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Kawasaki FJ100D - Service Manual

Other manuals for FJ100D -: Datasheet, Service Manual
Manual is about: 4-stroke air-cooled gasoline engine

Summary of FJ100D -

  • Page 1

    Fj100d 4-stroke air-cooled gasoline engine service manual for kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com easymotoculture.

  • Page 2

    For kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com easymotoculture.

  • 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 4

    For kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com easymotoculture.

  • Page 5: Fj100D

    Fj100d 4-stroke air-cooled gasoline engine service manual all rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of...

  • 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 (12)seal guide a seal guide is required for certain oil or grease seals during installation to avoid damage to the seal lips. Before a shaft passes through a seal, apply a little oil, preferably high-temperature grease on the lips to reduce rubber to metal fr...

  • Page 12

    1-4 general information model identification for kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com easymotoculture.

  • Page 13

    General information 1-5 general specifications item fj100d type of engine air-cooled, 4-stroke, ohv, single cylinder gasoline engine bore × stroke 56 mm × 40 mm (2.20 in. × 1.57 in.) piston displacement 99 cm³ (6.0 cu in.) direction of rotation counterclockwise facing the pto shaft compression relea...

  • Page 14

    For kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com easymotoculture.

  • Page 15: Periodic Maintenance

    Periodic maintenance 2-1 2 periodic maintenance table of contents periodic maintenance chart ................................................................................................... 2-2 torque and locking agent..................................................................................

  • Page 16

    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 17

    Periodic maintenance 2-3 torque and locking agent the following tables list the tightening torque for the major fasteners requiring use of a non-permanent locking agent or silicone sealant etc. Letters used in the “remarks” column mean: l: apply a non-permanent locking agent. O: apply engine oil. S:...

  • Page 18

    2-4 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 19

    Periodic maintenance 2-5 specifications item standard fuel system idle speed (1): low idle speed 1 600 rpm (r/min) high idle speed 4 000 rpm (r/min) air cleaner: type dual stage filtration system cleaner: first foam element second paper element engine top end cylinder head warp service limit: 0.03 m...

  • Page 20

    2-6 periodic maintenance special tools valve seat cutter, 45° - 24.5: 57001-1113 valve seat cutter, 45° - 27.5: 57001-1114 valve seat cutter, 32° - 25: 57001-1118 valve seat cutter, 32° - 28: 57001-1119 valve seat cutter holder, 5.5: 57001-1125 valve seat cutter holder bar: 57001-1128 for kawasaki d...

  • Page 21

    Periodic maintenance 2-7 periodic maintenance procedures fuel system low idle speed adjustment • disconnect all external loads from the engine. • start the engine and warm it up thoroughly. Warning always keep your hands clear of the moving parts. • move the throttle lever on dash to the idle positi...

  • Page 22

    2-8 periodic maintenance periodic maintenance procedures fuel system cleanliness inspection warning gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the engine switch “ ○ ” (stop). Do not smoke. Make sure the area is well-ventilated and free from any source of fl...

  • Page 23

    Periodic maintenance 2-9 periodic maintenance procedures fuel filter inspection • place a suitable container under the drain screw on the carburetor. • turn the fuel tap to the on position, and loosen the drain screw to drain the carburetor. • tighten the drain screw. If any water or dirt is found, ...

  • Page 24

    2-10 periodic maintenance periodic maintenance procedures air cleaner element cleaning and inspection note ○ in dusty areas, the elements should be cleaned more frequently than the recommended intervals. Warning because of the danger of highly flammable liquids, do not use gasoline or a low flash-po...

  • Page 25

    Periodic maintenance 2-11 periodic maintenance procedures engine top end cylinder head cleaning and inspection • remove the cylinder head (see cylinder head assembly removal in the engine top end chapter). • scrape the carbon deposits from the head and exhaust port with a suitable tool [a]. • to avo...

  • Page 26

    2-12 periodic maintenance periodic maintenance procedures • then check the valve clearance. ○ using a thickness gauge [a], measure the valve clearance beween the rocker arm [b] and the valve stem end. If the valve clearance is incorrect, adjust it. Valve clearance standard: exhaust 0.12 mm (0.005 in...

  • Page 27

    Periodic maintenance 2-13 periodic maintenance procedures valve seat inspection • remove the valve (see valve mechanism removal/instal- lation in the engine top end chapter). • inspect the valve seats for damage. If the seats are warped or distorted beyond recondition- ing, replace the cylinder head...

  • Page 28

    2-14 periodic maintenance periodic maintenance procedures seat cutter operating cares 1. This valve seat cutter is designed only for valve seat repair. Therefore the cutter must not be used for other purposes. 2. Do not drop or hit the valve seat cutter, or the diamond particles may fall off. 3. Do ...

