For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983
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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 |
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|
|
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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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) |
Ω |
ohm(s) |
L |
liter(s) |
|
|
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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.
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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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.
(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
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
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1-6 GENERAL INFORMATION
Model Identification
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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 |
|
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|
|
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 |
|
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Compression Release |
Automatic compression release |
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Low Idle Speed |
1 550 rpm |
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High Idle Speed |
3 600 rpm |
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Ignition System |
Transistorized-fly wheel magneto |
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RFI |
Per Canada and U.S.A. requirements |
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Starting System |
Electric starter and/or recoil starter |
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Charging System |
12 V - 13 amps with regulator |
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Spark Plug |
CHAMPION RCJ8Y |
|
NGK BPR4ES |
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Carburetor |
Float type, fixed main jet |
Float type, fixed main jet, two |
|||
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barrel |
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Fuel Pump |
Diaphragm type pulse pump |
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Air Cleaner |
Dual stage element, dry type/Heavy duty type |
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Governor |
Flyweight all speed governor |
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Lubrication System |
Pressure feed by positive displacement pump |
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Oil Filter |
Cartridge type full flow filter |
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Oil Pressure Switch |
ON-OFF switch (Option) |
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Oil Capacity (when |
1.8 L (1.9 US-qt) |
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1.9 L |
engine is completely |
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(2.0 US-qt) |
dry) |
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Cooling System |
Forced air cooling by fan |
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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.) |
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Recoil Starter Model |
425 mm × 359 mm × |
425 mm × 359 mm × |
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361 mm |
361 mm |
– |
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(16.7 in. × 14.1 in. × |
(16.7 in. × 14.1 in. × |
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14.2 in.) |
14.2 in.) |
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Dry Weight |
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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
Table of Contents
Periodic Maintenance Chart ................................................................................................... |
2-2 |
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|
Torque and Locking Agent...................................................................................................... |
2-4 |
2 |
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Specifications |
2-9 |
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Special Tools .......................................................................................................................... |
2-10 |
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Periodic Maintenance Procedures.......................................................................................... |
2-11 |
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Fuel System......................................................................................................................... |
2-11 |
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Low Idle Speed Adjustment .............................................................................................. |
2-11 |
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High Idle Speed Adjustment ............................................................................................. |
2-11 |
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Fuel System Cleanliness Inspection ................................................................................. |
2-13 |
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Element Cleaning and Inspection ..................................................................................... |
2-13 |
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Housing (Cap and Body) Inspection ................................................................................. |
2-15 |
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Engine Top End ................................................................................................................... |
2-15 |
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Cylinder Head Cleaning and Inspection............................................................................ |
2-15 |
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Valve Clearance Inspection .............................................................................................. |
2-16 |
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Valve Clearance Adjustment............................................................................................. |
2-17 |
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Valve Seat Inspection ....................................................................................................... |
2-17 |
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Valve Seat Repair ............................................................................................................. |
2-18 |
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Lubrication System .............................................................................................................. |
2-20 |
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Oil Level Inspection........................................................................................................... |
2-20 |
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Oil Change ........................................................................................................................ |
2-21 |
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Oil Filter Replacement ...................................................................................................... |
2-22 |
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Oil Cooler Cleaning........................................................................................................... |
2-22 |
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Electrical System ................................................................................................................. |
2-22 |
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Spark Plug Cleaning and Inspection................................................................................. |
2-22 |
|
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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
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INTERVAL |
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||
OPERATION |
Daily |
First |
Every |
Every |
|
Every |
Every |
Every |
Every |
Every |
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8 hr. |
25 hr. |
50 hr. |
|
100 |
200 |
250 |
300 |
500 |
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hr. |
hr. |
hr. |
hr. |
hr. |
|
Check and clean air inlet |
• |
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screen |
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Check and add engine oil |
• |
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Check for fuel and oil leakage |
• |
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Check for loose or lost nuts |
• |
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and screws |
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Check battery electrolyte level |
• |
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Clean air cleaner foam element |
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• |
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(1) |
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Clean air cleaner paper |
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• |
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element (1) |
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Clean cylinder and cylinder |
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• |
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head fins (1) |
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Tighten nut and screws |
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• |
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Change engine oil |
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• |
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• |
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Clean and re-gap spark plugs |
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• |
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Change oil filter |
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• |
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Change air cleaner paper |
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• |
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element (1) |
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Replace air cleaner element |
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• |
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(Heavy duty air cleaner model) |
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(1) |
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♦ |
Check and adjust valve |
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• |
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clearance |
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♦ |
Clean and lap valve seating |
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• |
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surface |
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♦ |
Clean combustion chambers |
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• |
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|
|
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||
|
|
|
|
|
|
|
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|
|
(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.
