Toro 22974, 23210, 23210G Service Manual
FR651V, FR691V, FR730V
FS651V, FS691V, FS730V
FX651V, FX691V, FX730V
4-Stroke Air-Cooled V-Twin Gasoline Engine
Service Manual
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
Starter 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.
•Refertothe sectional tableofcontents
for the exact pages to locate the specific topic required.
Electrical System 9
Troubleshooting 10
FR651V, FR691V, FR730V
FS651V, FS691V, FS730V
FX651V, FX691V, FX730V
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 Assurance 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 m ake 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.
© 2009 Kawasaki Heavy Industries, Ltd. First Edition (1):Jan. 9, 2009 (K)
LIST OF ABBREVIATIONS
A ampere(s) lb pound(s)
ABDC after bottom dead center
AC
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
L
alternating current min
hour(s) Ω ohm(s)
liter(s)
m
meter(s)
minute(s)
EMISSION CONTROL INFORMATION
Toprotect the environment in which weall live, Kawasaki has incorporatedcrankcaseemission
(1) and exhaust emission (2) control systems (EM) in compliance with applicable regulations of
the United States Environmental P rotection Agency and California Air Resources Board.
1. Crankcase Emission Control System
A sealed-type crankcase emission control system is used to eliminate blow-by gases. The
blow-by gases are led to the breather chamber through the crankcase. Then, it is led to the air
cleaner.
Oil is separated from the gases while passing through the inside of the breather chamber from
the crankcase, and then returned back to the bottom of crankcase.
2. Exhaust Emission Control System
The exhaust emission control system applied to this engine consists of a carburetor and an
ignition system having optimum ignition timing characteristics.
The carburetor has been calibrated to provide lean air/fuel mixture characteristics and opti-
mum fuel economy with a suitable air cleaner and exhaust system.
TAMPERING WITH EMISSION CONTROL SYSTEM PROHIBITED
Federal law and California State law prohibits the following acts or the causing thereof: (1) the
removal or rendering inoperative by any person other than for purposes of maintenance, repair,
or replacement, of any device or element of design incorporated into any new engine for the
purpose of emission control prior to its sale or delivery to the ultimate purchaser or while it is in
use, or (2) the use of the engine after such device or element of design has been removed or
rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below:
Do not tamper w ith 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
•
Foreword
This manual is designed primarily for use by
trainedmechanics in a properly equipped shop.
However,itcontainsenough detailand basic i nformationto make ituseful to theowner who desiresto perform his own basicmaintenance 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
beforestarting work, and then do the workca
fully in a clean area. Whenever special tools or
equipment are specified, do not use makeshift
tools or equipment. Precision measurem
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 genu
•
gine parts. Genuine parts provided as spare
parts are listed in the Parts Catalog.
Follow the procedure
•
fully. Don’t take shortcuts.
Remembertokeep complete records ofmain-
•
tenance and repair
parts installed.
with dates and any new
ine Kawasaki en-
s in this manual care-
re-
ents
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, ifyou 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
additiontoWARNINGandCAUTION)whichwill
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 WA
TION, or NOTE.
Indicates a conditional step or what action to
takebased on theresults o
tion in the procedural step or sub-step it fol-
lows.
In most chapters an e
of the system components follows the Table of
Contents. In these illustrations you will find the
instructionsind
ified tightening torque, oil, grease or a locking
agent during assembly.
icatingwhich parts require spec-
xploded view illustration
RNING, CAU-
fthe test or inspec-
GENERAL INFORMATION 1-1
General Information
Table of Contents
Before Servicing ..................................................................................................................... 1-2
Model Identification................................................................................................................. 1-5
General Specifications............................................................................................................ 1-7
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) Battery Ground
Remove the ground (–) lead from the battery before performing any disassembly operations on
the equipment. This prevents:
(a)t he possibility of accidentally turning the engine over while partially disassembled.