  • Page 29

    Periodic maintenance 2-15 periodic maintenance procedures • coat the seat with machinist’s dye. • fit a 45° cutter [a] to the holder and slide it into the valve guide. ○ resurface the valve seat with a 45° cutter, removing only enough material to produce a smooth and concentric seat. Caution do not ...

  • Page 30

    2-16 periodic maintenance periodic maintenance procedures • 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. • ...

  • Page 31

    Periodic maintenance 2-17 periodic maintenance procedures • remove the oil filler cap and pour in the specified type and amount of oil. Engine oil type: sf, sg, sh or sj class viscosity: sae 10w-30 capacity: 0.26 ∼ 0.46 l (0.27 ∼ 0.49 us qt) electrical system spark plug cleaning and inspection • rem...

  • Page 32

    For kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com easymotoculture.

  • Page 33: Fuel System

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

  • Page 34

    3-2 fuel system exploded view for kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com easymotoculture.

  • Page 35

    Fuel system 3-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 throttle valve screw 0.78 0.080 7 in·lb l 2 choke valve screw 0.78 0.080 7 in·lb l 3 pilot jet 0.54 0.055 5 in·lb 4 main jet 0.54 0.055 5 in·lb 5 float chamber mounting bolt 9.8 1.0 87 in·lb 6 fuel tank bolts 8.8 0.90 78 in·...

  • Page 36

    3-4 fuel system exploded view for kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com easymotoculture.

  • Page 37

    Fuel system 3-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 governor arm clamp nut 5.9 0.60 52 in·lb 2 control panel nut 1.5 0.15 13 in·lb 3. Low idle speed screw 4. High idle speed screw 5. Throttle lever 6. Governor arm 7. Governor shaft 8. Governor assembly o: apply engine oil. Fo...

  • Page 38

    3-6 fuel system specifications item standard carburetor make/type walbro/lmj throttle bore diameter 18 mm (0.71 in.) venturi diameter 12 mm (0.47 in.) main jet (mj) #54 pilot jet (pj) #52 pilot air screw turns out (ps) 1 7/8 ±1/2 (idle mixture screw turns out) float level float parallel to carbureto...

  • Page 39

    Fuel system 3-7 governor link mechanism control panel assembly removal • push the fastener in the center [a] with a screw driver or a pin-point tool, and remove the fastener. • remove: fuel tank (see fuel tank removal in this chapter) control panel assembly mounting bolts [a] • remove the control pa...

  • Page 40

    3-8 fuel system governor link mechanism governor arm removal • remove: control panel assembly (see control panel assembly removal in this chapter) • loosen the clamp nut [a] and take off the governor arm [b]. • unhook the throttle link rod spring [c] end loop and clear the throttle link rod lower en...

  • Page 41

    Fuel system 3-9 governor link mechanism governor assembly installation • install the sleeve [a] on the governor assembly [b]. Caution first install the sleeve. The sleeve cannot be in- stalled after the governor gear assembly has been installed. • to install, first place the thrust washer [c] on the...

  • Page 42

    3-10 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 dur- ing moderate to heavy load conditions. Fuel flows through the main jet and in...

  • Page 43

    Fuel system 3-11 carburetor low idle speed adjustment • refer to the low idle speed adjustment in the periodic maintenance chapter. High idle speed adjustment • refer to the high idle speed adjustment in the periodic maintenance chapter. Main jet replacement • place the engine (equipment) on a level...

  • Page 44

    3-12 fuel system carburetor carburetor removal warning gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the engine switch “ ○ ” (stop). Do not smoke. Make sure the area is well- ventilated and free from any source of flame or sparks; this includes any appliance w...

  • Page 45

    Fuel system 3-13 carburetor carburetor disassembly/assembly • 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 valve for assembli...

  • Page 46

    3-14 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 electrical appliance with a pilot light. Because of the danger of highly flammable liquids, do not ...

  • Page 47

    Fuel system 3-15 carburetor carburetor inspection warning gasoline is extremely flammable and can be ex- plosive under certain. Turn the engine switch “ ○ ” (stop). 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 pil...

  • Page 48

    3-16 fuel system fuel tank fuel tank removal • drain the fuel from the fuel system with the fuel tap. • remove: fuel tank bolts [a] • pull the fuel hose [a] out of the fuel tank by loosening the clamps, and remove the fuel tank. Fuel tank installation • connect the fuel hose and fuel tank with the c...

  • Page 49

    Fuel system 3-17 fuel tank fuel tap installation • connect the fuel hose and fuel tap [b] with the clasps of the clamps [a] as shown in the figure. • install the bracket, and tighten the bolts. Fuel tank and fuel tap cleaning warning clean the tank and cock in a well-ventilated area. Do not use gaso...

  • Page 50

    3-18 fuel system fuel filter fuel filter inspection • refer to the fuel filter inspection in the periodic mainte- nance chapter. Fuel filter cleaning warning clean the fuel filter in a well-ventilated area. Do not use gasoline or low-flash point solvent to clean the filter. • remove the fuel tap (se...

