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Kawasaki FH381V - Service Manual

Other manuals for FH381V -: Datasheet
Manual is about: 4–stroke air cooled v-twin gasoline engine

Summary of FH381V -

  • Page 1

    Fh381v fh430v 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...

  • Page 2

    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...

  • Page 3

    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 boa...

  • Page 4: Foreword

    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 us...

  • Page 5: General Information

    General information 1-1 general information table of contents 1 before servicing................................................................................................................................................................1-2 model identification ......................................

  • Page 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 accoun...

  • Page 7

    General information 1-3 before servicing (15) cotter pin replace any cotter pins that were removed with new ones, as removal deforms and breaks them. (16) lubrication engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricati...

  • Page 8

    1-4 general information model identification electric starter model recoil starter model cylinder number designation: no.1 cylinder is the left-hand cylinder viewed from the air cleaner. No.2 cylinder is the right-hand cylinder viewed from the air cleaner..

  • Page 9

    General information 1-5 general specifications items fh381v, fh430v type of engine forced air-cooled, vertical shaft, ohv, 4-stroke gasoline engine. Cylinder layout 90 v-twin bore x stroke 65 mm x 65 mm (2.56 in x 2.56 in) piston displacement 431 ml (26.3 cu. In) direction of rotation counterclockwi...

  • Page 10

    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 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. ...

  • Page 11

    General information 1-7 torque and locking agent fastener torque remarks n 1 m kgf 1 m ft 1 lb lubrication system: engine drain plugs 6.9 0.70 61 in 1 lb oil passage plug 3.9 0.40 35 in 1 lb oil pump cover plate mounting bolts 5.9 0.60 52 in 1 lb oil filter in the text camshaft/crankshaft: crankcase...

  • Page 12

    1-8 general information special tools piston ring pliers: 57001–115 oil pressure gauge, 5kgf/cm 2 : 57001–125 compression gauge: 57001–221 oil pressure gauge adapter, pt 1/8: 57001–1033 piston ring compression grip: 57001–1095 piston ring compression belt, Ø55 – Ø67: 57001–1096 valve seat cutter, 45...

  • Page 13

    General information 1-9 special tools compression gauge adapter m14 x 1.25: 57001–1159 oil filter wrench: 57001–1249 valve seat cutter holder Ø6: 57001–1360 hand tester: 57001–1394 kawasaki bond (silicone sealant) : 56019–120

  • Page 15: Periodic Maintenance

    Periodic maintenance 2-1 periodic maintenance table of contents 2 periodic maintenance chart..............................................................................................................................................2-2 specifications ..................................................

  • Page 16

    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...

  • Page 17

    Periodic maintenance 2-3 specifications item standard fuel system idle speed: (1) low idle speed 1550 r/min (rpm) high idle speed 3600 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...

  • Page 18

    2-4 periodic maintenance periodic maintenance procedures fuel system low idle speed adjustment • disconnect all possilble external loads from the engine. • start the engine and warm it up thoroughly. Always keep your hands clear of the moving parts. • move the throttle lever on dash to the idle posi...

  • Page 19

    Periodic maintenance 2-5 periodic maintenance procedures fuel system cleanliness inspection gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch off. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; th...

  • Page 20

    2-6 periodic maintenance periodic maintenance procedures air element removal • push down the latches [a] and remove the air cleaner case [b]. • remove: paper element [a] foam element [b] air element installation • install the element correctly on the air cleaner case. • be sure the foam element is i...

  • Page 21

    Periodic maintenance 2-7 periodic maintenance procedures • remove the foam element and the paper 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...

  • Page 22

    2-8 periodic maintenance periodic maintenance procedures 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 turnin...

  • Page 23

    Periodic maintenance 2-9 periodic maintenance procedures 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. La...

  • Page 24

    2-10 periodic maintenance 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] 37.5 cutter diameter of cutter [b] ks8b manufactured lot number operating procedures:...

  • Page 25

    Periodic maintenance 2-11 periodic maintenance procedures • 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 ...

  • Page 26

    2-12 periodic maintenance periodic maintenance procedures 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 conta...

  • Page 27

    Periodic maintenance 2-13 periodic maintenance procedures 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...

  • Page 29: Fuel System

    Fuel system 3-1 fuel system table of contents 3 exploded view...................................................................................................................................................................3-2 specifications ............................................................

  • Page 30

    3-2 fuel system exploded view 1. Pilot screw 2. Main jet t1: 0.7 n 1 m (0.07 kgf 1 m, 6 in 1 lb) t2: 2.3 n 1 m (0.23 kgf 1 m, 20 in 1 lb) t3: 4.5 n 1 m (0.46 kgf 1 m, 40 in 1 lb) t4: 5.9 n 1 m (0.60 kgf 1 m, 52 in 1 lb) t5: 6.9 n 1 m (0.70 kgf 1 m, 61 in 1 lb) l: apply non-permanent locking agent. O...

  • Page 31

    Fuel system 3-3 exploded view t1: 2.0 n 1 m (0.20 kgf 1 m , 18 in 1 lb) t2: 5.9 n 1 m (0.60 kgf 1 m , 52 in 1 lb) t3: 7.8 n 1 m (0.80 kgf 1 m , 69 in 1 lb) o: apply engine oil..

  • Page 32

    3-4 fuel system specifications standard item fh381v fh430v caburetors specifications: make/ type walbro lmf-2 walbro lmf-1 throttle bore diameter 24 mm (0.94 in.) venturi diameter 14 mm (0.55 in) 16 mm (0.63 in.) main jet (mj) #78 #88 pilot jet (pj) #40 pilot air screw turns out (ps) 1 1/4 1 5/8 (id...

  • Page 33

    Fuel system 3-5 governor link mechanism control panel assembly removal • remove: air cleaner (see cleaner body removal) control panel mounting bolts [a] • remove the control panel assembly [a] while unhooking the governor spring [b] end loop at the panel bracket. • clear the choke link rod lower end...

  • Page 34

    3-6 fuel system governor link mechanism governor arm installation • install the governor arm [a] onto the governor shaft [b] temporarily. • be sure the link spring [c] around the throttle link rod [d] is in place and that it pulls the governor arm and throttle lever [e] toward each other. • loosen t...

  • Page 35

    Fuel system 3-7 governor link mechanism governor assembly inspection visually check all governor parts for wear and damage. If any parts are worn or damaged, replace them. Governor shaft removal • split the crankcase (see camshaft/crankcase chapter). • unscrew the governor shaft plate screws [a], an...

  • Page 36

    3-8 fuel system carburetor fuel and air flow the main system of the carburetor consists of the main jet [a], main nozzle [b], and the main air passage [c] (main air jet [d]). The main system meters fuel to the engine during moderate to heavy load conditions. Fuel flows through the main jet and into ...

  • Page 37

    Fuel system 3-9 carburetor low idle speed adjustment refer to low idle speed adjustment in the periodic maintenance chapter (2nd chapter). High idle speed adjustment refer to high idle speed adjustment in the periodic maintenance chapter (2nd chapter). High altitude operation at high altitude, the s...

  • Page 38

    3-10 fuel system carburetor carburetor removal gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch off. Do not smoke. Make sure the area is well- ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light...

  • Page 39

    Fuel system 3-11 carburetor carburetor disassembly/assembly • refer to the illustration shown for disassembly and assembly. • there are several passage plugs (ball plugs) in the carburetor body. Do not remove. • before disassembly, mark the out side of choke valve and throttle valves for assembling ...

  • Page 40

    3-12 fuel system carburetor carburetor cleaning clean the carburetor in a well-ventilated area, and take care that there is no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline or low...

  • Page 41

    Fuel system 3-13 carburetor • with the float [a] assembly installed onto the carburetor body [b], hold the carburetor upside down at eye level. Gently support the float with a finger and bring it down slowly so that the float arm tab [c] just touches the float valve [d]. The float lower surface [e] ...

  • Page 42

    3-14 fuel system intake manifold intake manifold removal • remove: air cleaner (see cleaner body removal) engine upper cover carburetor (see carburetor removal) • remove the harness from the clamps [a] on the intake manifold. • unscrew the manifold mounting bolts [b]. Intake manifold installation • ...

