Kawasaki FJ180V User Manual
4-stroke air-cooled gasoline engine
Quick Reference Guide
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General Information 1
Periodic Maintenance 2
Fuel System 3
Cooling System 4
Engine Top End 5
Lubrication System 6
Camshaft/Crankshaft 7
Electrical System 8
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 con-
•
tents for the exact pages to locate
the specific topic required.
Troubleshooting 9
FJ180V
4-stroke air-cooled gasoline engine
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 Assurance Department/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 i t 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.
© 2002 Kawasaki Heavy Industries, Ltd. First Edition (1) : Nov. 20, 2002 (K)
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
DC direct current rpm revolution(s) per minute
F farad(s) TDC top dead center
F
ft foot, feet V volt(s)
g gram(s) W watt(s)
h hour(s) ohm(s)
L liter(s)
degree(s) Celsius r revolution
degree(s) Fahrenheit TIR total indicator reading
Read OWNER’S MANUAL before operating.
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 op-
timum 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 plug
•
Magneto or electronic ignition system
•
Fuel filter element
•
Air cleaner elements
•
Crankcase
•
Cylinder head
•
Breather chamber and internal parts
•
Intake pipe and tube
•
Foreword
This manual is designed primarily for use by
trained m echanics 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 Kaw asaki en-
•
gine parts. Genuine parts provided as spare
parts are listed in the Parts Catalog.
Follow the procedures in this manual care-
•
fully. Don’t take shortcuts.
Remember to keep complete records of main-
•
tenance and repair with dates and any new
parts installed.
How to Use This Manual
In this manual, the product is divided into
its major systems and these systems make up
the manual’s chapters. 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.
For example, if you want ignition coil information, 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 Ignition coil section.
Whenever you see these WARNING and
CAUTION symbols, heed their instructions!
Always follow safe operating and maintenance
practices.
WARNING
This warning symbol identifies special
instructions or procedures which, if not
correctly followed, could result in per-
sonal injury, or loss of life.
CAUTION
This caution symbol identifies special
instructions or procedures which, if not
strictly observed, could result in dam-
age to or destruction of equipment.
This manual contains four more symbols (in
addition to WARNING and CAUTION) which will
help you distinguish different types of information.
NOTE
This note symbol indicates points of par-
ticular interest for more efficient and con-
venient operation.
Indicates a procedural step or work to be
•
done.
Indicates a procedural sub-step or how to do
the work of the procedural step it follows. It
also precedes the text of a WARNING, CAU-
TION, or NOTE.
Indicates a conditional step or what action to
take based on the results of the test or inspec-
tion in the procedural step or sub-step it fol-
lows.
In most chapters an exploded view illustration
of the system components follows the Table of
Contents. In these illustrations you will find the
instructions indicating which parts require specified tightening torque, oil, grease or a locking
agent during assembly.
GENERAL INFORMATION 1-1
General Information
TABLE OF CONTENTS
Before Servicing ........................................................................................................................ 1- 2
Model Identification.................................................................................................................... 1- 4
General Specifications............................................................................................................... 1- 5
Torque and Locking Agent......................................................................................................... 1-6
1
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) 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, t he bolts, nuts, or screws
must be tightened in the order and method indicated.
(3) 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.
(4) 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, t ap 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.
(5) Edges
Watch for sharp edges, especially during m ajor engine disassembly and assembly. Protect your
hands with gloves or a piece of thick cloth when lifting the engine or turning it over.
(6) 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.
(7) 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 matter and perfectly smooth to avoid oil or compression leaks.
(8) 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.
(9) Oil Seal and Grease Seal
Replace any oil or grease seals that were removed with new ones, as removal generally damages seals.
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.
(10)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.
(11)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
GENERAL INFORMATION 1-3
Before Servicing
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 m akes reference to molybdenum disulfide grease (MoS2) in the assembly of certain
engine parts. Always check manufacturer recommendations before using such special lubricants.
(12)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.
(13)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.
(14)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
(15)Specifications
Specification terms are defined as follows:
"Standards" show dimensions or performances which brand-new parts or systems have.
"Service Limits" indicate the usable limits. If the measurement shows excessive wear or deteriorated performance, replace the damaged parts.
