
1. Muffler Comp for Late Models.
2. Muffler Comp for Early Models.
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5-6 ENGINE TOP END
Specifications
Item
Cylinder Head
Cylinder Compression (MIN) [390 kPa (57 psi)] (MIN) ←
Cylinder Head Warp 0.05 mm (0.002 in.)
Valves
Valve Head Thickness
Inlet, Exhaust 0.35 mm (0.014 in.) ←
Valve Stem Runout
Inlet, Exhaust 0.05 mm (0.002 in.) ←
Valve Stem Diameter
Inlet 5.95 mm (0.0234 in.) ←
Exhaust 5.93 mm (0.0233 in.) ←
Valve Clearance (Standard)
Inlet, Exhaust 0.10 ∼ 0.15 mm (0.004 ∼ 0.006 in.) ←
Valve Seating Surface Angle (Standard)
Inlet, Exhaust
Valve Seating Surface Width (Standard)
Inlet, Exhaust 0.6 ∼ 0.9 mm (0.024 ∼ 0.035 in.) ←
Valve Guide Inside Diameter
Inlet, Exhaust 6.08 mm (0.239 in.) ←
Valve Spring Free Length
Inlet, Exhaust
Rocker Arm Push Rod Runout
Inlet, Exhaust 0.5 mm (0.02 in.) ←
Cylinder, Piston
Piston Diamet
Piston Ring/Groove Clearance
Top 0.15 mm (0.006 in.) ←
Second 0.12 mm (0.005 in.) ←
Piston Ring Thickness
Top, Second 1.40 mm (0.055 in.) ←
Piston Ring End Gap
Top 0.70 mm (0.028 in.) ←
Second 0.78 mm (0.031 in.)
Oil 1.05 mm (0.041 in.) ←
Piston Pin Outside Diameter 15.96 mm (0.628 in.) ←
Piston Pin Hole Inside Diameter 16.08 mm (0.633 in.) ←
Connecting Rod Small End Inside
Diameter
Cylinder Inside Diameter:
Standard Cylinder 68.10 mm (2.681 in.) 74.10 mm (2.917 in.)
0.50 mm Oversize 68.60 mm (2.701 in.) 74.60 mm (2.937 in.)
Cylinder Inside Diameter Out Round 0.056 mm (0.0022 in.)
er
FH451V, FH500V, FH531V FH541V, FH580V
45°
31.0 mm (1.22 in.)
67.79 mm (2.669 in.) 73.79 mm (2.905 in.)
16.05 mm (0.632 in.)
Service Limit
←
←
←
←
←
←
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ENGINE TOP END 5-7
Specifications
Item
Cylinder Head
Cylinder Compression (MIN) [390 kPa (57 psi)] (MIN)
Cylinder Head Warp 0.05 mm (0.002 in.)
Valves
Valve Head Thickness
Inlet, Exhaust
Valve Stem Runout
Inlet, Exhaust 0.05 mm (0.002 in.)
Valve Stem Diameter
Inlet 5.95 mm (0.0234 in.)
Exhaust 5.93 mm (0.0233 in.)
Valve Clearance (Standard)
Inlet, Exhaust
Valve Seating Surface Angle (Standard)
Inlet, Exhaust 45°
Valve Seating Surface Width (Standard)
Inlet 0.8 ∼ 1.4 mm (0.03 ∼ 0.06 in.)
Exhaust
Valve Guide Inside Diameter
Inlet, Exhaust 6.08 mm (0.239 in.)
Valve Spring Free Length
Inlet, Exhaust 31.0 mm (1.22 in.)
Rocker Arm Push Rod Runout
Inlet, Exhaust 0.5 mm (0.02 in.)
Cylinder, Piston
Piston Diameter 74.99 mm (2.952 in.)
Piston Ring/Groove Clearance
Top
Second 0.16 mm (0.006 in.)
Piston Ring Thickness
Top, Second 1.40 mm (0.055 in.)
Piston Ring End Gap
Top 0.65 mm (0.026 in.)
Second 0.78 mm (0.031 in.)
Oil 1.05 mm (0.041 in.)
Piston Pin O utside Diameter 15.96 mm (0.628 in.)
Piston Pin Hole Inside Diameter
Connecting Rod Small End Inside
Diameter
Cylinder Inside Diameter:
Standard Cylinder 75.28 mm (2.964 in.)
0.50 mm Oversize 75.78 mm (2.983 in.)
Cylinder Inside Diameter Out Round 0.056 mm (0.0022 in.)
