Kawasaki FH500V User Manual
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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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