1-4 GENERAL INFORMATION
Model Identification
GENERAL INFORMATION 1-5
General Specifications
Items FJ180V
Type of engine Forced air-cooled, vertical shaft, OHV, 4-stroke gasoline engine
Bore x Stroke 65 mm x 54 mm (2.56 in x 2.13 in)
Piston displacement 179 mL (10.9 cu. in)
Direction of rotation Counterclockwise facing the PTO shaft
Compression release Automatic compression release
High idle speed 3200 rpm
Ignition system Flywheel magneto with CDI
RFI Per Canada and U.S.A. requirements
Starting system Recoil starter
Spark plug NGK BPR5ES
Carburetor Float type, fixed main jet
Air cleaner Dual stage element, dry type
Governor Flyweight all speed governor
Lubrication system Pressure feed by positive displacement pump
Oil capacity
(when engine is
completely dry)
Cooling system Forced air cooling by fan
Dimensions (L x W x H ) 390 mm x 307 mm x 284mm (15.4 in x 12.1 in x 11.2 in)
Dry weight 15.0 kg (33.3 lb)
Specifications subject to change without notice.
0.65 L (0.69 US-qt)
1-6 GENERAL INFORMATION
Torque and Locking Agent
The following tables list the tightening torque for the major f asteners, 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 an oil to the threads, seated surface, or washer.
S : Tighten the fasteners following the specified sequence.
SS : Apply silicone sealant.
Fastener
N·m
Fuel System:
Throttle Valve Screw 0.7 0.07 6in·lb
Main Jet 1.1 0.11 9.7 in·lb
Governor Arm Clamp Nut 7.8 0.80 69 in·lb
Priming Nut 1.2 0.12 11 in·lb
Fuel Tank Cover Bolts 6.9 0.70 61 in·lb
Tank Drain Bolt 6.9 0.70 61 in·lb
Float Chamber Mounting Bolt 5.4 0.55 48 in·lb
Drain Screw 4.2 0.43 37 in·lb
Cooling System:
Flywheel Bolt 42 4.3 31
Engine Top End:
Cylinder Head Bolts 22 2.2 16 =S
Valve Clearance Lock Screws 6.9 0.70 61 in·lb
Connecting Rod Big End 5.9 0.60 52 in·lb =O
Cap Bolts
Rocker Arm Bolts 28 2.8 20
Rocker Cover Mounting Bolts 5.9 0.60 52 in·lb
Spark Plug 22 2.2 16
Muffler Cover Self Tap Bolt (1) 6.9 0.70 61 in·lb
Lubrication System:
Oil Drain Plug 22 2.2 16 in·lb
Oil Filter Cover Bolt 6.9 0.70 61 in·lb
Camshaft/Crankshaft:
Crankcase Cover Bolts 8.8 0.90 78 in·lb =S
Electrical System:
Flywheel Bolt 42 4.3 31
Recoil Starter Mounting Bolts 6.9 0.70 61 in·lb
Recoil Starter Set Screw 1.0 0.10 8.9 in·lb
Spark Plug 22 2.2 16
Brake Lever Assembly Mounting Bolt 6.9 0.70 61 in·lb
Kill Switch Bolt 1.5 0.15 13 in·lb
Brake Arm Mounting Bolt 9.3 0.95 82 in·lb
Torque
Remarks
kgf·m ft·lb
GENERAL INFORMATION 1-7
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
PERIODIC MAINTENANCE 2 -1
Periodic Maintenance
TABLE OF CONTENTS
Periodic Maintenance Chart ...................................................................................................... 2-2
Specifications ............................................................................................................................ 2- 3
Special Tools ............................................................................................................................. 2- 4
Periodic Maintenance Procedures............................................................................................. 2- 5
Fuel System............................................................................................................................ 2- 5
High Idle Speed Adjustment ................................................................................................ 2- 5
Fuel System Cleanliness Inspection .................................................................................... 2- 5
Fuel Filter Inspection............................................................................................................2-6
Air Element Removal ........................................................................................................... 2- 6
Air Element Installation ........................................................................................................ 2-7
Air Element Cleaning and Inspection................................................................................... 2- 7
Air Cleaner Housing (Case and Body) Inspection ............................................................... 2- 8
Engine Top End ...................................................................................................................... 2- 8
Cylinder Head Cleaning and Inspection............................................................................... 2- 8
Valve Clearance Inspection ................................................................................................. 2- 8
Valve Clearance Adjustment ................................................................................................ 2- 9
Valve Seat Inspection .......................................................................................................... 2- 9
Valve Seat Repair ................................................................................................................ 2-10
Lubrication System ................................................................................................................. 2-13
Oil Level Inspection..............................................................................................................2-13
Oil Change ........................................................................................................................... 2-13
Electrical System .................................................................................................................... 2-14
Spark Plug Cleaning and Inspection.................................................................................... 2-14
Spark Plug Gap Inspection .................................................................................................. 2-14
2
2-2 PERIODIC MAINTENANCE
Periodic Maintenance Chart
To ensure satisfactory operation over an extended period of time, any engine requires normal maintenance regular intervals. The Periodic Maintenance Chart below shows periodic inspection and
maintenance items and suitable intervals. The bullet mark (
should be performed at that interval.