FH601V, FH641V, FH661V, FH680V, FH721V
0.35 mm (0.014 in.)
0.10 ∼ 0.15 mm (0.004 ∼ 0.006 in.)
1.1 ∼ 1.6 mm (0.04 ∼ 0.06 in.)
0.18 mm (0.007 in.)
16.08 mm (0.633 in.)
16.05 mm (0.632 in.)
Service Limit
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5-8 ENGINE TOP END
Specifications
Special Tools - Piston Ring Pliers: 57001-115
Compression Gauge, 20 kgf/cm²: 57001-221
Piston Ring Compressor Grip: 57001-1095
Piston Ring Compressor Belt,
Compression Gauge Adapter, M14 × 1.25: 5 70 0 1-1159
Valve Seat Cutter Holder Bar: 57001-1128
Valve Seat Cutter Holder,
Valve Seat Cutter, 45° Valve Seat Cutter, 32° Valve Seat Cutter, 45° Valve Seat Cutter, 32° -
35: 57001-1116
33: 57001-1199
30: 57001-1187
30: 57001-1120
67 ∼ 79: 57001-1097
6: 57001-1360
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ENGINE TOP END 5-9
Cylinder Head
Compression Measurement
Before measuring compression, check the following.
•
Be sure the battery is fully charged.
○
Thoroughly warm up the engine so that engine oil be-
○
tween the piston and cylinder wall will help sealing the
compression as it does during normal running.
Stop the engine.
○
Disconnect the spark plug caps of each cylinder and re-
•
move the spark plugs.
Attach the compression gauge assembly firmly into one
•
plug hole.
Special Tools - Compression Gauge, 20 kgf/cm²: 57001-221
[A]
Compression Gauge Adapter, M14 × 1.25:
57001-1159
Ground the spark plugs to the engine.
•
WARNING
To avoid fire, do not ground the spark plugs in proximity to the plug holes. Keep the plugs as far away
as possible from the plug holes.
Open the throttle fully. Run the engine by pulling the re-
•
coil starter grip s everal times until the compression gauge
stops rising. Read the highest compression value. (Recoil starter model)
Cylinder Compression (MIN) 390 kPa (57 psi)
Open the throttle fully. Run the engine by turning the en-
•
gine switch key several times until the compression gauge
stops rising. Read the highest compression value. (Electric starter model)
Cylinder Compression (MIN) 390 kPa (57 psi)
Repeat the measurement on the other cylinder.
•
If the compression is higher than the specified value, the
piston rings, cylinder and valves are probably in good condition.
If the compression is too high, check the following.
1. Carbon build-up on the piston crown and cylinder head
- clean off any carbon on the piston crown and cylinder
head.
2. Cylinder head gasket - use only the proper gasket. The
use of a gasket of incorrect thickness will change the
compression.
3. Valve guides and piston rings - worn valve guides and/or
worn piston oil rings may cause rapid carbon accumulation in the combustion chamber. This may be indicated
by white exhaust smoke.
If the cylinder compression is lower than the (MIN), check
the following:
1. Gas leakage around the cylinder head - replace the
damaged gasket with a new one and check the cylinder
head warp.
2. Condition of the valve seating.
3. Valve clearance.
4. Piston/cylinder wear, piston seizure.
5. Piston ring, piston ring groove.
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5-10 ENGINE TOP END
Cylinder Head
Cylinder Head Assembly Removal
Remove:
•
Air Cleaner and Carburetor (see Fuel System chapter)
Muffler (see Muffler Exhaust Pipe Removal)
Inlet Manifold (see Fuel System chapter)
Spark Plug
Unscrew the rocker cover mounting bolts [A], and remove
•
the cover [B] and the gasket.
When removing the #1, #2 cylinder head, set each pis-
•
ton at the top dead center (T.D.C) [A] of the compression
stroke.
Loosen the cylinder head bolts 1/4 turn in the sequence
•
as shown in the figure.
CAUTION
If the above procedure is not followed, the cylinder
head may be w arped during removal.
Repeat the sequence until all bolts are removed and lift
•
off the cylinder head assembly.
NOTE
Mark the push rods to reinstall in their original position
○
during assembly.
Cylinder Head Assembly Installation
Clean the mating surfaces of the cylinder heads and cylin-
•
ders.
Install the push rods in their original positions on each
•
cylinder (see Push Rod Installation).
Install the knock pins.
•
Set each piston at the T.D.C [A] of the compression
•
stroke.