(b)sparks at electrical connections which will occur when they are disconnected.
(c)damage t o 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 f or screws (particularlyfor the removal of screws held by a locking agent) in order
to avoid damaging the heads.
(6) Edges
Watchfor sharp edges, especiallyduring 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 commonlyavailable in North America is Standard solvent (genericname). Alwaysfollow 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 matter 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)B all Bearing, Needle Bearing
Do not remove a ball bearing or a needle bearing unless it is absolutely necessary. Replace any
ball or needle bearings that were removed with new ones. Install bearings with the manufacturer
and size marks facing out, applying pressure evenly with a suitable driver to the end of the race
that contacts the press fit portion, and press it evenly over the base component.
GENERAL INFORMATION 1-3
Before Servicing
(12)Oil Seal and Grease Seal
Replace any oil or grease seals that were removed with new ones, as removal generally dam-
ages 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.
(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 and Cotter Pin
When installing circlips and retaining rings, take care to compress or expand them only enough
to install them and no more. Install the circlip with i ts chamfered side facing load side as well.
Replace any circlips, retaining rings, and cotter pins that were removed with new ones, as removal weakens and deforms them. If old ones are reused, they could become detached while
running, leading to a problem.
(15)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.
(16)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.
(17)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.
(18)Inspection
When parts have been disassembled, visually inspect these parts for the following conditions
or other damage. If there i s 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
(19)Service Data
Service Data terms are defined as follows:
“Standards” show dimensions or performances which brand-new parts or systems have.
1-4 GENERAL INFORMATION
Before Servicing
“Service Limits” indicate the usable limits. If the measurement shows excessive wear or deteri-
orated performance, replace the dam aged parts.
Model Identification
FX Models
GENERAL INFORMATION 1-5
FR M odels
1-6 GENERAL INFORMATION
Model Identification
FS M odels
Cylinder Number Designation:
No.1 C ylinder is the left-hand cylinder viewed from the inlet pipe.
No.2 C ylinder is the right-hand cylinder viewed from the inlet pipe.
General Specifications
GENERAL INFORMATION 1-7
Item
Type of Engine Forced air-cooled, vertical shaft, OHV, 4-stroke gasoline engine
Cylinder Layout 90 V-Twin
Bore × Stroke 78 mm × 76 mm (3.07 in. × 2.99 in.)
Piston Displacement 726 cm³ (44.3 cu in.)
Direction of Rotation Counterclockwise facing the PTO shaft
Compression Release Automatic compression release
Low Idle Speed 1 550 r/min (rpm)
High Idle Speed 3 600 r/min (rpm)
Ignition System Transistorized-flywheel magneto
RFI Per Canada and U.S.A. requirements
Starting System:
FR and FS Models Electric starter
FX Models Shift type electric starter
Charging System:
FS and FX Models 12 V - 15 amps with regulator
FR Models 12 V - 3.6 amp without regulator
Spark Plug NGK BPR4ES
Carburetor:
FR and FS Models Float type, fixed main jet, internally vented, single barrel
FX Models Float type, fixed main jet, internally vented, two barrel
Fuel Pump Diaphragm type pulse pump
Air Cleaner:
FR Models Single stage element, dry type
FS Models Dual stage element, dry type
FX Models Dual stage element, heavy duty type
Governor Flyweight all speed governor
Lubrication System Pressure feed by positive displacement pump
Oil Filter Cartridge type full flow filter
Oil Capacity (when engine
is completely dry)
Cooling System Forced air cooling by fan
Dimensions (L × W × H ):
FR Models
FS Models 481 mm × 424 m m × 380 mm (18.9 in. × 16.7 in. × 15.0 in.)
FX Models 478 mm × 424 m m × 549 mm (18.8 in. × 16.7 in. × 21.6 in.)
Dry Weight (withoutmuffler):
FR Models 40.0 kg (88.2 lb)
FS Models 41.0 kg (90.4 lb)
FX Models 46.0 kg (101.4 lb)
2.0 L (2.1 US qt)
481 mm × 424 m m × 380 mm (18.9 in. × 16.7 in. × 15.0 in.)
FR651V,FR691V,FR730V, FS651V,FS691V, FS 730V,
FX651V, FX691V, FX730V
Specifications are subject to change without notice.
PERIODIC MAINTENANCE 2-1
Periodic Maintenance
Table of Contents
Periodic Maintenance Chart ................................................................................................... 2-2
Torque and Locking Agent...................................................................................................... 2-3
Specifications ......................................................................................................................... 2-5
Special Tools .......................................................................................................................... 2-6
Periodic Maintenance Procedures.......................................................................................... 2-7
Fuel System......................................................................................................................... 2-7
Low Idle Speed Adjustment.............................................................................................. 2-7
High Idle Speed Adjustment ............................................................................................. 2-7
Fuel System Cleanliness Inspection................................................................................. 2-8
Element Cleaning and Inspection..................................................................................... 2-9
Air Cleaner Housing (Cap and Body) Inspection.............................................................. 2-10
Engine Top End ................................................................................................................... 2-10
Cylinder Head Cleaning.................................................................................................... 2-10
Va lve Clearance Inspection .............................................................................................. 2-10
Va lve Clearance Adjustment............................................................................................. 2-11
Va lve Seat Inspection ....................................................................................................... 2-12
Valve Seat Repair............................................................................................................. 2-12
Lubrication System.............................................................................................................. 2-15
Engine Oil Level Inspection .............................................................................................. 2-15
Engine Oil Change............................................................................................................ 2-15
Oil Filter Replacement ...................................................................................................... 2-16
Electrical System................................................................................................................. 2-17
Spark Plug Cleaning and Inspection................................................................................. 2-17
Spark Plug Gap Inspection ............................................................................................... 2-17
2
2-2 PERIODIC MAINTENANCE
Periodic Maintenance Chart
To ensure satisfactory operation over an extended period of t ime, 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.
OPERATION
Daily
Check or clean air inlet screen
(1)
First
8hr.
Every
25 hr.
•
) designates that the corresponding item
•
INTERVAL
Every
100 hr.
Every
200 hr.
Every
250 hr.
Every
300hr.
Every
500 hr.
Check and add engine oil
Check for fuel and oil leakage
Check for loose or lost nuts and
screws
Check battery electrolyte level
Replace air cleaner primary
element (Heavy Duty Air
Cleaner) (FX Models) (1)
Check air cleaner secondary
element (Heavy Duty Air
Cleaner) (FX Models) (1)
Replace air cleaner secondary
element (Heavy Duty Air
Cleaner) (FX Models) (1)
Clean air cleaner foam element
(FS Models) (1)
Clean air cleaner paper element
(FR and FS Models) (1)
Replace air cleaner paper
element (FR and FS Models) (1)
Clean dust and dirt from cylinder
and cylinder head fins (1)
•
•
•
•
•
•
•
•
•
•
•
Tighten nuts and screws
Change engine oil
Clean and re-gap spark plugs
Change oil filter
Check and adjust valve
♦
clearance
Clean and lap valve seating
♦
surface
♦
Clean combustion chambers
(1): Service more frequently under dusty conditions.
♦: These items must be performed with the proper tools. See your authorized Kawasaki Engine
Dealer for service, unless you have the proper equipment and mechanical proficiency.
• •
•
•
•
•
•
•
PERIODIC MAINTENANCE 2-3
Torque and Locking Agent
The following tables list 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:
EO: Apply oil to the threads.
L: Apply a non-permanent locking agent to the threads.
Lh: Left-hand threads.
S: Tighten the fasteners following the specified sequence.
Fastener
Fuel System
Carburetor and Inlet Pipe Mounting Nuts 5.9 0.60 52 in·lb
Control Panel Mounting Bolt 5.9 0.60 52 in·lb
Governor Arm Clamp Nut 7.8 0.80 69 in·lb
Governor Arm Joint Bolt 5.9 0.60 52 in·lb Lh
Governor Shaft Plate Screws 2.0 0.20 18 in·lb
Inlet Manifold Bolts
FX Models
Air Cleaner Bracket Mounting Bolts 5.9 0.60 52 in·lb
Air Cleaner Holder Bracket Bolts
Carburetor and Inlet Pipe Mounting B olts
Choke Valve Screws 0.93 0.095 8.2 in·lb
Cover Plate Screw 2.4 0.24 21 in·lb
Drain Screw 2.0 0.20 18 in·lb
Float C hamber Mounting Screws 3.9 0.40 35 in·lb
Throttle Valve Screws 0.93 0.095 8.2 in·lb
FR and FS Models
Control Panel and Inlet Pipe Mounting Bolt 5.9 0.60 52 in·lb
Main Jet 2.3 0.23 20 in·lb
Solenoid Valve 4.5 0.46 40 in·lb
Throttle Valve Screws 0.68 0.069 6.0 in·lb L
FR651V, FR691V, FS651V, FS691V Models
Throttle Lever Mounting Screw 0.68 0.069 6.0 in·lb L
Cooling System
Cooling Fan Plate Mounting Bolts
Cooling Fan Screen Bolts
Flywheel Bolt 56 5.7 41
FX Models
Engine Shroud Bolts 5.9 0.60 52 in·lb
Fan Housing Bolts 5.9 0.60 52 in·lb
Guard Mounting Bolts 5.9 0.60 52 in·lb
FR and FS Models
Engine Shroud Bolts 8.8 0.90 78 in·lb
Fan Housing Bolts 8.8 0.90 78 in·lb
Engine Top End
Connecting Rod Big End C ap Bolts 9.8 1.0 87 in·lb EO
Cylinder Head Bolts (L = 50 mm) 46 4.7 34 S
N·m kgf·m ft·lb
5.9 0.60 52 in·lb
5.9 0.60 52 in·lb
5.9 0.60 52 in·lb
8.8 0.90 78 in·lb
5.9 0.60 52 in·lb
Torque
Remarks
S
2-4 PERIODIC MAINTENANCE
Torque and Locking Agent
Fastener
Cylinder Head Bolts (L = 60 mm) 46 4.7 34 S
Rocker Arm Bracket Bolts 14.7 1.5 11 L
Rocker Cover Bolts
Spark Plugs 22 2.2 16
Valve Clearance Adjusting Locknuts 11 1.1 97 in·lb
Lubrication System
Engine Oil Drain Plug 6.9 0.70 61 in·lb
Oil Pump Cover Plate Bolts 5.9 0.60 52 in·lb
FX Models
Oil Filler Mounting Bolt 5.9 0.60 52 in·lb
FR and FS Models
Oil Filler Mounting Bolt 8.8 0.90 78 in·lb
Camshaft/Crankshaft
Connecting Rod Big End Cap Bolts 9.8 1.0 87 in·lb EO
Crankcase C over Bolts 27.4 2.8 20 S
Crankcase Cover Oil Passage Plugs 3.9 0.40 35 in·lb L
Crankcase Oil Passage Plugs
Breather Chamber Cover Bolts
Breather Valve Mounting Screw 2.0 0.20 18 in·lb
Starter System
Starter Motor Mounting Bolts 19.6 2.0 14
FR and FS Models
Starter Motor Through Bolts 3.95 0.40 35 in·lb
Electrical System
Flywheel Bolt 56 5.7 41
Ignition Coil Bolts 5.9 0.60 52 in·lb
Spark Plugs 22 2.2 16
Stator Coil Screws 3.4 0.35 30 in·lb
N·m
5.9 0.60 52 in·lb
3.9 0.40 35 in·lb L
5.9 0.60 52 in·lb
Torque
kgf·m ft·lb
Remarks
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 Diameter
(mm)
4 2.0 0.20 17 in·lb
5 3.4 0.35 30 in·lb
6 5.9 0.60 52 in·lb
8 15 1.5 11
10 20 2.0 15
N·m kgf·m ft·lb
Torque
PERIODIC MAINTENANCE 2-5
Specifications
Item Standard
Fuel System
Idle Speed (1):
Low Idle Speed (Carburetor idle rpm) 1 450 r/min (rpm)
Low Idle Speed (Governor idle rpm) 1 550 r/min (rpm)
High Idle Speed 3 600 r/min (rpm)
Air Cleaner:
Type:
FR Models Single stage filtration system
FS and FX M odels Dual stage filtration system
Pre-cleaner:
FR Models Paper element
FS Models Foam element
FX Models P aper element
Second-stage cleaner:
FS Models P aper element
FX Models Foam element
Engine Top End
Valve Clearance:
Inlet, Exhaust 0.05 ∼ 0.10 mm (0.0020 ∼ 0.0039 in.)