Some adjustments require the use of special tools or other equipment. An electronic tachometer
will facilitate setting idle and running speeds.
) designates that the corresponding item
•
•
INTERVAL
Every
50 hr.
100 hr.
•
Every
•
•
Every
200 hr.
•
OPERATION
Daily
Check or clean air intake screen
Check and add engine oil
Check for fuel and oil leakage
Check for loose or lost nuts and
screws
Clean air cleaner foam element (1)
Clean air cleaner paper element (1)
Tighten nuts and screws
Change engine oil
Clean and re-gap spark plug
Change air cleaner paper element
(1)
Clean dust and dirt from cylinder
and cylinder head fins (1)
Check and adjust valve clearance
Clean and lap valve seating surface
Clean combustion chamber
(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.
First 8
hr.
•
•
•
•
Every
25 hr.
• •
Every
300 hr.
•
•
•
•
PERIODIC MAINTENANCE 2 -3
Specifications
Item Standard
Fuel System
High idle speed 3200 r/min (rpm)
Air cleaner:
Type Dual stage filtration system
Pre-cleaner Foam element
Second-stage cleaner Paper element
Engine Top End
Valve clearance Intake Exhaust 0.10 ~ 0.15 mm (0.004 ~ 0.006 in.)
Valve seating surface angle Intake Exhaust
Valve seating surface width Intake Exhaust 0.6 ~ 0.9 mm (0.024 ~ 0.035 in.)
Lubrication System
Engine oil:
Type SF, SG, SH or SJ class
Viscosity SAE30, SAE10W-30
Capacity [When engine is completely dry]
Level Operating range (grid area) on dipstick
45
0.65 L (0.69 US-qt)
Electrical System
Spark plug gap 0.75 mm (0.030 in.)
2-4 PERIODIC MAINTENANCE
Special Tools
Valve Seat Cutter, 45 - f27.5: 57001–1114
Valve Seat Cutter, 32 - f25.0: 57001–1118
Valve Seat Cutter, 32 - f28.0: 57001–1119
Valve Seat Cutter Holder Bar: 57001–1128
Valve Seat Cutter Holder - f6.0: 57001–1360
Periodic Maintenance Procedures
Fuel System
High Idle Speed Adjustment
CAUTION
Do not adjust high idle speed with the air cleaner
removed.
Start and warm up the engine throughly.
•
WARNING
Always keep your hands clear of the moving parts.
Move the throttle lever at a dash to the high idle position.
•
Loosen the control panel mounting bolts [A] enough to
•
move the control panel assembly.
Carefully move the control panel assembly right or left to
•
obtain the specified high idle speed.
PERIODIC MAINTENANCE 2 -5
High Idle Speed
3200 rpm
Tighten the Mounting bolts.
•
Fuel System Cleanliness Inspection
WARNING
Gasoline is extremely flammable and can be explosive under certain conditions. Turn the engine
switch stop position. 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 primer pipe from the tube.
•
Place a suitable container [B] under the drain screw [A]
•
on the carburetor.
Loosen the drain screw to drain the carburetor and check
•
to see if water or dirt has accumulated in the carburetor.