www.mymowerparts.com
For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983
PERIODIC MAINTENANCE 2-3
Periodic Maintenance Chart
FH601V, FH641V, FH661V, FH680V, FH721V
|
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|
INTERVAL |
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||
OPERATION |
Daily |
First |
Every |
Every |
|
Every |
Every |
Every |
Every |
Every |
|
|
|
8 hr. |
25 hr. |
50 hr. |
|
100 |
200 |
250 |
300 |
500 |
|
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|
hr. |
hr. |
hr. |
hr. |
hr. |
|
Check and clean air inlet |
• |
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screen |
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Check and add engine oil |
• |
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Check for fuel and oil leakage |
• |
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Check for loose or lost nuts |
• |
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and screws |
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Check battery electrolyte level |
• |
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Clean air cleaner foam element |
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• |
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(1) |
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Clean air cleaner paper |
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• |
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element (1) |
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Replace air cleaner paper |
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• |
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element (1) |
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Replace air cleaner primary |
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• |
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element (Heavy duty air |
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cleaner model) (1) |
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Check air cleaner secondary |
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|
• |
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element (Heavy duty air |
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cleaner model) (1) |
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Replace air cleaner secondary |
|
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|
• |
|
element (Heavy duty air |
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cleaner model) (1) |
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Clean cylinder and cylinder |
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• |
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head fins (1) |
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Tighten nut and screws |
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• |
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Change engine oil |
|
• |
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• |
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Clean and re-gap spark plugs |
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• |
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Check and clean oil cooler fins |
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• |
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(FH721V model) |
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Change oil filter |
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|
• |
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♦ |
Check and adjust valve |
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• |
|
clearance |
|
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||
♦ |
Clean and lap valve seating |
|
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|
• |
|
surface |
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||
♦ |
Clean combustion chambers |
|
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|
• |
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|
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|
|
|
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||
|
|
|
|
|
|
|
|
|
|
|
|
(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.
www.mymowerparts.com
For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983
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 |
|
www.mymowerparts.com
For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983
|
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 |
|
www.mymowerparts.com
For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983
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.
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 |
www.mymowerparts.com
For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983
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.) |
|
|
|
|
|
|
www.mymowerparts.com
For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983
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 |
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52 in·lb |
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Screen Bolts |
5.9 |
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52 in·lb |
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0.60 |
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Regulator Screws |
3.4 |
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0.35 |
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30 in·lb |
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Ignition Coil Bolts (Studs) |
7.8 |
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0.80 |
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69 in·lb |
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Ignition Coil Bolts (Bolts) |
5.9 |
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0.60 |
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52 in·lb |
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Starter Motor Mounting Bolts |
15 |
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1.5 |
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11 |
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Recoil Starter Mounting Nuts |
– |
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– |
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– |
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Recoil Starter Retainer Screw |
– |
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– |
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– |
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Spark Plugs |
22 |
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2.2 |
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16 |
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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.
Threads dia |
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Torque |
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(mm) |
N·m |
kgf·m |
ft·lb |
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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 |
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11 |
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For Kawasaki Discount Parts Call 606-678-9623 or 606-561-4983
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PERIODIC MAINTENANCE 2-9 |
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Specifications |
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Item |
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Standard |
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Fuel System |
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Idle Speed: (1) |
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Low Idle Speed |
1 550 r/min (rpm) |
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High Idle Speed |
3 600 r/min (rpm) |
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Air Cleaner: |
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Type |
Dual stage filtration system |
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Pre-cleaner |
Foam element |
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Second-stage cleaner |
Paper element |
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FH451V, FH500V, |
FH541V, FH580V |
FH601V, FH641V, |
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FH661V, FH680V, |
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FH531V |
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FH721V |
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Type |
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Heavy duty type |
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Cleaner |
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– |
Paper element |
– |
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Pre-cleaner |
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– |
– |
Primary element |
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Second-stage cleaner |
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– |
– |
Secondary element |
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Engine Top End |
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Valve Clearance: |
0.10 |
0.15 mm (0.004 0.006 in.) |
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Inlet, Exhaust |
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Valve Seating Surface Angle: |
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Inlet, Exhaust |
45° |
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Valve Seating Surface Width: |
0.6 |
0.9 mm (0.024 0.035 in.) |
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Inlet, Exhaust |
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Lubrication System |
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Engine Oil: |
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Type |
SF, SG, SH, SJ or SL class |
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Viscosity |
SAE 40, SAE 30, SAE 10W-30/SAE 10W-40, or SAE 5W-20 |
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Capacity |
1.5 L (1.6 US qt) (When the oil filter is not removed) |
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1.7 L (1.8 US qt) (When the oil filter is removed) except FH721 |
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1.8 L (1.9 US qt) (When the oil filter is removed) FH721 |
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Level |
Operating range (grid area) on dipstick |
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Electrical System |
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Spark Plug |
CHAMPION RCJ8Y, NGK BPR4ES |
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Spark Plug Gap |
0.75 mm (0.030 in.) |
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Item |
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Service Limit |
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Engine Top End |
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Cylinder Head Warp |
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0.05 mm (0.002 in.) |
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(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
NOTE
○High and low idle speeds may vary depending on the equipment on which the engine is used. Refer to the equipment specification.
•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.
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.
1550 rpm
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
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.
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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