Valve Seating Surface Angle:
Inlet, Exhaust 45°
Valve Seating Surface Width:
Inlet 1.2 ∼ 1.8 mm (0.047 ∼ 0.071 in.)
Exhaust 0.8 ∼ 1.6 m m (0.031 ∼ 0.063 in.)
Lubrication System
Engine Oil:
Type SF, SG, SH, SJ or SL class
Viscosity SAE 40, SAE 30, SAE 10W-30/SAE 10W-40, or
SAE 5W-20
Capacity 1.8 L (1.9 US qt) (When the oil filter is not removed)
2.1 L (2.2 US qt) (When the oil filter is removed)
Level Operating range (grid area (ADD and FULL)) on dipstick
Electrical System
Spark Plug NGK BPR4ES
Spark Plug Gap 0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.)
(1) Idle speeds may vary depending on each equipment. Refer to the equipment specification.
2-6 PERIODIC MAINTENANCE
Special Tools
Valve Seat Cutter, 45° - 35:
57001-1116
Valve Seat Cutter, 32° - 35:
57001-1121
Valve Seat Cutter Holder Bar:
57001-1128
Valve Seat Cutter, 45° - 30:
57001-1187
Valve Seat Cutter, 32° - 33:
57001-1199
Valve Seat Cutter Holder, 6:
57001-1360
Periodic Maintenance Procedures
Fuel System
NOTE
High and low idle speeds may vary depending on the
○
equipment on which the engine is used. Refer to the
equipment specification.
Low Idle Speed Adjustment
Disconnect all possible external loads from the engine.
•
Start the engine and warm it up thoroughly.
•
WARNING
Always keep your hands clear of the moving parts.
Move the throttle lever at a dash to the idle position.
•
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.
Low Idle Speed (Carburetor idle rpm)
1 4 50 r/min (rpm)
PERIODIC MAINTENANCE 2-7
Release the throttle lever.
•
Loosen the locknut [A].
•
Adjustthelow idlespeed set screw [B]on the controlplate
•
to obtain the specified governor low idle speed.
Low Idle Speed (Gover nor idle rpm)
1 5 50 r/min (rpm)
Tighten the locknut.
•
High Idle Speed Adjustment
NOTE
High idle speed adjustment should be made after the
○
idle speed adjustment is performed.
CAUTIO
Do not adjust high idle speed with the air cleaner
removed.
Start and warm up the engine thoroughly.
•
N
2-8 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
WARNING
Always keep your hands clear of the moving parts.
Loosen the locknut [A], and unscrew the high idle set
•
screw [B] few turns.
Movethethrottleleverondashtoobtainthe specified high
•
idle speed and leave it there.