Tighten the drain screw.
•
Torque - Drain Screw: 4.2 N·m (0.43 kgf·m, 37 in·lb)
Install the primer pipe in the tube (see Fuel System chap-
•
ter).
If any water or dirt is found, clean the carburetor and fuel
•
tank (see Fuel System chapter).
2-6 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Fuel Filter Inspection
Visually insect the fuel filter [A].
•
If the filter is clear with no signs of dirt or other contami-
nation, it is OK and need not be replaced.
If the filter is dark or looks dirty, replace with a new one.
Also check the rest of the fuel system for contamination.
Check the O-ring at the tank drain for damage. Replace
•
the O-ring with a new one if it is damaged.
Air Element Removal
Move the holders [A].
•
Push up the latches [A] and remove the air cleaner case
•
[B].
Remove:
•
Paper Element [A]
Foam Element [B]
Periodic Maintenance Procedures
Air Element Installation
Install:
•
Foam Element
Paper Element
Install the hollow [A] of the air cleaner case and projection
•
[B] of the air cleaner body are fitting.
Move the holders [A].
•
PERIODIC MAINTENANCE 2 -7
Air Element Cleaning and Inspection
NOTE
In dusty areas, the elements should be cleaned 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 paper element and the foam element.
•
Clean the foam element [A] in a bath of detergent and wa-
•
ter, and let the element air-dry throughly before installing
it.
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 or foam element.
2-8 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Air Cleaner Housing (Case and Body) Inspection
Clean the housing with detergent and water and dry thor-
•
oughly.
Check the housing for deformation or other damage. The
•
housing must seal well and permit only filtered air to reach
the carburetor.
If the housing is damaged, it must be replaced.
Check that no foreign material is obstructing the air pas-
•
sage.
Engine Top End
Cylinder Head Cleaning and Inspection
Remove the cylinder head (see Engine Top End chapter).
•
Scrape the carbon deposits from the head and exhaust
•
port with a suitable tool [A].
To avoid gouging, use scrapers that are made of a m ate-
•
rial that w ill not cause damage.
Clean the head in a bath of high flash-point solvent and
•
dry it with com pressed air.
WARNING
Clean the cylinder head in a well-ventilated area,
and take care that there are no sparks or flame any-
where near the working area, this includes any ap-
pliance with a pilot light. Do not use gasoline or a
low flash-point solvent to clean the cylinder head.
A fire or explosion could result.
Straight edge [A] across the mating surface of the head at
•
several different points, and measure warp by inserting a
thickness gauge [B] between the straightedge and head.
If warp exceeds the service limit, repair the mating sur-
face. Replace the cylinder head if the mating surface is
badly damaged.
Cylinder Head Warp
Service Limit: 0.03 mm (0.001 in.)
Check the cylinder head for cracks or other damage.
•
Cracks not visible to the eye may be detached by using
•
a metal crack detection system (Visual color check: com-
monly found at automotive parts tore.).
If a crack is present in the cylinder head, replace it.
•
Inspect the mating surface for burrs and nicks.
•
Valve Clearance Inspection
NOTE
Valve clearance must be checked when the engine is
cold (at room temperature).
Remove the rocker cover (see Engine Top End chapter).
•
Place the piston at top dead center (TDC) of the compres-
•
sion stroke turning the crankshaft rotational direction.
Periodic Maintenance Procedures
Then check the valve clearance.
•
Using a thickness gauge [A], measure the valve clearance
beween the rocker arm [B] and the valve stem end.
If the valve clearance is incorrect, adjust it.
Valve Clearance (when cold)
Intake, Exhaust
Valve Clearance Ad justment
Since valve repairs change the valve clearance, adjust
•
the valve clearance to the specification.
Assemble the cylinder head and install the cylinder head
•
assembly on the block (see Engine Top End chapter).
Turn the crankshaft to the proper direction until the piston
•
is at TDC of the compression stroke (described above).
Loosen the lock screws [A] and valve clearance adjusting
•
nuts [B].
Insert a 0.10 mm (0.004 in.) thickness gauge [C] between
•
the rocker arm and valve stem, and tighten the adjusting
nut until the thickness gauge begins to bind between the
rocker arm and valve stem end. Use a sweeping motion
with the thickness gauge while making this adjustment.
0.10 ~ 0.15 mm (0.004 ~ 0.006in.)
PERIODIC MAINTENANCE 2 -9
Valve Clearance (when cold)
Intake, Exhaust
Holding the adjusting nut with a wrench, tighten the lock
•
screw to the specified torque.
Torque - Valve Clearance Lock Screws: 6.9 N·m (0.70
kgf·m, 61 in·lb)
Do not overtighten.
•
Remeasure any clearance that was adjusted. Readjust if
•
necessary.
Valve Seat Inspection
Remove the valve (see Engine Top End chapter).
•
Inspect the valve seats for damage.
•
If the seats are warped or distorted beyond reconditioning, replace the cylinder head.
Pitted or worn valve seats can be refaced. Lap the valves
•
to the seats after refacing.
Coat the valve seat with machinist’s dye.
•
Push the valve into the guide.
•
Rotate the valve against the seat with a lapping tool.
•
Pull the valve out, and check the seating pattern on the
•
valve head. It must be the correct width [A] and even all
the way around.
0.10 ~ 0.15 mm (0.004 ~ 0.006in.)
2-10 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
NOTE
The valve stem and guide must be in good condition or
this check will not be valid.
Good [A]
Toowide[B]
Too narrow [C]
Uneven [D]
If the valve seating pattern is not correct, repair the seat.
Valve Seating Surface Width (STD)
Inlet, Exhaust
Valve Seat Repair
Follow the manufacturer’s instructions for use of valve
•
seat cutters.
Special Tools
Intake Valve:
Seat Cutter
Outside Cutter
Exhaust Valve:
Seat Cutter
Outside Cutter
Valve S eat Cutter Holder-f6.0
Valve Seat Cutter Holder Bar
If the manufacturer’s instructions are not available, use
the following procedure.
0.6 ~ 0.9 mm (0.024 ~ 0.035 in.)
:
45
32
45
32
- f27.5
- f28.0
- f27.5
- f25.0
57001-1114
:
57001-1119
:
57001-1114
:
57001-1118
:
57001-1360
:
57001-1128
Seat Cutter Operating Cares:
1. This valve seat cutter is designed only for valve seat re-
pair. Therefore the cutter must not be used for other purposes.
2. Do not drop or hit the valve seat cutter, or the diamond
particles may fall off.
3. Do not fail to apply engine oil to the valve seat cutter
before grinding the seat surface. Also wash off ground
particles sticking to the cutter with washing oil.
NOTE
Do not use a wire brush to remove the metal particles
from the cutter. It will take off the diamond particles.
4. Setting t he valve seat cutter holder [A] in position, op-
erate the cutter [B] with one hand [C]. Do not apply too
much force to the diamond portion.
NOTE
Prior to grinding, apply oil to the cutter, and during t he
operation wash off any ground particles sticking to the
cutter with washing oil.
5. After use wash the cutter with washing oil and apply a
thin layer of engine oil before storing.
Periodic Maintenance Procedures
Marks Stamped on the Cutter:
The marks stamped on the back of the cutter represent the
following.
1 Cutter number, selected from 1 to 12
30
37.5 Cutter diameter of cutter [B]
KS8B Manufactured lot number
Operating Procedures:
Clean the seat area carefully.
•
Recondition the valve seats with the valve seat cutters
•
(45
,32) and lap the valves.
Check the seats for good contact all the way around with
•
machinist’s dye.
Measure the seat width [A]. If it is more than the STD
•
width, the seating surface should be refaced.
If the valve seating pattern is not correct, repair the seat.
•
Cutter angle [A]
PERIODIC MAINTENANCE 2-11
Coat the seat with machinist’s dye.
•
Fit a 45 seat cutter [A] to the holder and slide it into the
•
valve guide.
Resurface the valve seat with a 45 cutter, removing only
enough material to produce a smooth and concentric
seat.
CAUTION
Do not grind the seat too much. Overgrinding will
reduce valve clearance by sinking the valve into the
head. If the valve sinks too far into the head, i t will
be impossible to adjust the clearance, and the cylinder head must be replaced. Do not turn the cutter
counterclockwise or drop it against the seat, or it
will be dulled.