Put new gaskets and the cylinder head assemblies on
•
each cylinder, then let the cylinder heads with push rods
aligned under the rocker arms.
NOTE
As the head gaskets are coated with sealing agents, be
○
careful not to damage the surfaces.
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ENGINE TOP END 5-11
Cylinder Head
Tighten the cylinder head bolts following the tightening
•
sequence in the figure.
Torque - Cylinder Head Bolts: 25 N·m (2.6 kgf·m, 19.0 ft·lb)
CAUTION
A torque wrench must be used to assure proper
torque. Improper tightening of the head bolts may
result in warping of the cylinder head.
Check and adjust the valve clearance.
•
Install the gaskets and rocker covers.
•
Torque - Rocker Cover Mounting Bolts: 5.9 N·m (0.60
kgf·m, 52 in·lb)
Install the other removed parts.
•
Push Rod Removal
Set each piston at the T.D.C of the compression stroke.
•
Remove the rocker covers (see Cylinder Head Assembly
•
Removal).
Loosen the valve clearance adjusting nuts [A].
•
Move the rocker arms [B] to clear the push rod upper
•
ends.
Pull out the push rods.
•
NOTE
Mark the push rods to reinstall in their original position
○
during assembly.
Push Rod Installation
Set each piston at the T.D.C of the compression stroke.
•
Install the push rods [A] in their original positions on each
•
cylinder.
To Install the push rod in a correct position on the tappet
○
[B], insert the push rod so that the end of the push rod
is sliding down [C] along inside wall [D] of the crankcase
and position the push rod end on to the tappet.
Check that both inlet and exhaust push rods on each
•
cylinder are at lowest position on the cam lobes [E]. If the
piston is not at the T.D.C of the compression stroke, turn
the flywheel clockwise one turn (360°) and reset each piston at the T.D.C of the compression stroke.
Be sure the end of the push rods are correctly seated on
•
the tappets.
Tighten the valve clearance adjusting nuts.
•
Check and adjust the valve clearance.
•
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5-12 ENGINE TOP END
Cylinder Head
Push Rod Inspection
Place the push rod on V blocks as far apart as possible,
•
and set a dial gauge on the rod at a halfway point between
the blocks. Turn the rod to measure the runout. The difference between the highest and the lowest dial readings
is the amount of runout.
If the runout exceeds the service limit, replace the rod with
a new one.
Rocker Arm Push Rod Runout
Service Limit: 0.5 mm (0.02 in.)
Valve M echanism Removal/Installation
Remove the cylinder head assembly (see Cylinder Head
•
Assembly Removal).
NOTE
When removing the valve mechanism parts, record their
○
position to reinstall in their original position during assembly.
Remove:
•
Valve Clearance Adjusting Nuts [A]
Rocker Arms [B]
Support the valve head in the combustion chamber with
•
a suitable block.
To remove the collets [A], push down the valve retainer
•
[B] with thumbs and remove the collets.
Remove the spring [C] and the valve [D] .
•
Remove the stem seals [A].
•
NOTE
Remove the stem seals only if the replacement of the
○
stem seals is necessary.
Valve guide [B] is not replaceable, do not remove it.
○
Valve Installation.
•
Apply engine oil to the valve stems to avoid damaging the
○
stem seals.
Check to see that the valve moves up and down smoothly
○
in the guide .
Check the valve seating surface [A] between the valve [B]
○
and the valve seat [C].
Rocker Arm Installation
•
Soak the valve clearance adjusting nuts and the rocker
○
arm in the engine oil.
Install the rocker arm.
○
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ENGINE TOP END 5-13
Valves
Cylinder Head Cleaning and Inspection
Refer to the Cylinder Head Cleaning and Inspection in the
•
Periodic Maintenance chapter.
Valve Clearance Inspection
Refer to the Valve Clearance Inspection in the Periodic
•
Maintenance chapter.
Valve Clearance Adjustment
Refer to the Valve Clearance Adjustment in the Periodic
•
Maintenance chapter.
Valve Seat Inspection
Refer to the Valve S eat Inspection in the Periodic Mainte-
•
nance chapter.
Valve Seat Repair
Refer to the Valve Seat Repair in the Periodic Mainte-
•
nance chapter.
Valve Head Thickness
Remove the valve (see Valve Mechanism Removal/Instal-
•
lation).
Measure the valve head thickness.
•
If the valve head thickness (valve margin) [A] is less than
the service limit, replace the valve with a new one.