High Idle Speed
3 600 r/min (rpm)
Turn the high idle set screw so that the end of it just
•
touches the speed control lever [C], and tighten the lock
nut.
Check the idle speed, and readjust the idle speed if nec-
•
essary.
CAUTION
Be sure to make the idle and fast idle speeds re-
spectively correspond to those of the equipment.
Fuel System Cleanliness Inspection
WARNING
Gasoline is extremely flammable and can be ex-
plosive under certain conditions. Turn the engine
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.
FX Models
Place a suitable container [A] under the drain screw [B]
•
on the carburetor.
Turn out the drain screw a few turns to drain the carbu-
•
retor and check if water or dirt has accumulated in the
carburetor.
Tighten the drain screw.
•
FR and FS Models
Place a suitable container under the carburetor.
•
Remove:
•
Solenoid Valve Connector [A]
Solenoid Valve [B]
Float Chamber [C] and Gasket
Check if water or dirt has accumulated in t he carburetor.
•
Install the removed parts (see appropriate chapters).
•
If any water or dirt is found, clean the carburetor (see
Carburetor Cleaning in the Fuel System chapter) and fuel
tank. And check the fuel filter (see Fuel Filter Inspection
in the Fuel System chapter).
Periodic Maintenance Procedures
Element Cleaning and Inspection
Aircleanerelementsarenotrecommendedtobe 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.
FX Models
Remove the elements (see Element Removal in the Fuel
•
System chapter).
Replace the primary element [A] every 250 hrs.
•
PERIODIC MAINTENANCE 2-9
Replace the secondary element [A] with a new one if dirty
•
when primary element is checked.
Replace the secondary element every 500 hrs.
•
CAUTION
Do not wash air cleaner elements. Do not oil air
cleaner elements. Do not use pressurized air to
clean air cleaner elements.
FR Models
Remove the paper element (see Air Cleaner Element Re-
•
moval).
Clean the paper element [A] by tapping it gently on a flat
•
surface to remove dust. If the element is very dirty, re-
place it with a new one.
FS 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 t he element air-dry thoroughly.
Clean the paper element [B] by tapping it gently on a flat
•
surface to remove dust. If the element is very dirty, re-
place it with a new one.
2-10 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Air Cleaner H ousing (Cap and Body) Inspection
FX Models
Remove:
•
Elements (see E lement Removal in the Fuel System
chapter)
Air Cleaner Housing (see Air Cleaner Body and Bracket
Removal in the Fuel System chapter)
Clean the housing with detergent and water and dry the
•
housing thoroughly.
Check the housing for deformation or other damage.
•
Seal the housing well and permit only filtered air to reach
○
the carburetor.
Ifthehousing is damaged, replace thehousing with anew
one.
Check that no foreign material is obstructing the air pas-
•
sage.
Engine Top End
Cylinder Head Cleaning
Scrape the carbon deposits from the cylinder head and
•
the exhaust port with a suitable tool [A
To avoid gouging, use scrapers that are made of a m ate-
○
rial that will not cause damage.
Clean the head in a bath of high-flas
•
dry it with compressed air.
].
h point solvent and
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.
Valve Clearance Inspection
NOTE
Valve clearance must be checked when the engine is
○
cold (at room temperature).
Remove the rocker covers (see Cylinder Head Assembly
•
Removal in the Engine Top End chapter).
Place the piston at the top dead center (TDC) of the com-
•
pressionstroke by turning the crankshaft clockwise facing
the flywheel.
Periodic Maintenance Procedures
No.1 Cylinder
The left projection [A] on the flywheel is faced with the
○
right leg [B] on the #1 ignition coil [C] as shown in the
figure.
Checkthe inlet andexhaust valves are closed completely,
○
ifnot, turn the flywheel one turn(360°) clockwise and face
the left projection with the right leg again.
No.2 Cylinder
The left projection [A] on the flywheel is faced with the
○
right leg [B] on the #2 ignition coil [C] as shown in the
figure. Follow No.1 cylinder alignment.
