Kawasaki FH721V User Manual

4.4 (10)
Kawasaki FH721V 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

bottom dead center

PS

horsepower

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

V

volt(s)

g

gram(s)

W

watt(s)

h

hour(s)

ohm(s)

L

liter(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 optimum 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 engine parts. Genuine parts provided as spare parts are listed in the Parts Catalog.

Follow the procedures in this manual carefully. Don’t take shortcuts.

Remember to keep complete records of maintenance 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 locating 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 want 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 personal injury, or loss of life.

CAUTION

This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage 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 particular interest for more efficient and convenient operation.

Indicatesdone. a procedural step or work to be 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 inspection in the procedural step or sub-step it follows.

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

 

 

1

Before Servicing .....................................................................................................................

1-2

Model Identification.................................................................................................................

1-4

General Specifications............................................................................................................

1-7

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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 cleaning 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, Retaining 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

Deterioration

Seizure

 

(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 deteri-

orated performance, replace the damaged parts.

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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

FH451V, FH500V,

FH541V, FH580V

FH601V, FH641V,

 

FH721V

FH531V

FH661V, FH680V

 

 

 

 

 

Type

Forced air-cooled, vertical shaft, OHV, 4-stroke gasoline engine.

Cylinder Layout

90 V-Twin

 

 

 

 

Bore × Stroke

68 mm × 68 mm

74 mm × 68 mm

75.2 mm × 76 mm

 

 

(2.68 in. × 2.68 in.)

(2.91 in. × 2.68 in.)

(2.96 in. × 2.99 in.)

 

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

3 600 rpm

 

 

 

 

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

 

 

 

barrel

 

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

1.8 L (1.9 US-qt)

 

 

 

1.9 L

engine is completely

 

 

 

 

(2.0 US-qt)

dry)

 

 

 

 

 

Cooling System

Forced air cooling by fan

 

 

 

Dimensions

425 mm × 359 mm ×

425 mm × 359 mm ×

458 mm × 430 mm × 381 mm

(L × W × H )

324 mm

324 mm

Electric Starter Model

(16.7 in. × 14.1 in. ×

(16.7 in. × 14.1 in. ×

(18.0 in. × 16.9 in. × 15.0 in.)

 

12.8 in.)

12.8 in.)

 

 

 

Recoil Starter Model

425 mm × 359 mm ×

425 mm × 359 mm ×

 

 

 

 

361 mm

361 mm

 

 

(16.7 in. × 14.1 in. ×

(16.7 in. × 14.1 in. ×

 

 

 

 

 

 

14.2 in.)

14.2 in.)

 

 

 

Dry Weight

 

 

 

 

 

Electric Starter Model

34 kg (75 lbs)

34 kg (75 lbs)

40.5 kg (89.3 lbs)

 

41.2 kg

Recoil Starter Model

32 kg (71 lbs)

32 kg (71 lbs)

 

(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

2

 

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

 

 

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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 () designates that the corresponding item 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

 

 

 

 

 

 

INTERVAL

 

 

 

OPERATION

Daily

First

Every

Every

 

Every

Every

Every

Every

Every

 

 

8 hr.

25 hr.

50 hr.

 

100

200

250

300

500

 

 

 

 

 

 

 

hr.

hr.

hr.

hr.

hr.

 

Check and clean air inlet

 

 

 

 

 

 

 

 

 

 

screen

 

 

 

 

 

 

 

 

 

 

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 screws

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

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

 

 

 

 

 

 

 

 

 

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

Daily

First

Every

Every

 

Every

Every

Every

Every

Every

 

 

8 hr.

25 hr.

50 hr.

 

100

200

250

300

500

 

 

 

 

 

 

 

hr.

hr.

hr.

hr.

hr.

 

Check and clean air inlet

 

 

 

 

 

 

 

 

 

 

screen

 

 

 

 

 

 

 

 

 

 

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 surface, or washer.

S: Tighten the fasteners following the specified sequence.

SS: Apply silicone sealant.

FH451V, FH500V, FH531V, FH541V, FH580V

 

FH451V, FH500V, FH531V,

 

Fastener

 

FH541V, FH580V

 

 

Remarks

 

 

Torque

 

 

 

 

 

 

 

 

 

N·m

 

kgf·m

 

ft·lb

 

Fuel System

 

 

 

 

 

 

 

Carburetor (FH451V, FH500V, FH531V)

 

 

 

 

 

 

 

Choke Valve Screw

0.7

 

0.07

 

6 in·lb

 

Throttle Valve Screws

1.0

 

0.1

 

9 in·lb

 

Pilot Jet

1.7

 

0.17

 

15

in·lb

 

Main Jet

0.7

 

0.07

 

6 in·lb

 

Main Air Jet

0.7

 

0.07

 

6 in·lb

 

Main Nozzle

2.0

 

0.20

 

17 in·lb

 

Pilot Air Jet

0.7

 

0.07

 

6 in·lb

 

Drain Screw

1.3

 

0.13

 

11 in·lb

 

Ground Lead Screw (Carburetor Side)

3.4

 

0.35

 

30 in·lb

 

Fuel Shut Off Solenoid Valve

6.9

 

0.70

 

61

in·lb

 

Float Bowl Mounting Bolt

8.8

 

0.90

 

78

in·lb

 

Carburetor (FH541V, FH580V)

 

 

 

 

 

 

 

Throttle Valve Screws

0.7

 

0.07

 

6 in·lb

L

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

4.5

 

0.46

 