Valve Head Thickn ess
S
ervice Limit (Inlet, Exhaust):0.35 mm (0.014 in)
Valve Stem Runout
Support the valve on V blocks at each end of the stem.
•
Position a dial gauge perpendicular to the stem.
•
Turn the valve and read the v ariation on the dial gauge.
•
If the stem runout is greater than service limit, replace the
valve.
Valve Stem Runout
Service Limit (Inlet, Exhaust): 0.05 mm (0.002 in.)
Valve Stem Diameter
Measure the diameter of the valve stem [A] in two direc-
•
tions at proper angles, at four different positions on the
stem.
If any single measured valve stem diameter is less than
the service limit, replace the valve with a new one.
Valve Ste m Diameter
Service Limit:
Inlet:
Exhaust:
5.95 mm (0.234 in.)
5.93 mm (0.233 in.)
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5-14 ENGINE TOP END
Valves
Valve Guide Inside Diameter
Use a small bore gauge or a micrometer to measure the
•
inside diameter [A] of the valve guide [B] at three positions
down the guide length.
If the measured valve diameter is greater than the service
limit, replace the cylinder head with a new one.
Valve Guide Inside Diameter
Service Limit:
Inlet, Exhaust 6.08 mm (0.2 39 in.)
Valve Spring Inspection
Inspect the valve spring for pitting, cracks, rusting, and
•
burns. Replace the spring with a new one if necessary.
Measure the free length [A] of the spring.
•
If the measured free length is less than the service limit,
replace the spring with a new one.
Valve Spring Free Length
Service Limit: 31.0 mm (1.22 in.)
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ENGINE TOP END 5-15
Cylinder, Piston
Piston Removal
Split the crankcase (see Camshaft/Crankshaft chapter).
•
Remove the camshaft (see Camshaft/Crankshaft chap-
•
ter).
Turn the crankshaft to expose the connecting rod cap
•
bolts [A].
Remove the bolts and take off the connecting rod caps
•
[B].
NOTE
Record the positions of the connecting rod caps for re-
○
installing the caps.
Push the connecting rod end into the cylinder, and pull the
•
piston and connecting rod out of the cylinder.
CAUTION
Note a location of the arrow match mark [A] on the
piston head in relation to K Mark [B] on the connecting rod.
No.1 cylinder K Mark on the connecting rod is face
to face with No.2 cylinder K Mark on the connecting
rod.
Keep parts together as a set.
Remove the piston pin snap ring [A] with needle nose
•
pliers [B].
Remove the piston by pushing the piston pin [A] to the
•
direction from which the snap ring was removed.
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5-16 ENGINE TOP END
Cylinder, Piston
Remove the top and second rings with piston ring pliers.
•
Special Tool - Piston Ring P liers: 57001-115
If the special tool is not available, carefully spread the ring
•
opening with your thumbs, then push up to the opposite
side of the ring [A] to remove it.
Remove the 3-piece oil r ing with your thumbs in the same
•
manner.
Piston Installation
Install the expander [A] in the piston oil ring groove so
•
that the expander ends [B] touch together, never overlap
them.
Install the upper and lower steel rails. There is no UP or
•
Down to the rails. They can be installed either way.
Do not mix u p the top and second rings.
•
Install the top and second rings as shown in the figure.
•
The rings s hould turn freely in the grooves.
Piston Head [A]
TopRingforF
Second Ring for F
Top R in g fo r ,
Second Ring for F
Align the piston and rings with the piston ring end gap as
•
shown in the figure.
Arrow Match Marks [A]
Top Ring End Gap, Upper Steel Rail End Gap [B]
30° ∼ 45° [C]
Second Ring End Gap, Lower Steel Rail End Gap [D]
Apply engine oil to the piston pins.
•
Assemble the pistons onto the connecting rods as follow:
•
No.1 cylinder piston; align the arrow match mark on the
piston crown with the K mark on the connecting rod.
Both marks must face the PTO side.
No.2 cylinder piston; align the arrow match mark on the
piston head with K Mark on the connecting rod to face
the magnet side.
No.1 cylinder Piston [A]
No.2 cylinder Piston [B]
Arrow Match Marks [C]
KMark[D]
Opposite K Mark [E]
H451V, 500V, 531V, 541V, 580V [B]
H451V, 500V, 531V, 54 1V, 580V [C]
FH601V, 641V, 661V, 680V, 721V [D]
H601V, 641V, 661V, 68 0V, 721V [E]
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