PERIODIC MAINTENANCE 2-11
Then check the valve clearance.
•
Usingathicknessgauge[A],measurethe valveclearance
○
between the rocker arm [B] and the valve stem end.
If the valve clearance is incorrect, adjust it.
Valve Clearance (when cold)
Inlet, Exhaust 0.05 ∼ 0.10 mm (0.0020 ∼ 0.0039 in.)
Valve Clearance Adjustment
Since valve repairs change the valve clearance, adjust
•
the valve clearance to the specified.
Turnthecrankshaftin properdirection until the pistonis at
•
the TDC of the compression stroke (as described above).
Loosen the locknut [A] and adjusting bolt [B].
•
Insert a 0.05 mm (0.0020 in.) thickness gauge [C] be-
•
tween the rocker arm and valve stem end, and turn the
adjusting bolt until the thickness gauge begins to bind be-
tween the rocker arm and valve stem end. Sweep the
thickness gauge during this adjustment.
Valve Clearance (when cold)
Inlet, Exhaust:
0.05 ∼ 0.10 mm (0.0020 ∼ 0.0039 in.)
2-12 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Holding the adjusting bolt with a spanner [A], tighten the
•
adjusting locknut [B] to the specified torque.
Torque - Valve Clearance Adjusting Locknuts: 11 N·m (1.1
kgf·m, 87 in·lb)
Donot overtighten the valve clearanceadjustinglocknuts.
•
After the valve clearance adjustment, measure the valve
•
clearance again. Readjust the valve clearance if necessary.
Valve Seat Inspection
Removethevalve(seeValveMechanismRemoval/Instal-
•
lation in the Engine Top End chapter).
Inspect the valve seats for damage.
•
If the seats are warped or distorted beyond reconditioning, replace the cylinder head with a new one.
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.
NOTE
The valve stem and guide must be in good condition or
○
this check w ill 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)
Exhaust
Inlet
Valve Seat Repair
Followthemanufacture’sinstructionsforuse of valve seat
•
cutters.
Special Tools-Valve Seat Cutter Holder Bar: 57001-1128
Exhaust Valve
Valve Seat Cutter, 45° Valve Seat Cutter, 32° -
0.8 ∼ 1.6 mm (0.039 ∼ 0.059 in.)
1.2 ∼ 1.8 mm (0.043 ∼ 0.067 in.)
Valve Seat Cutter Holder,
30: 57001-1187
33: 57001-1199
6: 57001-1360
Inlet Valve
Valve Seat Cutter, 45° Valve Seat Cutter, 32° -
Ifthe manufacture’s instructions are not available, use the
following procedure.
35: 57001-1116
35: 57001-1121
Periodic Maintenance Procedures
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, op-
erate the cutter [B] with one hand [C]. Do not apply too
much force to the diamond portion.
NOTE
Prior to grinding, apply engine oil to the cutter, and dur-
○
ing the operation wash off any ground particles sticking
to the cutter with washing oil.
PERIODIC MAINTENANCE 2-13
5. After use wash the cutter with washing oil and apply a
thin layer of engine oil before storing.
Marks Stamped on the Cutter
The marks stamped on the back of the cutter represent the
following.
32° Cutter angle [A]
37.5 Cutter diameter [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 standard
•
width, the seating surface should be r efaced.
If the valve seating pattern is not correct, repair the seat.
2-14 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
Coat the seat with machinist’s dye.
•
Fit a 45° 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
beimpossible 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.
Use a 32° seat cutter [A] to narrow the seat width to the
•
standard width.
Turntheseatcutteroneturnatatimewhile pressingdown
○
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
Keepthe seat width as closeas possible to thestandard
○
width.
Make a light contact on the valve seat 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 m achinist’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 lapper.
Coat the face of valve sparingly with a fine lapping com-
•
pound.
Use the lappingtool [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.
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