40 in·lb

 

Governor Arm Clamp Nut

7.8

 

0.80

 

69 in·lb

 

Governor Shaft Plate Screws

2.0

 

 

 

18 in·lb

 

 

0.20

 

 

Holder Plate Nuts (Air Cleaner, Carburetor

5.9

 

0.60

 

52

in·lb

 

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

5.9

 

0.60

 

52 in·lb

 

Air Cleaner Type)

 

 

 

 

 

 

 

Air Cleaner Body Bracket Nuts (Heavy Duty

9.8

 

1.0

 

87 in·lb

 

Air Cleaner Type)

 

 

 

 

 

 

 

Control Panel Mounting Bolts

 

 

 

52

in·lb

 

5.9

 

0.60

 

 

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)

5.9

 

0.60

 

52

in·lb

 

Plug Screw (Engine Shroud)

3.4

 

0.35

 

30 in·lb

 

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PERIODIC MAINTENANCE 2-5

Torque and Locking Agent

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FH451V, FH500V, FH531V,

 

Fastener

FH541V, FH580V

 

Remarks

 

 

Torque

 

 

 

 

 

 

 

N·m

kgf·m

 

ft·lb

 

Engine Top End

 

 

 

 

 

 

Cylinder Head Bolts

25

 

2.6

 

19.0

S

Valve Clearance Lock Screws

6.9

 

 

 

61 in·lb

 

 

0.70

 

 

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)

17

 

1.7

 

12.0

 

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

 

 

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

 

 

 

 

30 in·lb

 

3.4

 

0.35

 

 

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

5.9

 

0.60

 

52 in·lb

 

Recoil Starter Retainer Screw

7.8

 

0.80

 

69 in·lb

 

Spark Plugs

22

 

2.2

 

16

 

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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

 

Torque

 

 

(mm)

N·m

kgf·m

ft·lb

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

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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

 

FH680V, FH721V

 

Remarks

 

 

Torque

 

 

 

 

 

 

 

N·m

 

kgf·m

 

ft·lb

 

Fuel System

 

 

 

 

 

 

Choke Valve Screw

1.0

 

 

 

8.9 in·lb

L

 

0.10

 

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)

20

 

2.0

 

15

 

Float Bowl Mounting Screw (Carburetor)

3.9

 

0.40

 

35 in·lb

 

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

5.9

 

0.60

 

52 in·lb

 

Air Cleaner Type)

 

 

 

 

 

 

Air Cleaner Body Bracket Nuts (Heavy Duty

9.8

 

1.0

 

87 in·lb

 

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

 

Engine Top End

 

 

 

 

 

 

Cylinder Head Bolts

25

 

2.6

 

19

S

Valve Clearance Lock Screws

6.9

 

0.70

 

61 in·lb

 

Connecting Rod Big End Cap Bolts

21

 

2.1

 

15

O

(For M7 × P1.0 screw thread spec.)

 

 

 

 

 

 

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2-8 PERIODIC MAINTENANCE

Torque and Locking Agent

 

FH601V, FH641V, FH661V,

 

Fasteners

FH680V, FH721V

 

Remarks

 

 

Torque

 

 

 

 

 

 

 

N·m

kgf·m

 

ft·lb

 

Connecting Rod Big End Cap Bolts

9.8

 

1.0

 

87 in·lb

O

(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)

17

 

1.7

 

12

 

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)

44

 

4.5

 

33

 

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

 

 

 

52 in·lb

 

 

0.60

 

 

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

 

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

 

Torque

 

 

(mm)

N·m

kgf·m

ft·lb

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

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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

Paper element

 

 

 

 

FH451V, FH500V,

FH541V, FH580V

FH601V, FH641V,

 

 

FH661V, FH680V,

 

 

FH531V

 

 

 

FH721V

 

 

 

 

 

Type

 

 

Heavy duty type

Cleaner

 

Paper element

Pre-cleaner

 

Primary element

Second-stage cleaner

 

Secondary element

Engine Top End

 

 

 

 

Valve Clearance:

0.10

0.15 mm (0.004 0.006 in.)

 

Inlet, Exhaust

 

Valve Seating Surface Angle:

 

 

 

 

Inlet, Exhaust

45°

 

 

 

Valve Seating Surface Width:

0.6

0.9 mm (0.024 0.035 in.)

 

Inlet, Exhaust

 

Lubrication System

 

 

 

 

Engine Oil:

 

 

 

 

Type

SF, SG, SH, SJ or SL class

 

Viscosity

SAE 40, SAE 30, SAE 10W-30/SAE 10W-40, or SAE 5W-20

Capacity

1.5 L (1.6 US qt) (When the oil filter is not removed)

 

 

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

Level

Operating range (grid area) on dipstick

 

Electrical System

 

 

 

 

Spark Plug

CHAMPION RCJ8Y, NGK BPR4ES

 

Spark Plug Gap

0.75 mm (0.030 in.)

 

 

 

 

 

 

 

 

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° - 33: 57001-1199

Valve Seat Cutter, 32° - 30: 57001-1120

Oil Filter Wrench: 57001-1249

Valve Seat Cutter Holder Bar: 57001-1128

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)

1450 rpm

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)

1550 rpm

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 3 600 rpm

Tighten the M6 Mounting bolts.

Torque - Control Panel 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 Cleanliness 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 carburetor 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, replace it with a new one.

CAUTION

Do not use compressed air to clean the paper element. Do not oil the paper element or the foam element.

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, replace 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 require 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 require 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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