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- FH451V
- Service Manual
Kawasaki FH451V Service Manual
Summary of FH451V
Page 1
Fh451v, fh500v, fh531v fh541v, fh580v, fh601v fh641v, fh680v, fh721v 4-stroke air-cooled v-twin gasoline engine.
Page 3: Quick Reference Guide
This quick reference guide will assist you in locating a desired topic or pro- cedure. •bend the pages back to match the black tab of the desired chapter num- ber 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 th...
Page 5: Fh451V, Fh500V, Fh531V
Fh451v, fh500v, fh531v fh541v, fh580v, fh601v fh641v, fh680v, fh721v 4–stroke air cooled v-twin 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...
Page 6
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 7
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 8: Foreword
Foreword this manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic in- formation to make it useful to the owner who de- sires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the prope...
Page 9: General Information
General information 1-1 1 general information table of contents before servicing ..................................................................................................................... 1-2 model identification................................................................................
Page 10
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 in- cluded wherever necessary. Nevertheless, even a detailed acco...
Page 11
General information 1-3 before servicing when pressing in a seal which has manufacturer’s marks, press it in with the marks facing out. Seals should be pressed into place using a suitable driver, which contacts evenly with the side of seal, until the face of the seal is even with the end of the hole...
Page 12
1-4 general information model identification electric starter model-fh500v recoil starter model-fh500v 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 13
General information 1-5 model identification electric starter model-fh580v electric starter model-fh680v.
Page 14
1-6 general information general specifications items fh451v, fh500v, fh531v fh541v, fh580v fh601v, fh641v, fh680v fh721v type of engine forced air-cooled, vertical shaft, ohv, 4-stroke gasoline engine. Cylinder layout 90 v-twin bore × stroke 68 mm × 68 mm 74 mm × 68 mm 75.2 mm × 76 mm (2.68 in. × 2....
Page 15
General information 1-7 periodic maintenance chart to ensure satisfactory operation over an extended period of time, any engine requires normal main- tenance regular intervals. The periodic maintenance chart below shows periodic inspection and maintenance items and suitable intervals. The bullet mar...
Page 16
1-8 general information periodic maintenance chart fh601v, fh641v, fh680v, fh721v operation interval daily first 8 hr. Every 25 hr. Every 50 hr. Every 100 hr. Every 200 hr. Every 300 hr. Check or clean air intake screen • check and add engine oil • check for fuel and oil leakage • check for loose or...
Page 17
General information 1-9 torque and locking agent the following tables lists the tightening torque for the major fasteners, and the parts requiring use of a non-permanent locking agent or liquid gasket. Letters used in the "remarks" column mean: l : apply a non-permanent locking agent to the threads....
Page 18
1-10 general information torque and locking agent fh451v, fh500v, fh531v, fh541v, fh580v torque fastener n·m kgf·m ft·lb remarks rocker cover mounting bolts 5.9 0.6 52 in·lb exhaust pipe flange nuts 15 1.5 11 spark plugs 22 2.2 16 lubrication system: engine drain plugs (plastic) 6.9 0.7 61 in·lb eng...
Page 19
General information 1-11 torque and locking agent the following tables lists the tightening torque for the major fasteners, and the parts requiring use of a non-permanent locking agent or liquid gasket. Letters used in the "remarks" column mean: l : apply a non-permanent locking agent to the threads...
Page 20
1-12 general information torque and locking agent fh601v, fh641v, fh680v, fh721v fasteners torque remarks n·m kgf·m ft·lb oil pressure switch 9.8 1.0 87 in·lb ss oil passage plug 3.9 0.40 35 in·lb oil pump cover plate mounting bolts 5.9 0.6 52 in·lb oil filter in the text ← ← oil cooler mounting joi...
Page 21
General information 1-13 special tools compression gauge : 57001–221 piston ring pliers : 57001–115 piston ring compressor grip : 57001–1095 piston ring compressor belt, 67 ∼ 79 : 57001–1097 valve seat cutter holder bar : 57001–1128 valve seat cutter holder, 6 : 57001–1360 valve seat cutter, 45° – 3...
Page 22
1-14 general information special tools oil filter wrench : 57001–1249 hand tester : 57001–1394 kawasaki bond (silicone sealant) : 56019–120
Page 23: Fuel System
Fuel system 2-1 2 fuel system table of contents exploded view................................... 2-2 specifications .................................... 2-10 governor link mechanism................. 2-11 control panel assembly removal 2-11 control panel assembly installation ...........................
Page 24
2-2 fuel system exploded view [fh451v, fh500v, fh531v].
Page 25
Fuel system 2-3 exploded view [fh451v, fh500v, fh531v] 1. Pilot screw 2. Pilot air jet 3. Main air jet 4. Main jet 5. Pilot jet 6. Solenoid valve 7. Out vent tube (before 2003/5 product model) t1: 0.7 n·m (0.07 kgf·m, 6 in·lb) t2: 1.0 n·m (0.10 kgf·m, 9 in·lb) t3: 1.3 n·m (0.13 kgf·m, 11 in·lb) t4: ...
Page 26
2-4 fuel system exploded view [fh541v, fh580v].
Page 27
Fuel system 2-5 exploded view [fh541v, fh580v] 1. Pilot screw 2. Main jet 3. Solenoid valve t1: 0.7 n·m (0.07 kgf·m, 6 in·lb) t2: 2.3 n·m (0.23 kgf·m, 20 in·lb) t3: 4.5 n·m (0.46 kgf·m, 40 in·lb) t4: 3.4 n·m (0.35 kgf·m, 30 in·lb) t5: 5.9 n·m (0.6 kgf·m, 52 in·lb) l: apply non-permanent locking agen...
Page 28
2-6 fuel system exploded view [fh601v, fh641v, fh680v, fh721v].
Page 29
Fuel system 2-7 exploded view [fh601v, fh641v, fh680v, fh721v] 1. Pilot screw 2. Pilot air jet 3. Main air jet 4. Main jet 5. Pilot jet 6. Solenoid valve 7. Out vent tube (before 2003/5 product model) t1: 1.0 n·m (0.10 kgf·m, 9 in·lb) t2: 3.9 n·m (0.40 kgf·m, 35 in·lb) t3: 2.0 n·m (0.20 kgf·m, 18 in...
Page 30
2-8 fuel system exploded view.
Page 31
Fuel system 2-9 exploded view [fh451v, fh500v, fh531v] t1: 5.9 n·m (0.60 kgf·m , 52 in·lb) t2: 2.0 n·m (0.20 kgf·m , 17 in·lb) t3: 7.8 n·m (0.80 kgf·m , 69 in·lb) [fh541v, fh580v] t1: 5.9 n·m (0.60 kgf·m , 52 in·lb) t2: 2.0 n·m (0.20 kgf·m , 17 in·lb) t3: 7.8 n·m (0.80 kgf·m , 69 in·lb) [fh601v, fh6...
Page 32
2-10 fuel system specifications standard fh451v, fh601v, fh641v, item fh500v fh531v fh541v fh580v fh680v, fh721v carburetor specifications: make/type mikuni b24t1 ← walbro lmf ← nikki 621266 throttle bore diameter 24 mm ← ← ← 26 mm (1.02 in.) (0.94 in.) venturi diameter 16 mm 18 mm 16 mm 18 mm 21 mm...
Page 33
Fuel system 2-11 governor link mechanism control panel assembly removal • remove: air cleaner (see cleaner body removal) air cleaner mount bracket bolts [a] air cleaner mount bracket [b] earth lead (starter model) control panel mounting bolts [c] • remove the control panel assembly [a] while unhooki...
Page 34
2-12 fuel system governor link mechanism • for fh541v, fh580v model; as shown in the figure. 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 inplace and that it pulls the governor arm ...
Page 35
Fuel system 2-13 governor link mechanism governor assembly installation • fit the snap rings [a] into the grooves securely. • spin the governor plate by hand and check that the steel balls and governor plate operate freely. Governor assembly inspection ○ visually check all governor parts for wear an...
Page 36
2-14 fuel system carburetor fuel and air flow the main system of the carburetor consists of the main jet [a], valve seat [b] main nozzle [c], and the main air pas- sage [d] (main air jet [e]). The main system meters fuel to the engine during moderate to heavy load conditions. Fuel flows through the ...
Page 37
Fuel system 2-15 carburetor fuel shut off solenoid valve (electric starter model) to avoid after firing when stopping the engine, a solenoid actuated fuel shut off solenoid valve [a] is installed in the carburetor bowl. The valve shuts off the fuel supply to the valve seat [b] simultaneously when th...
Page 38
2-16 fuel system carburetor warning always keep your hands clear of the moving parts. • move the throttle lever at a dash to the high idle position and match the lever hole position with the panel hole by inserting 6 mm dia., pin or bolt [a]. • loosen two m6 control panel mounting bolts [b] enough t...
Page 39
Fuel system 2-17 carburetor main jet replacement • place the engine (equipment) on a level surface. • close the fuel shut off valve in the equipment. • drain the fuel in the carburetor completely by unscrewing the drain screw at the bottom of the float chamber. • remove the carburetor (see carbureto...
Page 40
2-18 fuel system carburetor fuel system cleanliness inspection warning gasoline is extremely flammable and can be ex- plosive 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 app...
Page 41
Fuel system 2-19 carburetor • for fh541v, fh580v model; as shown in the figure. • for fh601v, 641v, 680v, 721v model; note the following. ○ unhook the throttle link spring [b] at the link clip [f] with a long nose plier. ○ unhook the link clip [f] and remove the throttle [d] and choke link rods [e] ...
Page 42
2-20 fuel system carburetor carburetor disassembly/assembly - fh451v, 500v, 531v • refer to the illustration shown for disassembly and as- sembly. • there are several passage plugs (ball plugs) in the car- buretor body. Do not remove. • before disassembly, mark the out side of choke valve and thrott...
Page 43
Fuel system 2-21 carburetor carburetor disassembly/assembly-fh541v, fh580v • refer to the illustration shown for disassembly and as- sembly. • there are several passage plugs (ball plugs) in the car- buretor body. Do not remove. • before disassembly, mark the out side of choke valve and throttle val...
Page 44
2-22 fuel system carburetor carburetor disassembly/assembly-fh601v, 641v, 680v, 721v. • refer to the illustration shown for disassembly and as- sembly. • there are several passage plugs (ball plugs) in the car- buretor body. Do not remove. • before disassembly, mark the out side of choke valve and t...
Page 45
Fuel system 2-23 carburetor • replace the pilot screw [a] in accordance with the follow- ing procedure if necessary. ○ remove the pilot screw plug [b] (material: stainless steel) as follows: punch a hole in the plug and pry it out with an awl or other suitable tool. ○ turn in the pilot screw and cou...
Page 46
2-24 fuel system carburetor carburetor cleaning warning 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 gasolin...
Page 47
Fuel system 2-25 carburetor carburetor inspection warning gasoline is extremely flammable and can be explo- sive under certain. 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 ligh...
Page 48
2-26 fuel system carburetor • inspect the tapered portion [a] of the pilot screw [b] for wear or damage. If the pilot screw is worn or damaged on the taper portion, replace it. • check the spring for weakened condition, replace it, if necessary. • for fh601v, 641v, 680v, 721v model; as shown in the ...
Page 49
Fuel system 2-27 intake manifold intake manifold removal • remove: air cleaner (see cleaner body removal) engine upper cover • cut off the band [a] and harness and/or wire lead are released from intake manifold. • unscrew the manifold mounting bolts [b]. • then lifting up the intake manifold middle ...
Page 50
2-28 fuel system intake manifold intake manifold inspection • inspect the intake manifold for cracks or porous casting. • cracks not visible to the eye may be detected by using a metal crack detection system. (visual color check: com- monly found at automotive parts store.) if a crack is present in ...
Page 51
Fuel system 2-29 fuel pump, fuel filter the fuel pump cannot be disassembled, if any damage for the pump is noticed replace it with a new one. Fuel pump inspection • check the vent hole [a] and filter [b] for plugging or clog- ging. If vent hole and filter are plugged or clogged, remove the foreign ...
Page 52
2-30 fuel system air cleaner element removal - fh451v, 500v, 531v, 541v, 580v • pull the hooks [a] to outside and remove the air cleaner cover [b]. • remove: wing bolt [a] foam element [b] paper element [c] element removal - fh601v, 641v, 680v, 721v • remove air cleaner case nut air cleaner case win...
Page 53
Fuel system 2-31 air cleaner • 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. Caution do not use compressed air to clean the paper ele- ment. Do not oil the paper or foam element. Element cleaning and insp...
Page 54
2-32 fuel system air cleaner cleaner body installation - fh451v, 500v, 531v, 541v, 580v • connect the breather tube from the crankcase to the pipe at the back of the cleaner body. • tighten the holder plate nuts and cleaner body mounting screws. Torque - holder plate nuts: 5.9 n·m (0.6 kgf·m, 52 in·...
Page 55: Cooling System
Cooling system 3-1 3 cooling system table of contents exploded view........................................................................................................................ 3-2 cooling fan ...................................................................................................
Page 56
3-2 cooling system exploded view.
Page 57
Cooling system 3-3 exploded view [fh451v, fh500v, fh531v] t1: 3.9 n·m (0.40 kgf·m, 35 in·lb) t2: 5.9 n·m (0.60 kgf·m, 52 in·lb) t3: 17 n·m (1.7 kgf·m, 12.0 ft·lb) t4: 56 n·m (5.7 kgf·m, 41 ft·lb) t5: 7.8 n·m (0.8 kgf·m, 69 in·lb) [fh541v, fh580v] t1: 3.9 n·m (0.40 kgf·m, 35 in·lb) t2: 5.9 n·m (0.60 ...
Page 58
3-4 cooling system cooling fan cooling fan removal • refer to flywheel removal in electrical system chapter. Cooling fan installation • refer to flywheel installation in electrical system chap- ter. Cooling fan inspection • visually inspect the blades [a] in the cooling fan [b]. If they are any crac...
Page 59: Engine Top End
Engine top end 4-1 4 engine top end table of contents exploded view........................................................................................................................ 4-2 specifications ................................................................................................
Page 60
4-2 engine top end exploded view.
Page 61
Engine top end 4-3 exploded view [fh451v, fh500v, fh531v] t1: 5.9 n·m (0.60 kgf·m, 52 in·lb) t2: 5.9 n·m (0.60 kgf·m, 52 in·lb) t3: 25 n·m (2.6 kgf·m, 19.5 ft·lb) t4: 28 n·m (2.8 kgf·m, 20 ft·lb) t5: 22 n·m (2.2 kgf·m, 16 ft·lb) [fh541v, fh580v] t1: 9.8 n·m (1.0 kgf·m, 87 in·lb) t2: 5.9 n·m (0.60 kg...
Page 62
4-4 engine top end exploded view.
Page 63
Engine top end 4-5 exploded view [fh451v, fh500v, fh531v] t2: 15 n·m (1.5 kgf·m, 11.0 ft·lb) [fh541v, fh580v] t2: 15 n·m (1.5 kgf·m, 11.0 ft·lb) [fh601v, fh641v, fh680v, fh721v] t2: 15 n·m (1.5 kgf·m, 11.0 ft·lb).
Page 64
4-6 engine top end specifications item service limit fh451v, fh500v, fh531v fh541v, fh580v cylinder head: cylinder compression (min) [390 kpa (57 psi)] (min) ← cylinder head warp 0.05 mm (0.002 in.) ← valves: valve head thickness intake, exhaust 0.35 mm (0.014 in.) ← valve stem runout intake, exhaus...
Page 65
Engine top end 4-7 specifications item service limit fh601v, fh641v, fh680v, fh721v cylinder head: cylinder compression (min) [390 kpa (57 psi)] (min) cylinder head warp 0.05 mm (0.002 in.) valves: valve head thickness intake, exhaust 0.35 mm (0.014 in.) valve stem runout intake, exhaust 0.05 mm (0....
Page 66
4-8 engine top end specifications special tools - compression gauge : 57001 - 221 compression gauge adapter m14 × 1.25: 57001–1159 piston ring pliers: 57001 - 115 piston ring compression grip: 57001 - 1095 piston ring compression belt, 67 - 79: 57001–1097 valve seat cutter holder bar: 57001–1128 val...
Page 67
Engine top end 4-9 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 be- tween the piston and cylinder wall will help seal compres- sion as it does during normal running. ...
Page 68
4-10 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 ...
Page 69
Engine top end 4-11 cylinder head • tighten the cylinder head bolts following the tightening sequence. Torque - cylinder head bolts: 25 n·m (2.6 kgf·m, 19.0 ft·lb) caution a torque wrench must be used to assure proper torque. Improper tightening of the head bolts can result in warping of the cylinde...
Page 70
4-12 engine top end cylinder head push rod inspection • place the push rod in v blocks that are as far apart as pos- sible, 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 read- ings is the ...
Page 71
Engine top end 4-13 cylinder head cleaning and inspection • 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 mate- rial that will not cause damage. • clean the head in a bath of high flash-point solvent and dry it...
Page 72
4-14 engine top end valves valve clearance inspection note ○ valve clearance must be checked when the engine is cold (at room temperature). • remove the rocker cover (see cylinder head removal). • place the piston at top dead center (tdc) of the compres- sion stroke turning the crankshaft clockwise ...
Page 73
Engine top end 4-15 valves valve seat inspection • remove the valve. (see valve mechanism removal/in- stallation) • inspect the valve seats for damage. If the seats are warped or distorted beyond recondition- ing, replace the cylinder head. • pitted or worn valve seats can be refaced. Lap the valves...
Page 74
4-16 engine top end valves 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 t...
Page 75
Engine top end 4-17 valves • 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. Overgr...
Page 76
4-18 engine top end valves • 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, b...
Page 77
Engine top end 4-19 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 78
4-20 engine top end cylinder, piston piston removal • split the crankcase (see camshaft/crankshaft chapter). • remove the camshaft (see camshaft/crankshaft chap- ter). • turn the crankshaft to expose the connecting rod cap bolts [a]. • remove the bolts and take off the connecting rod caps [b]. Note ...
Page 79
Engine top end 4-21 cylinder, piston • remove the top and second rings with piston ring pliers. Special tool - piston ring pliers: 57001–115 • if the special tool is not available, carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring [a] to remove it. ...
Page 80
4-22 engine top end cylinder, piston • when installing a piston pin snap ring, compress it only enough to install it and no more. Fit a new piston pin snap ring into the side of the piston so that the ring opening [a] does not coincide with the notch [b] in the edge of the piston pin hole. Caution d...
Page 81
Engine top end 4-23 cylinder, piston piston/cylinder seizure • in case of seizure, remove the piston. • visually inspect the cylinder and piston damage. If there is only light damage, smooth the position with #400 emery cloth. Remove the small aluminum deposits from the cylinder with #400 emery clot...
Page 82
4-24 engine top end cylinder, piston • measure the piston ring thickness [a]. ○ use a micrometer to measure at several points around the rings. If any of the measurement are less than the service limit, replace the entire set of rings. Piston ring thickness service limit top, second 1.40 mm (0.055 i...
Page 83
Engine top end 4-25 cylinder, piston • measure the inside diameter [a] of the small end of the connecting rod at several points. Use a dial bore gauge. If the inside diameter is more than the service limit, re- place the connecting rod. Connecting rod small end inside diameter service limit: 16.05 m...
Page 84
4-26 engine top end cylinder, piston cylinder boring and honing always resize to exactly 0.5 mm (0.02 in.) over the stan- dard bore size. If this is done accurately, the stock oversize rings and pis- ton will fit perfectly and proper clearance will be maintained. Resizing the cylinder bore can be do...
Page 85
Engine top end 4-27 cylinder, piston caution stop the drill press before measuring and remove the hone from the cylinder. Note ○ the finish should not be smooth, but have a 40 to 60 degree crosshatch pattern. • hone the cylinder until it is about 0.007 to 0.009 mm (0.0003 to 0.0004 in) large to allo...
Page 86
4-28 engine top end 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 87: Lubrication System
Lubrication system 5-1 5 lubrication system table of contents exploded view........................................................................................................................ 5-2 engine oil flow chart..................................................................................
Page 88
5-2 lubrication system exploded view.
Page 89
Lubrication system 5-3 exploded view [fh451v, fh500v, fh531v] t1: 3.9 n·m (0.40 kgf·m, 35 in·lb) t2: 6.9 n·m (0.7 kgf·m, 61 in·lb) (plastic) t3: 9.8 n·m (1.0 kgf·m, 87 in·lb) t4: 20 n·m (2.0 kgf·m, 14.5 ft·lb) (metal) t5: 39 n·m (4.0 kgf·m, 29 ft·lb) (metal) t6: 17 n·m (1.7 kgf·m, 12.0 ft·lb) (plast...
Page 90
5-4 lubrication system engine oil flow chart fh451v, fh500v, fh531v, fh601v, fh641v, fh680v, fh721v.
Page 91
Lubrication system 5-5 engine oil flow chart fh541v fh580v fh601v, fh641v, fh680v, fh721v (on and after 2003/5 product model).
Page 92
5-6 lubrication system specifications item standard engine oil: grade 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) ··· except fh721v 1.8 l (1.9 us-qt) ··· fh721v level op...
Page 93
Lubrication system 5-7 engine oil, oil filter, and oil cooler caution engine operation with insufficient, deteriorated, or contaminated 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 ...
Page 94
5-8 lubrication system engine oil, oil filter, and oil cooler 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 c...
Page 95
Lubrication system 5-9 engine oil, oil filter, and oil cooler oil filter removal • using a strap wrench or oil filter wrench [a], remove the oil filter [b]. Special tool - oil filter wrench : 57001–1249 ○ when unscrewing the oil filter, place a suitable container beneath the oil drip tray to receive...
Page 96
5-10 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 pa...
Page 97
Lubrication system 5-11 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 sp...
Page 98
5-12 lubrication system oil pump, relief valve • before fh500-a50136, fh531-a07510 model, as shown in the figure. • measure the outside diameter [a] of the outer rotor with a micrometer at several points. If the rotor diameter is less than the service limit, replace both the inner and outer rotor. O...
Page 99
Lubrication system 5-13 oil pump, relief valve • measure the outside [a] diameter of the pump shaft with a micrometer at several points. If the diameter is less than the service limit, replace the pump shaft. Pump shaft outside diameter service limit: 10.923 mm (0.4300 in.) • measurer the inside dia...
Page 100
5-14 lubrication system 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]. • before fh500-a50136, fh531-a07510 model, as shown in the figure. Oil screen ins...
Page 101
Lubrication system 5-15 oil screen cleaning and inspection • clean the oil screen with high flash-point solvent and re- move any particles stuck to it. Warning clean the screen in a well-ventilated area, and take care that there is no spark or flame anywhere near the working area. Because of the dan...
Page 103: Camshaft/crankshaft
Camshaft/crankshaft 6-1 6 camshaft/crankshaft table of contents exploded view........................................................................................................................ 6-2 specifications ......................................................................................
Page 104
6-2 camshaft/crankshaft exploded view.
Page 105
Camshaft/crankshaft 6-3 exploded view [fh451v, fh500v, fh531v] t1: 5.9 n·m (0.6 kgf·m, 52 in·lb) t2: 25 n·m (2.6 kgf·m, 19.0 ft·lb) t3: see engine top end chapter. [fh541v, fh580] t1: 5.9 n·m (0.6 kgf·m, 52 in·lb) t2: 25 n·m (2.6 kgf·m, 19.0 ft·lb) t3: see engine top end chapter. [fh601v, fh641v, fh...
Page 106
6-4 camshaft/crankshaft specifications service limit fh451v, 500v, fh541v, fh601v, 641v, item 531v, 580v 680v, 721v camshaft, tappet: cam lobe height intake 29.131 mm ← 29.621 mm (1.1469 in.) (1.166 in.) exhaust 29.131 mm ← 29.621 mm (1.1469 in.) (1.166 in.) camshaft journal diameter pto side 15.985...
Page 107
Camshaft/crankshaft 6-5 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 108
6-6 camshaft/crankshaft 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·m...
Page 109
Camshaft/crankshaft 6-7 crankcase cleaning • remove: camshaft and tappets (see camshaft, tappet removal) crankshaft (see crankshaft removal) • clean up the crankcase and cover with a high flash-point solvent, and blow out any foreign particles that may be in the pockets inside of the crankcase with ...
Page 110
6-8 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 emis- sion control system is used to eliminate blow-by gases. The blow-b...
Page 111
Camshaft/crankshaft 6-9 breather breather element removal - fh451v, 500v, 531v, 541v, 580v • remove the bolts [a] and breather chamber cover [b]. • remove the element [a]. • check to see that the plate [b] is in place under the ele- ment [a]. Breather element installation - fh451v, 500v, 531v, 541v,...
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6-10 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 113
Camshaft/crankshaft 6-11 camshaft, tappet camshaft disassembly • remove the governor assembly (see fuel system chap- ter). • remove: spring [a] ○ do not remove the acr (automatic compression release) weight [b]. Camshaft assembly • install the governor assembly (see fuel system chapter). • after ass...
Page 114
6-12 camshaft/crankshaft camshaft, tappet • measure both camshaft journals at several points around the journal circumference. If the journal diameter is less than the service limit, re- place the camshaft. Pto side camshaft journal diameter service limit: 15.985 mm (0.6293 in.) flywheel side camsha...
Page 115
Camshaft/crankshaft 6-13 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...
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6-14 camshaft/crankshaft crankshaft, connecting rod connecting rod bend/twist • measure connecting rod bend. ○ select an arbor of the same diameter as the connecting rod big end, and insert the arbor through the connecting rod big end. ○ select an arbor of the same diameter as the piston pin and at ...
Page 117
Camshaft/crankshaft 6-15 crankshaft, connecting rod connecting rod big end bearing/crankpin wear • apply a light film of oil on the thread of the cap bolts. • install the cap bolts and tighten the bolts to the specified torque (see piston installation in engine top end chap- ter). • measure the insi...
Page 118
6-16 camshaft/crankshaft crankshaft, connecting rod crankshaft main journal/wear • measure both main journals at several points around the journal circumference. If the journal diameter is less than the service limit, re- place the crankshaft with a new one. Pto side crankshaft journal diameter [a] ...
Page 119: Electrical System
Electrical system 7-1 7 electrical system table of contents exploded view........................................................................................................................ 7-2 specifications ..........................................................................................
Page 120
7-2 electrical system exploded view.
Page 121
Electrical system 7-3 exploded view [fh451v, fh500v, fh531v] t1: 3.9 n·m (0.40 kgf·m, 35 in·lb) t2: 5.9 n·m (0.60 kgf·m, 52 in·lb) t3: 7.8 n·m (0.80 kgf·m, 69 in·lb) t4: 22 n·m (2.2 kgf·m, 16 ft·lb) t5: 56 n·m (5.7 kgf·m, 41 ft·lb) [fh541v, fh580v] t1: 3.9 n·m (0.40 kgf·m, 35 in·lb) t2: 5.9 n·m (0.6...
Page 122
7-4 electrical system exploded view.
Page 123
Electrical system 7-5 exploded view [fh451v, fh500v, fh531v] t1: 3.9 n·m (0.40 kgf·m, 35 in·lb) t2: 5.9 n·m (0.60 kgf·m, 52 in·lb) t3: 7.8 n·m (0.80 kgf·m, 69 in·lb) t4: 17 n·m (1.7 kgf·m, 12 ft·lb) [fh541v, fh580v] t1: 3.9 n·m (0.40 kgf·m, 35 in·lb) t2: 5.9 n·m (0.60 kgf·m, 52 in·lb) t3: 7.8 n·m (0...
Page 124
7-6 electrical system specifications standard fh451v, 500v, 531v, fh601v, 641v, item 541v, 580v 680v, 721v service limit charging system: regulated output voltage 14.1 v dc 15 v dc alternator stator coil resistance in the text – – – unregulated stator output 28.4 v ac/3000 rpm 26v ac/3000 rpm regula...
Page 125
Electrical system 7-7 wiring diagram [fh451v, fh500v, fh531v, fh541v, fh580v] electric starter model.
Page 126
7-8 electrical system wiring diagram [fh451v, fh500v, fh531v] recoil starter (with charging coil) model.
Page 127
Electrical system 7-9 wiring diagram [fh451v, fh500v, fh531v] recoil starter model.
Page 128
7-10 electrical system wiring diagram [fh601v, fh641v, fh680v, fh721v] electric starter model.
Page 129
Electrical system 7-11 precautions there are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ do not reverse the battery lead connections. This will burn out the diodes in the electrical parts. ○ always check battery condi...
Page 130
7-12 electrical system charging system flywheel, stator coil removal • remove: recoil starter (see recoil starter removal) • loosen the fan housing bolts [a] and remove the fan housing [b]. • remove: ignition coils (see ignition coil removal) stud bolts [a] • hold the flywheel with a suitable tool, ...
Page 131
Electrical system 7-13 charging system ○ remove: ignition coil (see ignition coil removal) stud bolts [a] ○ hold the flywheel with a suitable tool, remove the flywheel bolt and washer. • using a suitable flywheel puller [a], remove the flywheel [b]. Caution always use flywheel puller. • remove: wood...
Page 132
7-14 electrical system charging system • install the fan [a] so that two positioning bosses [b] fit around flywheel ignition magnet [c]. • install the plate [d] so that the notch [e] inserts into the slot in the flywheel. • install the screen [a] so that the projections [b] fit into the recess [c] o...
Page 133
Electrical system 7-15 charging system ○ install: spacer [a] screen [b] ○ position three sets [c] of screen notches around the fan blades. ○ tighten the screen bolts [d] torque - screen bolts: 5.9 n·m (0.6 kgf·m, 52 in·lb) charging system operational inspection • check battery condition. Note ○ alwa...
Page 134
7-16 electrical system charging 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 Ω (recoil starter model with electri...
Page 135
Electrical system 7-17 charging system regulator resistance • set the kawasaki hand tester selector switch to the r × 100 Ω 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 charging ...
Page 136
7-18 electrical system ignition system this engine ignition is controlled by a solid state ignition assembly and requires no periodic main- tenance except for the spark plugs. The system consists of the following: inductive ignition assemblies permanent magnet flywheel spark plugs stop switch igniti...
Page 137
Electrical system 7-19 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 connector ...
Page 138
7-20 electrical system 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 × 1 k Ω range. Special tool - hand tester: 57001–1394 ○ make the measurements shown in the table. Ignit...
Page 139
Electrical system 7-21 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 140
7-22 electrical system starter system starter motor assembly • assembly is the reverse of disassembly. • apply a small amount of grease [a] to the armature shaft. • do not reuse the snap ring [b]. Replace it with a new one. • check the cap and replace it with a new one if damaged. • fit the projecti...
Page 141
Electrical system 7-23 starter system • measure the depth of the grooves between the commu- tator segments. If the grooves are shallower than the specified limit, re- place the armature with a new one. If the grooves are only dirty, clean them carefully. Commutator groove depth limit less than 0.9 m...
Page 142
7-24 electrical system starter system • test the armature winding for shorts. ○ place the armature on a growler [a]. ○ hold a thin metal strip (e.G., hack saw blade) on top of the armature. ○ turn on the growler and rotate the armature one complete turn. If the metal strip vibrates, the windings are...
Page 143
Electrical system 7-25 starter system recoil starter disassembly • remove the recoil starter (see recoil starter removal). • pull the handle [a] out 30 cm (1 ft), and clamp the rope [b] with the clip [c] so it can not wind back onto the reel [d]. • pry the knot [e] out of the handle and untie it. • ...
Page 144
7-26 electrical system starter system if the recoil spring [a] must be removed from the cassette [b], hold the cassette with the opening side facing down- ward in a suitable container and tap the cassette to re- move the recoil spring. Recoil starter assembly warning wear gloves during the recoil sp...
Page 145
Electrical system 7-27 starter system • install: retainer [a] washer [b] screw [c] torque - recoil starter retainer screw: 7.8 n·m (0.80 kgf·m, 69 in·lb) • turn the reel two turns counterclockwise to preload the recoil spring. • while holding the reel to keep it from unwinding, feed the end of the r...
Page 147: Troubleshooting
Troubleshooting 8-1 8 troubleshooting table of contents engine troubleshooting guide ............................................................................................... 8-2 starter motor troubleshooting guide ..................................................................................
Page 148
8-2 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 149
Troubleshooting 8-3 engine troubleshooting guide.
Page 150
8-4 troubleshooting engine troubleshooting guide.
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Troubleshooting 8-5 engine troubleshooting guide.
Page 152
8-6 troubleshooting starter motor troubleshooting guide 1. Disconnect spark plug caps from the spark plugs. 2. Turn engine switch to “start” position and check condi- tion. Warning engine may be cranked in this test. Do not touch any rotating parts of engine and equipment during test. Caution if sta...
Page 153
Part no.99924-2045-05 printed in japan.