Kawasaki FJ180V Manual

4-stroke air-cooled gasoline engine

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
Electrical System	8	j
Troubleshooting	9	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.

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 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.

© 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	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)

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 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 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 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 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 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, CAUTION, 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.

GENERAL INFORMATION 1-1

General Information	1
TABLE OF CONTENTS
Before Servicing ........................................................................................................................	1- 2
Model Identification....................................................................................................................	1- 4
General Specifications...............................................................................................................	1- 5
Torque and Locking Agent.........................................................................................................	1- 6

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, the 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, 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.

(5) 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.

(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 makes 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 dete-

riorated 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	0.65 L (0.69 US-qt)
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.

1-6 GENERAL INFORMATION

Torque and Locking Agent

The following tables list the tightening torque for the major fasteners, and the parts requiring use of

anon-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								Torque													Remarks
			N·m							kgf·m								ft·lb
Fuel System:
Throttle Valve Screw	0.7							0.07								6 in·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

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	2

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 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.

OPERATION								INTERVAL
					Daily	First 8	Every	Every	Every	Every	Every
						hr.	25 hr.	50 hr.	100 hr.	200 hr.	300 hr.
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.

		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	45
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]
		0.65 L (0.69 US-qt)
Level		Operating range (grid area) on dipstick
Electrical System
Spark plug gap		0.75 mm (0.030 in.)

2-4 PERIODIC MAINTENANCE

Special Tools

Valve Seat Cutter, 45		- 27.5: 57001–1114		Valve Seat Cutter Holder Bar: 57001–1128

Valve Seat Cutter, 32 - 25.0: 57001–1118

Valve Seat Cutter Holder - 6.0: 57001–1360

Valve Seat Cutter, 32 - 28.0: 57001–1119

PERIODIC MAINTENANCE 2-5

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.

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)

•Installter). the primer pipe in the tube (see Fuel System chap-

•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 contamination, 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[B]. up the latches [A] and remove the air cleaner case

•Remove:

Paper Element [A] Foam Element [B]

PERIODIC MAINTENANCE 2-7

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].

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 water, 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 thoroughly.

•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.

•Checksage. that no foreign material is obstructing the air pas-

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 material that will not cause damage.

•Clean the head in a bath of high flash-point solvent and dry it with compressed air.

WARNING

Clean the cylinder head in a well-ventilated area, and take care that there are no sparks or flame anywhere near the working area, this includes any appliance with a pilot light. 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 surface. 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: commonly 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 compression stroke turning the crankshaft rotational direction.

PERIODIC MAINTENANCE 2-9

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	0.10 ~ 0.15 mm (0.004 ~ 0.006in.)

Valve Clearance Adjustment

•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.

Valve Clearance (when cold)

Intake, Exhaust 0.10 ~ 0.15 mm (0.004 ~ 0.006in.)

•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.

•Remeasurenecessary. any clearance that was adjusted. Readjust if

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.

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] Too wide [B]

Too narrow [C] Uneven [D]

If the valve seating pattern is not correct, repair the seat.

Valve Seating Surface Width (STD)

Inlet, Exhaust 0.6 ~ 0.9 mm (0.024 ~ 0.035 in.)

Valve Seat Repair

•Follow the manufacturer’s instructions for use of valve seat cutters.

Special Tools

Intake Valve:

Seat Cutter	45		- 27.5	:	57001-1114
Outside Cutter	32		- 28.0	:	57001-1119
Exhaust Valve:				:	57001-1114
Seat Cutter	45		- 27.5
Outside Cutter	32		- 25.0	:	57001-1118
Valve Seat Cutter Holder- 6.0				:	57001-1360
Valve Seat Cutter Holder Bar				:	57001-1128

If the manufacturer’s instructions are not available, use the following procedure.

Seat Cutter Operating Cares:

1.This valve seat cutter is designed only for valve seat repair. 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 the valve seat cutter holder [A] in position, operate the cutter [B] with one hand [C]. Do not apply too much force to the diamond portion.

NOTE

Prior to grinding, apply oil to the cutter, and during the operation wash off any ground particles sticking to the cutter with washing oil.

5.After use wash the cutter with washing oil and apply a thin layer of engine oil before storing.

PERIODIC MAINTENANCE 2-11

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	Cutter angle [A]

37.5Cutter 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.

•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, it will be impossible to adjust the clearance, and the cylinder head must be replaced. Do not turn the cutter counterclockwise or drop it against the seat, or it will be dulled.

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 possible burrs at the edge of the seat.

•After resurfacing the seat, inspect for even valve seating.

Apply a machinist’s dye to the valve face, insert the valve, and snap it closed against the seat several times. The valve surface should show good contact all the way around. Be sure the valve seat is centered on the valve face. The position of the valve in the seat is evident after lapping the valve.

If the seat does not make proper contact, lap the valve into seat with a vacuum cap tool.

•Coat the face of valve sparingly with a fine lapping compound.

•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 mark on the valve face. The lapping mark should appear on or near the center of the valve face.

•When the engine is assembled, be sure to adjust the valve clearances (see Valve Clearance Adjustment).

PERIODIC MAINTENANCE 2-13

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.

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 may be hot enough to burn you severely.

•Check the washer [B] at the drain plug for damage. Replace 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:	SF, SG, SH or SJ Class
Viscosity:	SAE30, SAE10W-30
Capacity:	[When engine is completely dry]
	0.65 L (0.69 US-qt)

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]

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	0.75 mm (0.030 in.)
Standard: