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- FH451V
- Service Manual
Kawasaki FH451V Service Manual
Summary of FH451V
Page 1
Fh451v, fh500v, fh531v fh541v, fh580v, fh601v fh641v, fh661v, fh680v fh721v 4-stroke air-cooled v-twin gasoline engine service manual.
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, fh661v, fh680v fh721v 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 p...
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 model identification heavy duty air cleaner type.
Page 15
General information 1-7 general specifications item fh451v, fh500v, fh531v fh541v, fh580v fh601v, fh641v, fh661v, fh680v fh721v type forced air-cooled, vertical shaft, ohv, 4-stroke gasoline engine. Cylinder layout 90 v-twin bore × stroke 68 mm × 68 mm (2.68 in. × 2.68 in.) 74 mm × 68 mm (2.91 in. ×...
Page 17: Periodic Maintenance
Periodic maintenance 2-1 2 periodic maintenance table of contents periodic maintenance chart ................................................................................................... 2-2 torque and locking agent..................................................................................
Page 18
2-2 periodic maintenance 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 ma...
Page 19
Periodic maintenance 2-3 periodic maintenance chart fh601v, fh641v, fh661v, fh680v, fh721v interval operation daily first 8 hr. Every 25 hr. Every 50 hr. Every 100 hr. Every 200 hr. Every 250 hr. Every 300 hr. Every 500 hr. Check and clean air inlet screen • check and add engine oil • check for fuel...
Page 20
2-4 periodic maintenance 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 21
Periodic maintenance 2-5 torque and locking agent fh451v, fh500v, fh531v, fh541v, fh580v torque fastener n·m kgf·m ft·lb remarks engine top end cylinder head bolts 25 2.6 19.0 s valve clearance lock screws 6.9 0.70 61 in·lb connecting rod big end cap bolts 5.9 0.60 52 in·lb o (fh541v, fh580v) 9.8 1....
Page 22
2-6 periodic maintenance torque and locking agent the table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cle...
Page 23
Periodic maintenance 2-7 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 24
2-8 periodic maintenance torque and locking agent fh601v, fh641v, fh661v, fh680v, fh721v torque fasteners n·m kgf·m ft·lb remarks connecting rod big end cap bolts (for m6 × p1.0 screw thread spec.) 9.8 1.0 87 in·lb o rocker arm bolts 28 2.8 20 rocker cover mounting bolts 5.9 0.60 52 in·lb exhaust pi...
Page 25
Periodic maintenance 2-9 specifications item standard fuel system idle speed: (1) low idle speed 1 550 r/min (rpm) high idle speed 3 600 r/min (rpm) air cleaner: type dual stage filtration system pre-cleaner foam element second-stage cleaner paper element fh451v, fh500v, fh531v fh541v, fh580v fh601v...
Page 26
2-10 periodic maintenance special tools valve seat cutter, 45° - 35: 57001-1116 valve seat cutter, 32° - 30: 57001-1120 valve seat cutter holder bar: 57001-1128 valve seat cutter, 32° - 33: 57001-1199 oil filter wrench: 57001-1249 valve seat cutter holder, 6: 57001-1360
Page 27
Periodic maintenance 2-11 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 and...
Page 28
2-12 periodic maintenance periodic maintenance procedures 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 pane...
Page 29
Periodic maintenance 2-13 periodic maintenance procedures 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...
Page 30
2-14 periodic maintenance periodic maintenance procedures • 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 element or th...
Page 31
Periodic maintenance 2-15 periodic maintenance procedures • 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 ...
Page 32
2-16 periodic maintenance periodic maintenance procedures • check the cylinder head for cracks or other damage. • cracks not visible to the eye may be detected by coating the suspected area with mixture of 25% kerosene and 75% light engine oil. • wipe the area dry and immediately apply a coating of ...
Page 33
Periodic maintenance 2-17 periodic maintenance procedures valve clearance adjustment • since valve repairs change the valve clearance, adjust the valve clearance as specified. • assemble the cylinder head and install the cylinder head assembly on the block (see cylinder head installation). • turn th...