  • Page 43

    Fuel system 3-15 intake manifold intake manifold inspection • inspect the intake manifold for cracks. • cracks not visible to the eye may be detected by using a metal crack detection system. (visual color check: commonly found at automotive parts store.) if a crack is present in the intake manifold,...

  • Page 44

    3-16 fuel system fuel pump, fuel filter the fuel pump cannot be disassembled, if any damage to the pump is noticed replace it with a new one. Fuel pump inspection refer to fuel pump inspection in the periodic maintenance chapter (2nd chapter). Fuel filter inspection refer to fuel filter inspection i...

  • Page 45

    Fuel system 3-17 air cleaner element removal refer to air element removal in the periodic maintenance chapter (2nd chapter). Element installation refer to air element instalation in the periodic maintenance chapter (2nd chapter). Element cleaning and inspection refer to air element cleaning and insp...

  • Page 47: Cooling System

    Cooling system 4-1 cooling system table of contents 4 exploded view...................................................................................................................................................................4-2 cooling fan..........................................................

  • Page 48

    4-2 cooling system exploded view t1: 3.4 n 1 m (0.35 kgf 1 m, 30 in 1 lb) t2: 5.9 n 1 m (0.60 kgf 1 m, 52 in 1 lb) t3: 7.8 n 1 m (0.80 kgf 1 m, 69 in 1 lb) t4: 15 n 1 m (1.5 kgf 1 m, 11 ft 1 lb) t5: 56 n 1 m (5.7 kgf 1 m, 41 ft 1 lb).

  • Page 49

    Cooling system 4-3 cooling fan cooling fan removal refer to flywheel removal in electrical system chapter. Cooling fan installation refer to flywheel installation in electrical system chapter. Cooling fan inspection • visually inspect the blades [a] in the cooling fan [b]. If they are any cracks, wa...

  • Page 51: Engine Top End

    Engine top end 5-1 engine top end table of contents 5 exploded view...................................................................................................................................................................5-2 specifications ......................................................

  • Page 52

    5-2 engine top end exploded view t1: 5.9 n 1 m (0.60 kgf 1 m, 52 in 1 lb) t2: 6.9 n 1 m (0.70 kgf 1 m, 61 in 1 lb) t3: 22 n 1 m (2.2 kgf 1 m, 16 ft 1 lb) t4: 25 n 1 m (2.6 kgf 1 m, 19 ft 1 lb) t5: 28 n 1 m (2.8 kgf 1 m, 20 ft 1 lb) o: apply engine oil. G: apply grease. S: follow the specific tighten...

  • Page 53

    Engine top end 5-3 exploded view t1: 15 n 1 m (1.5 kgf 1 m, 11 ft 1 lb).

  • Page 54

    5-4 engine top end specifications item service limit cylinder head: cylinder compression (min) [390 kpa (57 psi)] (min) cylinder head warp 0.03 mm (0.001 in.) valves: valve head thickness intake, exhaust 0.35 mm (0.014 in.) valve stem runout intake, exhaust 0.05 mm (0.002 in.) valve stem diameter in...

  • Page 55

    Engine top end 5-5 cylinder head compression measurement • before measuring compression, do the following: be sure the battery is fully charged. Thoroughly warm up the engine so that engine oil between the piston and cylinder wall will help seal compression as it does during normal running. Stop the...

  • Page 56

    5-6 engine top end cylinder head cylinder head assembly removal • remove: air cleaner and carburetor (see fuel system chapter) muffler (see muffler exhaust pipe removal) intake manifold (see fuel system chapter) spark plug • unscrew the rocker cover mounting bolts [a], and remove the cover [b] and g...

  • Page 57

    Engine top end 5-7 cylinder head push rod removal • set each cylinder at t.D.C of power stroke. • remove the rocker covers (see cylinder head assembly removal). • loosen the valve clearance adjusting nuts [a]. • move the rocker arms [b] to clear the push rod upper ends. • pull out the push rods. Not...

  • Page 58

    5-8 engine top end cylinder head push rod inspection • place the rocker arm push rod in v blocks that are as far apart as possible, and set a dial gauge on the rod at a point halfway between the blocks. Turn the rod to measure the runout. The difference between highest and the lowest dial readings i...

  • Page 59

    Engine top end 5-9 cylinder head cleaning and inspection refer to cylinder head cleaning and inspection in the periodic maintenance chapter (2nd chapter). Rocker arm inspection • clean and inspect the rocker arm where it touches the push rod and valve stem. If the contact points [a] are worn or dama...

  • Page 60

    5-10 engine top end valves valve clearance inspection refer to valve clearance inspection in the periodic maintenance chapter (2nd chapter). Valve clearance adjustment refer to valve clearance adjustment in the periodic maintenance chapter (2nd chapter). Valve seat inspection refer to valve seat ins...

  • Page 61

    Engine top end 5-11 valves valve spring inspection • inspect the valve spring for pitting, cracks, rusting, and burns. Replace the spring if necessary. • measure the free length [a] of the spring. If the measurement is less than the service limit, replace the spring. Valve spring free length service...

  • Page 62

    5-12 engine top end cylinder, piston piston removal • split the crankcase (see camshaft/crankshaft chapter). • remove the camshaft (see camshaft/crankshaft chapter). • turn the crankshaft to expose the connecting rod cap bolts [a]. • remove the bolts and take off the connecting rod caps [b]. Note no...

  • Page 63

    Engine top end 5-13 cylinder, piston piston installation • install the expander [a] in the piston oil ring groove so that the expander ends [b] touch together, never overlap. • install the upper and lower steel rails. There is no up or down to the rails. They can be installed either way. • do not mi...

  • Page 64

    5-14 engine top end cylinder, piston • apply engine oil to the piston skirt and the cylinder bore. Using the piston ring compressor grip [a] and the belt [b], lightly tap the top of the piston with a plastic mallet [c] to insert the piston and connecting rod into the cylinder. Special tools - piston...

  • Page 65

    Engine top end 5-15 cylinder, piston piston cleaning • remove the piston and piston rings (see piston removal). Caution never clean the piston head with the engine assembled. Carbon particles will fall between the piston and cylinder, and damage the crankshaft bearings. • scrape the carbon off [a] t...

  • Page 66

    5-16 engine top end cylinder, piston piston ring end gap • remove the piston rings. • push each ring (one at a time) in the cylinder bore to a point close to the bottom of the cylinder bore. Use the piston to push it in to be sure it is square. • measure the gap [a] between the ends of the ring [b] ...

  • Page 67

    Engine top end 5-17 cylinder, piston piston diameter • measure the outside diameter [a] of the piston 12.5 mm (0.9 in.) up [b] from the bottom of the piston at a right angle to the direction of the piston pin hole. If the measurement is less than the service limit, replace the piston. Piston diamete...

  • Page 68

    5-18 engine top end cylinder, piston change to a honing stone for finishing, the final bore diameter should be as shown in the table. Be sure the correct stone is used and the stone is not worn. • clean the cylinder at the top and bottom of the cylinder to remove burns and pieces of the base and hea...

  • Page 69

    Engine top end 5-19 muffler/exhaust pipe installation muffler/exhaust pipe removal • loosen the clamp nut [a]. • remove the bolt [b] on the muffler bracket and take off the muffler. • unscrew the exhaust pipe flange nuts [a], and remove the exhaust pipe [b] with pipe cover [c]. Use a penetrating oil...

  • Page 71: Lubrication System

    Lubrication system 6-1 lubrication system table of contents 6 exploded view...................................................................................................................................................................6-2 engine oil flow chart........................................

  • Page 72

    6-2 lubrication system exploded view t1: 3.9 n 1 m (0.40 kgf 1 m, 35 in 1 lb) t2: 5.9 n 1 m (0.60 kgf 1 m, 52 in 1 lb) t3: 6.9 n 1 m (0.70 kgf 1 m, 61 in 1 lb) t4: see the text o: apply engine oil..

  • Page 73

    Lubrication system 6-3 specifications.

  • Page 74

    6-4 lubrication system specifications item standard engine oil: type sf, sg, sh or sj class viscosity sae40, sae30, sae10w-30/sae10w-40, or sae5w-20 capacity [when filter is not removed] 1.5 l (1.6 us qt) [when filter is removed] 1.7 l (1.8 us qt) level operating range (grid area) on dipstick oil pr...

  • Page 75

    Lubrication system 6-5 engine oil and oil filter caution engine operation with insufficient, deteriorated, or contami- nated engine oil will cause accelerated wear and may result in engine seizure and accident. Before starting the engine for the first time, add oil: the engine is shipped dry. Preoil...

  • Page 76

    6-6 lubrication system pressurized lubrication system the engine lubrication circuit is a pressurized system consisting of a positive displacement pump which picks up oil through a filter screen from the crankcase. The oil is pumped to a replaceable oil filter cartridge, through the engine’s oil pas...

  • Page 77

    Lubrication system 6-7 oil pump, relief valve oil pump, relief valve removal • remove the crankcase cover (see camshaft/crankshaft chapter). • unscrew the mounting bolts and remove the oil pump parts assembly (pump gear, pump cover plate, pump shaft, pins and rotors). • take off the relief valve spr...

  • Page 78

    6-8 lubrication system oil pump, relief valve • measure the inside diameter [a] of the pump housing with an inside micrometer at several points. If the inside diameter is more than the service limit, replace the crankcase cover. Pump housing inside diameter service limit: 40.801 mm (1.6063 in.) • me...

  • Page 79

    Lubrication system 6-9 oil screen oil screen removal • remove the crankcase cover (see camshaft/crankcase chapter). • unscrew the mounting bolts [a] and remove the oil pump parts assembly. • remove the oil screen [b] oil screen installation • clean the oil screen thoroughly whenever it is removed fo...

  • Page 81: Camshaft/crankshaft

    Camshaft/crankshaft 7-1 camshaft/crankshaft table of contents 7 exploded view...................................................................................................................................................................7-2 specifications ............................................

  • Page 82

    7-2 camshaft/crankshaft exploded view t1: 5.9 n 1 m (0.60 kgf 1 m, 52 in 1 lb) t2: 25 n 1 m (2.6 kgf 1 m, 19 ft 1 lb) t3: see engine top end chapter. O: apply engine oil. G: apply grease. M: apply molybdenum disulfide grease. Ss: apply silicone sealant. S: follow the specific tightening sequence..

  • Page 83

    Camshaft/crankshaft 7-3 specifications item service limit camshaft, tappet: cam lobe height intake 29.131 mm (1.1469 in.) exhaust 29.131 mm (1.1469 in.) camshaft journal diameter pto side 15.985 mm (0.6293 in.) flywheel side 15.985 mm (0.6293 in.) camshaft bearing inside diameter crankcase 16.136 mm...

  • Page 84

    7-4 camshaft/crankshaft crankcase crankcase cover removal • set the engine on a clean surface while parts are being removed. • drain the oil (see lubrication system chapter). • remove: exhaust pipe and muffler (see engine top end chapter) control panel (see fuel system chapter) governor arm (see fue...

  • Page 85

    Camshaft/crankshaft 7-5 crankcase • check to see that the crankcase dowel pins [a] are in place on the crankcase. • install the gasket on the crankcase. • install the crankcase cover and tighten the crankcase cover bolts following the tightening sequence shown. Torque - crankcase cover bolts: 25 n 1...

  • Page 86

    7-6 camshaft/crankshaft breather the function of the breather is to create a vacuum in the crankcase which prevents oil from being forced out of the engine through the piston rings, oil seals or gaskets. A sealed-type crankcase emission control system is used to eliminate blow-by gases. The blow-by ...

  • Page 87

    Camshaft/crankshaft 7-7 breather breather chamber cover removal • remove the bolts [a] and breather chamber cover [b]. Breather chamber cover installation • apply sealant [a] to the mating surface of the crankcase. Sealant - kawasaki bond (silicone sealant) : 56019-120 • install a new gasket and the...

  • Page 88

    7-8 camshaft/crankshaft camshaft, tappet camshaft, tappet removal • set the engine on a clean surface while parts are being removed. • drain the oil (see lubrication system chapter). • remove: muffler (see engine top end chapter) throttle control panel (see fuel system chapter) carburetor (see fuel ...

  • Page 89

    Camshaft/crankshaft 7-9 camshaft, tappet camshaft disassembly • remove the governor assembly (see fuel system chapter). • remove: spring [a] do not remove the acr (automatic compression release) weight [b]. Camshaft assembly • install the governor assembly (see fuel system chapter). • after assembli...