2-12 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Use a 32 seat cutter [A] to narrow the seat width to the
•
STD width.
Turn the seat cutter one turn at a time while pressing down
very lightly. Check the seat width after each turn.
CAUTION
The 32 cutter removes material very quickly.
Check the seat width frequently to prevent over
grinding.
NOTE
Keep the seat width as close as possible to the STD
width.
Make a light pass with the 45 cutter to remove any pos-
•
sible burrs at the edge of the seat.
After resurfacing the seat, inspect for even valve seating.
•
Apply a machinist’s dye to the valve face, insert the
valve, and snap it closed against the seat several times.
The valve surface should show good contact all the way
around. Be sure the valve seat is centered on the valve
face. The position of the valve in the seat is evident after
lapping the valve.
If the seat does not make proper contact, lap the valve
into seat with a vacuum cap tool.
Coat the face of valve sparingly with a fine lapping com-
•
pound.
Use the vacuum cup tool [A], to grip top of the valve [B].
•
Rotate the valve in a circular motion to lap the valve to the
seat.
Lift the valve slightly from the seat every 8 to 10 strokes,
•
continue lapping operation until a uniform ring appears
around entire surface of the valve face.
When lapping is completed, wash all parts in solvent to
•
remove lapping compound. Dry the parts thoroughly.
Note the position of the lapping m ark on the valve face.
•
The lapping mark should appear on or near the center of
the valve face.
When the engine is assembled, be sure to adjust the valve
•
clearances (see Valve Clearance Adjustment).
Periodic Maintenance Procedures
Lubrication System
Oil Level Inspection
Place the engine on a level surface.
•
Remove the oil filler cap [A] and wipe its dipstick [B] with
•
a clean cloth.
Insert the dipstick into gauge hole [C] without screwing it
•
in, then check the oil Level.
The oil level should be the operating range [A] (grid area)
•
on the dipstick.
If the oil level is below “ADD” range [B], add enough engine oil to bring oil level to the operating range.
CAUTION
Do not add more oil above the operating range. Excess oil will cause a smoking condition.
PERIODIC MAINTENANCE 2-13
Use the same type and make of oil that is already in the
engine.
NOTE
If the engine oil type and make are unknown, use any
brand of the specified oil to top up the level in preference
to running the engine with the oil level low. Then at your
earliest convenience, change the oil completely.
If the oil level is above “FULL” range [C], drain the excess
oil by loosening the drain plug.
Oil Change
Change the oil after first 8 hours of operation. Thereafter
•
change oil every 100 hours.
Start and warm up the engine so the oil will drain easily.
•
Stop the engine.
Place the engine on a level surface.
•
Place a suitable container under the engine.
•
Remove the drain plug [A] and drain the oil.
•
WARNING
Be careful of hot oil when drained. It m ay be hot
enough to burn you severely.
Check the washer [B] at the drain plug for damage. Re-
•
place the washer with a new one if it is damaged.
Install the drain plug with the washer and tighten it.
•
Torque - Oil Drain Plug : 22 N·m (2.2 kgf·m, 16 ft·lb)
2-14 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Remove the oil filler cap and pour in the specified type
•
and amount of oil.
Engine Oil :
Type:
Viscosity:
Capacity:
Electrical System
Spark Plug Cleaning and Inspection
Remove the spark plug (See Electrical System chapter).
•
If the plug is oily or has carbon build up on it, clean the
plug using a high flash-point solvent and a wire brush or
other suitable tool.
If the spark plug electrodes are corroded or damaged,
or if the insulator is cracked, replace the plug. Use the
standard spark plug or its equivalent.
Insulator [A]
Center Electrode [B]
Plug Gap [C]
Side Electrode [D]
SF, SG, SH or SJ Class
SAE30, SAE10W-30
[When engine is completely dry]
0.65 L (0.69 US-qt)
Spark Plug Gap Inspection
Measure the gap with a wire-type thickness gauge.
•
If the gap is incorrect, carefully bend the side electrode
with a suitable tool to obtain the correct gap.
Spark Plug Gap
Standard: 0.75 mm (0.030 in.)
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