Page 34
2-18 periodic maintenance periodic maintenance procedures valve seat repair • follow the manufacture’s instructions for use of valve seat cutters special tools inlet valve: valve seat cutter 45° - 35 57001-1116 valve seat cutter 32° - 33 57001-1199 exhaust valve: valve seat cutter 45° - 30 57001-118...
Page 35
Periodic maintenance 2-19 periodic maintenance procedures 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 widt...
Page 36
2-20 periodic maintenance periodic maintenance procedures • coat the valve face sparingly with a fine lapping com- pound. • use the vacuum cap tool [a], to grip the 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...
Page 37
Periodic maintenance 2-21 periodic maintenance procedures oil change • change the oil after first 8 hours of operation. Thereafter change oil every 100 hours of operation. • start and warm up the engine to drain the oil easily. • stop the engine. • place the engine on a level surface. • place a suit...
Page 38
2-22 periodic maintenance periodic maintenance procedures oil filter replacement • drain the engine oil (see oil change). • remove the oil filter [a] with the oil filter wrench [b] or strap wrench. Special tool - oil filter wrench: 57001-1249 ○ when unscrewing the oil filter, place a suitable contai...
Page 39: Fuel System
Fuel system 3-1 3 fuel system table of contents exploded view........................................................................................................................ 3-2 specifications ......................................................................................................
Page 40
3-2 fuel system exploded view [fh451v, fh500v, fh531v].
Page 41
Fuel system 3-3 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 42
3-4 fuel system exploded view [fh541v, fh580v].
Page 43
Fuel system 3-5 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 (0.60 kgf·m, 52 in·lb) l: apply non-permanent locking age...
Page 44
3-6 fuel system exploded view [heavy duty air cleaner type].
Page 45
Fuel system 3-7 exploded view [heavy duty air cleaner type] 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: 5.9 n·m (0.60 kgf·m, 52 in·lb) t5: 9.8 n·m (1.0 kgf·m, 87 in·lb) l: apply non-permanent...
Page 46
3-8 fuel system exploded view [fh601v, fh641v, fh661v, fh680v, fh721v].
Page 47
Fuel system 3-9 exploded view [fh601v, fh641v, fh661v, 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·...
Page 48
3-10 fuel system exploded view [heavy duty air cleaner type].
Page 49
Fuel system 3-11 exploded view [heavy duty air cleaner type] 1. Main jet 2. Pilot screw 3. Solenoid valve r: replacement parts 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·lb) t4: 2.5 n·m (0.25 kgf·m, 22 in·lb) t5: 6.9 n·m (0.70 kgf·m, 61 in·lb)...
Page 50
3-12 fuel system exploded view.
Page 51
Fuel system 3-13 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, fh...
Page 52
3-14 fuel system specifications standard item fh451v, fh500v fh531v fh541v fh580v fh601v, fh641v, fh661v, fh680v, fh721v carburetor specifications: make/type mikuni b24t1 ← walbro lmf ← nikki 621266 throttle bore diameter 24 mm (0.94 in.) ← ← ← 26 mm (1.02 in.) venturi diameter 16 mm (0.63 in.) 18 m...
Page 53
Fuel system 3-15 governor link mechanism control panel assembly removal • remove: air cleaner (see air cleaner body removal) air cleaner mount bracket bolts [a] air cleaner mount bracket [b] ground lead (electric starter model) control panel mounting bolts [c] • remove the control panel assembly [a]...
Page 54
3-16 fuel system governor link mechanism • for fh541v, fh580v model; the governor arm is 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 in place and that it pu...
Page 55
Fuel system 3-17 governor link mechanism governor assembly installation • fit the snap ring [a] into the groove securely. • turn the governor plate by hand and check that the steel balls and governor plate move freely. Governor assembly inspection ○ visually check all governor parts for wear or dama...
Page 56
3-18 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 passage [d] (main air jet [e]). The main system meters fuel to the engine during moderate to heavy load conditions. Fuel flows through the ma...
Page 57
Fuel system 3-19 carburetor the pilot system includes the pilot jet [f], pilot screw [g] (idle mixture screw), pilot air jet [h], pilot outlet [i], and the bypass holes [j]. The pilot system meters the fuel/air mixture while the engine is idling and running under a light load. Under these conditions...