  • Page 90

    7-10 camshaft/crankshaft camshaft, tappet • measure the inside diameter [a] of the camshaft bearing on the crankcase at several points. This bearing is not replaceable. Replace the crankcase if the inside diameter is more than the service limit. Camshaft bearing inside diameter (crankcase) service l...

  • Page 91

    Camshaft/crankshaft 7-11 crankshaft, connecting rod connecting rod removal • remove: piston (see engine top end chapter) connecting rod installation • install: piston (see engine top end chapter) crankshaft removal • set the engine on a clean surface while parts are being removed. • drain the oil (s...

  • Page 92

    7-12 camshaft/crankshaft crankshaft, connecting rod • measure connection rod twist. With the big-end arbor still on the v blocks, hold the connection rod horizontally and measure the amount that the small end arbor varies from being parallel with the surface plate over a 100 mm length of the arbor t...

  • Page 93

    Camshaft/crankshaft 7-13 crankshaft, connecting rod crankshaft runout • measure the crankshaft runout. Set the crankshaft in a flywheel alignment jig or on v blocks gauge. Set a dial gauge against both bearing journals. Turn the crankshaft slowly to measure the runout. The difference between the hig...

  • Page 95: Electrical System

    Electrical system 8-1 electrical system table of contents 8 exploded view...................................................................................................................................................................8-2 specifications ................................................

  • Page 96

    8-2 electrical system exploded view t1: 3.4 n 1 m (0.35 kgf 1 m, 30 in 1 lb) t2: 5.9 n 1 m (0.60 kgf 1 m, 52 in 1 lb) t3: 7.8 n 1 m (0.80 kgf 1 m, 69 in 1 lb) t4: 22 n 1 m (2.2 kgf 1 m, 16 ft 1 lb) t5: 56 n 1 m (5.7 kgf 1 m, 41 ft 1 lb).

  • Page 97

    Electrical system 8-3 exploded view t1: 3.9 n 1 m (0.40 kgf 1 m, 35 in 1 lb) t2: 5.9 n 1 m (0.60 kgf 1 m, 52 in 1 lb) t3: 7.8 n 1 m (0.80 kgf 1 m, 69 in 1 lb) t4: 15 n 1 m (1.5 kgf 1 m, 11 ft 1 lb) g: apply grease. O: apply engine oil..

  • Page 98

    8-4 electrical system specifications item standard service limit charging system: regulated output voltage 14.1 v dc/3600 rpm 15 v dc/3600 rpm alternator stator coil resistance in the text – – – unregulated stator output 28.4 v ac/3000 rpm 26v ac/3000 rpm regulator resistance in the text ignition sy...

  • Page 99

    Electrical system 8-5 wiring diagram.

  • Page 100

    8-6 electrical system wiring diagram.

  • Page 101

    Electrical system 8-7 wiring diagram.

  • Page 102

    8-8 electrical system precautions there are a number of important precautions that are musts when servicing electrical systems. Learn and observe all the rules below. Do not reverse the battery lead connections. This will burn out the diodes in the electrical parts. Always check battery condition be...

  • Page 103

    Electrical system 8-9 charging, ignition system flywheel, stator coil removal • remove: recoil starter (see recoil starter removal) nuts [a] and guard [b] screws [c] and screen [d] spacer [e] • loosen the fan housing bolts [a] and remove the fan housing [b]. • remove: ignition coils (see ignition co...

  • Page 104

    8-10 electrical system charging, ignition system • remove: woodruff key [a] stator coil lead connector [b] stator coil screw [c] stator coil [d] flywheel, stator coil installation • install the stator coil and tighten the screws. Torque - stator coil screws: 3.4 n 1 m (0.35 kgf 1 m, 30 in 1 lb) • us...

  • Page 105

    Electrical system 8-11 charging, ignition system • install the fan housing and tighten the bolts. Torque - fan housing bolts: 5.9 n 1 m (0.60 kgf 1 m, 52 in 1 lb) • install: recoil starter (see recoil starter installation) • install: spacer [a] screen [b] position three sets [c] of screen notches ar...