Page 58
3-20 fuel system 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 59
Fuel system 3-21 carburetor • using a proper standard tip screwdriver, carefully replace the main jet (a) with a new one for expected altitude. • tighten the main jet to the specified torque (see carbure- tor disassembly assembly notes). • install the float chamber, gasket and float bowl bolt. • for...
Page 60
3-22 fuel system carburetor • for fh541v, fh580v model; see the figure. • for fh601v, fh641v, fh661v, fh680v, fh721v 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 link rod [d] and choke...
Page 61
Fuel system 3-23 carburetor • for fh601v, fh641v, fh661v, fh680v, fh721v model; inlet manifold [a] gaskets [b] insulator [c] carburetor [d] gasket [e] • install the air cleaner (see air cleaner body installation). • take care not to bend the throttle link rod and choke link rods during installation....
Page 62
3-24 fuel system carburetor carburetor disassembly/assembly-fh451v, fh500v, fh531v • refer to the illustration for disassembly and assembly. • there are several passage plugs (ball plugs) in the car- buretor body. Do not remove them. • before disassembly, mark the out side of choke valve and throttl...
Page 63
Fuel system 3-25 carburetor carburetor disassembly/assembly-fh541v, fh580v • refer to the illustration for disassembly and assembly. • there are several passage plugs (ball plugs) in the car- buretor body. Do not remove them. • before disassembly, mark the out side of choke valve and throttle valves...
Page 64
3-26 fuel system carburetor carburetor disassembly/assembly-fh601v, fh641v, fh661v, fh680v, fh721v • refer to the illustration for disassembly and assembly. • there are several passage plugs (ball plugs) in the car- buretor body. Do not remove them. • before disassembly, mark the out side of choke v...
Page 65
Fuel system 3-27 carburetor carburetor disassembly/assembly-fh680v and fh721v late models • refer to the illustration for disassembly and assembly. • there are several passage plugs (ball plugs) in the car- buretor body. Do not remove them. • before disassembly, mark the out side of choke valve and ...
Page 66
3-28 fuel system carburetor • replace the pilot screw [a] with a new one if necessary in accordance with the following procedure. ○ 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 ...
Page 67
Fuel system 3-29 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 68
3-30 fuel system 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 69
Fuel system 3-31 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 with a new one. • check the spring condition, replace it with a new one if necessary. • for fh601v, fh641v, fh661v, fh680v, ...
Page 70
3-32 fuel system inlet manifold inlet manifold removal • remove: air cleaner (see air cleaner body removal) engine upper cover • cut off the band [a] and release the harness and/or lead from the inlet manifold. • unscrew the manifold mounting bolts [b]. • then lifting up the inlet manifold middle se...
Page 71
Fuel system 3-33 inlet manifold inlet manifold inspection • inspect the inlet 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 stores). If a crack is present in the...
Page 72
3-34 fuel system fuel pump, fuel filter the fuel pump cannot be disassembled. If any damage of the pump is noticed replace it with a new one. Fuel pump inspection • check the vent hole [a] and the filter [b] for plugging or clogging. If the vent hole and the filter are plugged or clogged, re- move t...
Page 73
Fuel system 3-35 air cleaner (standard type) element removal fh451v, fh500v, fh531v, fh541v, fh580v • 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, fh641v, fh661v, fh680v, fh721v • remove air cle...
Page 74
3-36 fuel system air cleaner (standard type) • pull the breather tube [a] off the pipe at the back of the body, and remove the air cleaner body [b]. Fh601v, fh641v, fh661v, fh680v, fh721v • remove the element (see element removal). • remove the clamp [a], and pull off the breather tube [b]. • loosen...
Page 75
Fuel system 3-37 air cleaner (standard type).
Page 76
3-38 fuel system air cleaner (heavy duty type) element removal • unhook the two retaining clamps [a] and remove the cap [b] from the air cleaner body. • remove: primary element [a] secondary element [b] for fh541v, fh580v • remove: element [a] element installation • slide the secondary element and p...
Page 77
Fuel system 3-39 air cleaner (heavy duty type) air cleaner body removal • remove the air cleaner elements (see element re- moval). • loosen the clamps [a], and remove the inlet hose [b]. • remove the bolt [c]. • take out the air cleaner body [d] from the arrow side [e] in the figure. Air cleaner bod...
Page 78
3-40 fuel system air cleaner (heavy duty type) air cleaner body installation • install the air cleaner body bracket with the bolts to the specified torque. Torque - air cleaner body bracket bolts: 5.9 n·m (0.60 kgf·m, 52 in·lb) • set the air cleaner body [a] onto the bracket so that the air inlet du...
Page 79
Fuel system 3-41 air cleaner (heavy duty type) air cleaner body clamp bolt [a] collar [b] spring [c] nut [d] 15° [e] housing (cap and body) inspection • refer to the housing (cap and body) inspection in the periodic maintenance chapter..
Page 81: Cooling System
Cooling system 4-1 4 cooling system table of contents exploded view........................................................................................................................ 4-2 cooling fan ...................................................................................................
Page 82
4-2 cooling system exploded view.
Page 83
Cooling system 4-3 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 (0.80 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 84
4-4 cooling system cooling fan cooling fan removal • refer to the flywheel removal in electrical system chap- ter. Cooling fan installation • refer to the flywheel installation in electrical system chapter. Cooling fan inspection • visually inspect the blades [a] in the cooling fan [b]. If they have...
Page 85: Engine Top End
Engine top end 5-1 5 engine top end table of contents exploded view........................................................................................................................ 5-2 specifications ................................................................................................
Page 86
5-2 engine top end exploded view.
Page 87
Engine top end 5-3 exploded view [fh451v, fh500v, fh531v] t1: 5.9 n·m (0.60 kgf·m, 52 in·lb) t2: 6.9 n·m (0.70 kgf·m, 61 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: 6.9 n·m (0.70 kg...
Page 88
5-4 engine top end exploded view.
Page 89
Engine top end 5-5 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, fh661v, fh680v, fh721v] t2: 15 n·m (1.5 kgf·m, 11.0 ft·lb) 1. Muffler comp for late models. 2. Muffler comp for early models..
Page 90
5-6 engine top end specifications service limit item 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 inlet, exhaust 0.35 mm (0.014 in.) ← valve stem runout inlet, exhaust 0....
Page 91
Engine top end 5-7 specifications service limit item fh601v, fh641v, fh661v, 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 inlet, exhaust 0.35 mm (0.014 in.) valve stem runout inlet, exhaust 0.05 mm...
Page 92
5-8 engine top end specifications special tools - piston ring pliers: 57001-115 compression gauge, 20 kgf/cm²: 57001-221 piston ring compressor grip: 57001-1095 piston ring compressor belt, 67 ∼ 79: 57001-1097 compression gauge adapter, m14 × 1.25: 57001-1159 valve seat cutter holder bar: 57001-1128...
Page 93
Engine top end 5-9 cylinder head compression measurement • before measuring compression, check 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 sealing the compression as it does during normal r...
Page 94
5-10 engine top end cylinder head cylinder head assembly removal • remove: air cleaner and carburetor (see fuel system chapter) muffler (see muffler exhaust pipe removal) inlet manifold (see fuel system chapter) spark plug • unscrew the rocker cover mounting bolts [a], and remove the cover [b] and t...
Page 95
Engine top end 5-11 cylinder head • tighten the cylinder head bolts following the tightening sequence in the figure. 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 may result in warping ...
Page 96
5-12 engine top end cylinder head push rod inspection • place the push rod on v blocks as far apart as possible, and set a dial gauge on the rod at a halfway point between the blocks. Turn the rod to measure the runout. The dif- ference between the highest and the lowest dial readings is the amount ...
Page 97
Engine top end 5-13 valves cylinder head cleaning and inspection • refer to the cylinder head cleaning and inspection in the periodic maintenance chapter. Valve clearance inspection • refer to the valve clearance inspection in the periodic maintenance chapter. Valve clearance adjustment • refer to t...
Page 98
5-14 engine top end valves valve guide inside diameter • use a small bore gauge or a micrometer to measure the inside diameter [a] of the valve guide [b] at three positions down the guide length. If the measured valve diameter is greater than the service limit, replace the cylinder head with a new o...
Page 99
Engine top end 5-15 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 100
5-16 engine top end 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, then push up to the opposite side of the ring [a] to remove it. • r...
Page 101
Engine top end 5-17 cylinder, piston • when installing a piston pin snap ring, compress it only enough to install it. Do not compress the piston pin snap ring too hard. • 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] on t...
Page 102
5-18 engine top end cylinder, piston caution the connecting rod and the connecting rod big end cap are machined at the factory in the assembled state, so they must be replaced together as a set. • apply engine oil to the inner surface [a] of the connecting rod big end [b] and caps [c]. • install the...
Page 103
Engine top end 5-19 cylinder, piston piston cleaning • remove the piston and the piston rings (see piston re- moval). Caution never clean the piston head with the engine assem- bled. Carbon particles will fall between the piston and cylinder, and damage the crankshaft bearings. • scrape the carbon o...
Page 104
5-20 engine top end cylinder, piston • measure the piston ring thickness [a]. ○ use a micrometer to measure the ring thickness at several points around the rings. If any of the measurement are less than the service limit, replace the entire set of rings with new ones. Piston ring thickness service l...
Page 105
Engine top end 5-21 cylinder, piston • measure the inside diameter [a] of the piston pin hole at several points on both side. Use a dial bore gauge. If the inside diameter is greater than the service limit, re- place the piston with a new one. Piston pin hole inside diameter service limit: 16.08 mm ...
Page 106
5-22 engine top end cylinder, piston cylinder inside diameter model item standard service limit standard cylinder 67.98 ∼ 68.00 mm (2.676 ∼ 2.677 in.) 68.10 mm (2.681 in.) fh451v, fh500v, fh531v 0.5 mm oversize cylinder 68.48 ∼ 68.50 mm (2.696 ∼ 2.697 in.) 68.60 mm (2.701 in.) standard cylinder 73.9...
Page 107
Engine top end 5-23 cylinder, piston change to a honing stone for finishing, the final inside di- ameter should be as shown in the table. • be sure to use correct finishing stone and the stone should not be worn. • clean the cylinder at the top and bottom of the cylinder to remove burns and pieces o...
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5-24 engine top end muffler/exhaust pipe installation muffler/exhaust pipe removal early models; • loosen the clamp nut [a]. • remove the bolt [b] on the muffler bracket and take off the muffler. Late models; • loosen the clamp nut [a]. • remove the bolts [b] on the muffler bracket and take off the ...
Page 109
Engine top end 5-25 muffler/exhaust pipe installation inspection • inspect the exhaust pipe or muffler for dents, cracks, rust and holes. If the exhaust pipe or muffler is damaged, replace the exhaust pipe or the muffler with a new one for the best performance and minimum noise. • check the muffler ...
Page 111: Lubrication System
Lubrication system 6-1 6 lubrication system table of contents exploded view........................................................................................................................ 6-2 engine oil flow chart..................................................................................
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6-2 lubrication system exploded view.
Page 113
Lubrication system 6-3 exploded view [fh451v, fh500v, fh531v] t1: 3.9 n·m (0.40 kgf·m, 35 in·lb) t2: 6.9 n·m (0.70 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) (plas...
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6-4 lubrication system engine oil flow chart fh451v, fh500v, fh531v, fh601v, fh641v, fh661v, fh680v, fh721v.
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Lubrication system 6-5 engine oil flow chart fh541v fh580v fh601v, fh641v, fh661v, fh680v, fh721v (on and after 2003/5 product model).
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6-6 lubrication system specifications item standard engine oil: grade sf, sg, sh, sj or sl class viscosity sae40, sae30, sae10w-30/sae10w-40, or sae5w-20 capacity: when the oil filter is not removed 1.5 l (1.6 us qt) when the oil filter is removed 1.7 l (1.8 us qt) ··· except fh721v 1.8 l (1.9 us-qt...
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Lubrication system 6-7 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 118
6-8 lubrication system engine oil, oil filter, and oil cooler oil cooler removal (fh721v) • remove the oil filter (see oil filter removal). • unscrew the mounting joint [a] and remove the oil cooler [b]. • check the o-ring [c] in the groove of the oil cooler for damage. • replace the o-ring with a n...
Page 119
Lubrication system 6-9 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...
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6-10 lubrication system pressurized lubrication system oil pressure switch inspection when the oil pressure falls below 98 kpa (14.2 psi), the oil pressure switch activates the oil warning lamp to alert the operator or lubricating problem. • to check the oil warning system, insert the switch key int...
Page 121
Lubrication system 6-11 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...
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6-12 lubrication system oil pump, relief valve oil pump, relief valve inspection • remove the oil pump (see oil pump, relief valve re- moval). • visually inspect the pump gear, the outer and inner rotor, and the cover plate. If there is any damage or uneven wear, replace them with new ones. ○ check ...
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Lubrication system 6-13 oil pump, relief valve • before fh500-a50136, fh531-a07510 model, the pump housing is as shown in the figure. • 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 with ...
Page 124
6-14 lubrication system oil pump, relief valve if cleaning does not solve the problem, replace the relief valve parts with new ones. If necessary, put the ball in position and lightly tap the ball with a suitable tool to form a perfect seat. • measure the free length [a] of the spring with a vernier...
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Lubrication system 6-15 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, the oil screen is as shown in the figu...
Page 126
6-16 lubrication system oil screen cleaning and inspection • clean the oil screen with high-flash point solvent and re- move any particles on 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 danger of...
Page 127: Camshaft/crankshaft
Camshaft/crankshaft 7-1 7 camshaft/crankshaft table of contents exploded view........................................................................................................................ 7-2 specifications ......................................................................................
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7-2 camshaft/crankshaft exploded view.
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Camshaft/crankshaft 7-3 exploded view [fh451v, fh500v, fh531v] t1: 5.9 n·m (0.60 kgf·m, 52 in·lb) t2: 25 n·m (2.6 kgf·m, 19.0 ft·lb) t3: see engine top end chapter. [fh541v, fh580v] t1: 5.9 n·m (0.60 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,...
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7-4 camshaft/crankshaft specifications service limit item fh451v, 500v, 531v, fh541v, 580v fh601v, 641v, 661v, 680v, 721v camshaft, tappet cam lobe height: inlet 29.131 mm (1.1469 in.) ← 29.621 mm (1.166 in.) exhaust 29.131 mm (1.1469 in.) ← 29.621 mm (1.166 in.) camshaft journal diameter pto side 1...
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Camshaft/crankshaft 7-5 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...
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7-6 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 in the figure. Torque - crankcase cover...
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Camshaft/crankshaft 7-7 crankcase • measure the inside diameter [a] of the crankshaft journal bearing on the crankcase at several points. This bearing is not replaceable. Replace the crankcase with a new one if the inside diameter is greater than the service limit. Crankshaft journal bearing inside ...
Page 134
7-8 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...
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Camshaft/crankshaft 7-9 breather [heavy duty air cleaner type for fh541v, fh580v].
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7-10 camshaft/crankshaft breather [heavy duty air cleaner type for fh601v, fh641v,fh680v, fh721v].
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Camshaft/crankshaft 7-11 breather breather element removal - fh451v, 500v, 531v, 541v, 580v • remove the bolts [a] and the 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, ...
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7-12 camshaft/crankshaft camshaft, tappet camshaft, tappet removal • set the engine on a clean surface while parts are re- moved. • drain the oil (see lubrication system chapter). • remove: muffler (see engine top end chapter) throttle control panel (see fuel system chapter) carburetor (see fuel sys...
Page 139
Camshaft/crankshaft 7-13 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...
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7-14 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 with a new one. Pto side camshaft journal diameter service limit: 15.985 mm (0.6293 in.) flywh...
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Camshaft/crankshaft 7-15 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 re- moved. • drain the oil (see l...
Page 142
7-16 camshaft/crankshaft crankshaft, connecting rod connecting rod bend/twist • measure the connecting rod bend. ○ select an arbor of the same diameter of the connecting rod big end, and insert the arbor through the connecting rod big end. ○ select an arbor of the same diameter of the piston pin and...
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Camshaft/crankshaft 7-17 crankshaft, connecting rod • measure the crankpin width [a] with a dial caliper. If the crankpin width is greater than the service limit, re- place the crankshaft with a new one. Crankpin width model service limit fh451v, 500v, 531v 39.50 mm (1.56 in.) fh541v, 580v 39.50 mm ...
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7-18 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 145: Starter System
Starter system 8-1 8 starter system table of contents exploded view........................................................................................................................ 8-2 specifications ................................................................................................
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8-2 starter system exploded view.
Page 147
Starter system 8-3 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: 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 (0.80...
Page 148
8-4 starter system specifications standard item fh451v, 500v, 531v, 541v, 580v fh601v, 641v, 661v, 680v, 721v service limit electric starter system starter motor: carbon brush length (with spring boss) 12.7 mm (0.500 in.) 6.4 mm (0.250 in.) commutator groove depth (approx.) 2.0 mm (0.078 in.) 0.9 mm...
Page 149
Starter system 8-5 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 - starter ...
Page 150
8-6 starter system starter system starter motor assembly • assemble the starter motor in 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. • fi...
Page 151
Starter system 8-7 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 0.9 mm (0.035 in.) ...
Page 152
8-8 starter 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 int...
Page 153
Starter system 8-9 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. • remo...
Page 154
8-10 starter system starter system if necessary, remove the recoil spring [a] as follows: ○ place the cassette [b] facing down in a suitable container. ○ tap the cassette [b] to remove the recoil spring. Recoil starter assembly warning wear gloves during the recoil spring installation to avoid injur...
Page 155
Starter system 8-11 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 rope...
Page 157: Electrical System
Electrical system 9-1 9 electrical system table of contents exploded view........................................................................................................................ 9-2 specifications ..........................................................................................
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9-2 electrical system exploded view.
Page 159
Electrical system 9-3 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 160
9-4 electrical system specifications standard item fh451v, 500v, 531v, 541v, 580v fh601v, 641v, 661v, 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/3 000 rpm 26 v ac/3 000 rp...
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Electrical system 9-5 wiring diagram [fh451v, fh500v, fh531v, fh541v, fh580v] electric starter model.
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9-6 electrical system wiring diagram [fh451v, fh500v, fh531v] recoil starter (with charging coil) model.
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Electrical system 9-7 wiring diagram [fh451v, fh500v, fh531v] recoil starter model.
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9-8 electrical system wiring diagram [fh601v, fh641v, fh661v, fh680v, fh721v] electric starter model.
Page 165
Electrical system 9-9 precautions there are a number of important precautions that you must follow when servicing electrical systems. Learn and observe all the rules below. ○ do not reverse the battery cable connections. This will burn out the diodes in the electrical parts. ○ always check the batte...
Page 166
9-10 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 167
Electrical system 9-11 charging system ○ remove: ignition coil (see ignition coil removal) stud bolts [a] ○ hold the flywheel with a suitable tool, remove the flywheel bolt and the washer. • using a suitable flywheel puller [a], remove the flywheel [b]. Caution always use flywheel puller. • remove: ...
Page 168
9-12 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 169
Electrical system 9-13 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 (0.60 kgf·m, 52 in·lb) charging system operational inspection • check the battery condition. Note ○...
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9-14 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 171
Electrical system 9-15 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: (without charging ...
Page 172
9-16 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 173
Electrical system 9-17 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 the ignition coil on the crankcase so that the stop switch lead co...
Page 174
9-18 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 ○ measure the ignition coil winding resistance as...
Page 175: Troubleshooting
Troubleshooting 10-1 10 troubleshooting table of contents engine troubleshooting guide ............................................................................................... 10-2 starter motor troubleshooting guide ...............................................................................
Page 176
10-2 troubleshooting engine troubleshooting guide if the engine malfunctions, check if the way the engine is used is correct. If the engine malfunc- tions even if the engine is used correctly, systematically carry out troubleshooting starting with simple points. This chart describes typical troubles...
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Troubleshooting 10-3 engine troubleshooting guide.
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10-4 troubleshooting engine troubleshooting guide.
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Troubleshooting 10-5 engine troubleshooting guide.
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10-6 troubleshooting starter motor troubleshooting guide 1. Disconnect the 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 i...
Page 181
Part no.99924-2045-08 printed in japan.