  • Page 106

    8-12 electrical system charging, ignition system stator coil resistance • disconnect the connector [a]. • measure the stator coil resistance. (electric starter model) connect an ohmmeter between stator pins [b]. Stator coil resistance (electric starter model) 0.01 to 0.1 (recoil starter model with e...

  • Page 107

    Electrical system 8-13 charging, ignition system regulator resistance • set the kawasaki hand tester selector switch to the r 2 100 position. • connect the test leads to the points shown on the chart and read the resistance. There are two(2) types of regulator on fh engines as follows: (with out cha...

  • Page 108

    8-14 electrical system charging, ignition system this engine ignition is controlled by a solid state ignition assembly and requires no periodic maintenance except for the spark plugs. The system consists of the following: inductive ignition assemblies permanent magnet flywheel spark plugs stop switc...

  • Page 109

    Electrical system 8-15 charging, ignition system ignition coil removal • remove: fan housing (see flywheel, stator coil removal) spark plug cap [a] stop switch lead connector [b] bolts [c] ignition coil [d] ignition coil installation • install ignition coil on crankcase so that the stop switch lead ...

  • Page 110

    8-16 electrical system charging, ignition system ignition coil inspection • remove the ignition coils (see ignition coil removal). • measure the winding resistance as follows: set the hand tester to the r 2 1 k range. Special tool - hand tester: 57001–1394 make the measurements shown in the table. I...

  • Page 111

    Electrical system 8-17 starter system starter motor removal • remove the mounting bolts [a] and pull the starter motor [b] from the engine. Starter motor installation • clean the starter motor and engine mounting flanges to ensure good electrical contact and tighten the mounting bolts. Torque - star...

  • Page 112

    8-18 electrical system starter system starter motor assembly • assembly is the reverse of disassembly. • apply a small amount of grease to the armature shaft [a]. • press the springs and holding the brush leads with suitable clips. • fit the brush assembly [a] into the armature [b]. • fit the projec...

  • Page 113

    Electrical system 8-19 starter system armature inspection • inspect the surface of the commutator [a]. If it is scratched or dirty, polish it with a piece of very fine emery cloth [b], and clean out the grooves. • measure the depth of the grooves between the commutator segments. If the grooves are s...

  • Page 114

    8-20 electrical system starter system pinion clutch inspection • turn the pinion gear by hand. The pinion gear should turn clockwise freely. If the pinion clutch does not operate as it should, or if it makes noise, replace the pinion clutch. Recoil starter removal • remove: recoil starter mounting n...

  • Page 115

    Electrical system 8-21 starter system • remove: screw [a] washer [b] retainer [c] center spring [d] washer [e] pawls [f] return springs [g] when removing the reel [a], be careful that the recoil spring [b] under the reel does not fly loose and cause injury. The spring is under great pressure. Note t...

  • Page 116

    8-22 electrical system starter system recoil starter assembly wear gloves during the recoil spring installation to avoid injury. The recoil spring must be assembled with great pressure. • lightly grease the recoil spring. • set the recoil spring into the spring cassette. • wind the rope clockwise [a...

  • Page 117

    Electrical system 8-23 starter system • while holding the reel to keep it from unwinding, feed the end of the rope through the hole in the case. • clip the rope as shown to hold it. • install the handle [a], and secure it with a knot [b]. • remove the clip [c] to release the rope..

  • Page 119: Troubleshooting

    Troubleshooting 9-1 troubleshooting table of contents 9 engine troubleshooting guide..........................................................................................................................................9-2 starter motor troubleshooting guide..........................................

  • Page 120

    9-2 troubleshooting engine troubleshooting guide if the engine malfunctions, check if the way the engine is used is correct. If engine malfunctions even if engine is used correctly, systematically carry out troubleshooting starting with simple points. This chart describes typical troubleshooting pro...

  • Page 121

    Troubleshooting 9-3 engine troubleshooting guide.

  • Page 122

    9-4 troubleshooting engine troubleshooting guide.

  • Page 123

    Troubleshooting 9-5 engine troubleshooting guide.

  • Page 124

    9-6 troubleshooting starter motor troubleshooting guide 1. Disconnect spark plug caps from the spark plugs. 2. Turn engine switch to “start” position and check condition. Engine may be cranked in this test. Do not touch any rotating parts of engine and equipment during test. Caution if starter does ...