  • Page 51

    Fuel system 3-19 air cleaner element removal • refer to the air cleaner element removal in the periodic maintenance chapter. Element installation • refer to the air cleaner element installation in the peri- odic maintenance chapter. Element cleaning and inspection • refer to the air cleaner element ...

  • Page 52

    For kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com easymotoculture.

  • Page 53: Cooling System

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

  • Page 54

    4-2 cooling system exploded view for kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com easymotoculture.

  • Page 55

    Cooling system 4-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 fan housing bolts 8.8 0.90 78 in·lb 2 flywheel bolt 25 2.5 18 3. Fan housing for kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com easymotoculture.

  • Page 56

    4-4 cooling system cooling fan cooling fan removal • refer to the flywheel removal in the electrical system chapter. Cooling fan installation • refer to the flywheel installation in the electrical system chapter. Cooling fan inspection • visually inspect the blades [a] in the cooling fan [b]. If the...

  • Page 57: Engine Top End

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

  • Page 58

    5-2 engine top end exploded view for kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com easymotoculture.

  • Page 59

    Engine top end 5-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks cylinder head bolts (used) 25 2.5 18 s 1 cylinder head bolts (new) 32 3.3 24 s 2 valve clearance locknuts 6.9 0.70 61 in·lb 3 rocker arm bolts 23 2.3 17 4 connecting rod big end cap bolts 9.0 0.90 80 in·lb o 5 exhaust pipe ...

  • Page 60

    5-4 engine top end specifications item service limit cylinder head cylinder compression 200 kpa (29 psi) (min) cylinder head warp 0.03 mm (0.001 in.) valves valve head thickness: exhaust 0.50 mm (0.020 in.) inlet 0.50 mm (0.020 in.) valve stem runout: exhaust tir 0.05 mm (0.002 in.) inlet tir 0.05 m...

  • Page 61

    Engine top end 5-5 specifications item standard valves valve clearance: exhaust 0.12 mm (0.005 in.) inlet 0.12 mm (0.005 in.) valve seating surface angle: exhaust 45° inlet 45° valve seating surface width: exhaust 0.5 ∼ 1.1 mm (0.02 ∼ 0.04 in.) inlet 0.5 ∼ 1.1 mm (0.02 ∼ 0.04 in.) valve guide inside...

  • Page 62

    5-6 engine top end special tools compression gauge, 20 kgf/cm²: 57001-221 compression gauge adapter, m14 × 1.25: 57001-1159 for kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com easymotoculture.

  • Page 63

    Engine top end 5-7 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 64

    5-8 engine top end cylinder head cylinder head assembly removal • remove: fan housing (see flywheel removal in the electrical system chapter) muffler assembly (see muffler assembly removal in this chapter) spark plug (see spark plug removal in the electrical system chapter) • unscrew the rocker cove...

  • Page 65

    Engine top end 5-9 cylinder head • tighten the cylinder head bolts following the tightening sequence as shown in the figure. Torque - cylinder head bolts: used: 25 n·m (2.5 kgf·m, 18 ft·lb) new: 32 n·m (3.3 kgf·m, 24 ft·lb) caution a torque wrench must be used to assure proper torque. Improper tight...

  • Page 66

    5-10 engine top end cylinder head push rod installation • set the piston at tdc of power stroke in. • install the push rods [a] in their original positions on each cylinder. ○ to install the push rod in the correct position on the tappet [b], insert the push rod so end of the push rod is sliding dow...

  • Page 67

    Engine top end 5-11 cylinder head • support the valve head in the combustion chamber with a suitable block. • press the valve retainer [a] with thumbs and move the valve stem end toward the recessed corner of the valve retainer, then pull out the valve retainer. • remove the spring [b] and valve [c]...

  • Page 68

    5-12 engine top end valves valve clearance inspection • refer to the valve clearance inspection in the periodic maintenance chapter. Valve clearance adjustment • refer to the valve clearance adjustment in the periodic maintenance chapter. Valve seat inspection • refer to the valve seat inspection in...

  • Page 69

    Engine top end 5-13 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 places down the length of the guide. If the measurement is more than the service limit, replace the cylinder head with a new one. Valve g...

  • Page 70

    5-14 engine top end cylinder, piston piston removal • remove: cylinder head assembly (see cylinder head assembly removal in this chapter) camshaft (see camshaft removal in the camshaft/crankshaft chapter) • turn the crankshaft to expose the connecting rod cap bolts [a]. • remove the bolts and take o...

  • Page 71

    Engine top end 5-15 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 72

    5-16 engine top end cylinder, piston • apply engine oil to the piston skirt and the cylinder bore. • facing the arrow mark [a] on the top of the piston toward the flywheel side [b], lightly tap the top of the piston with a plastic mallet [c] to insert the piston and connecting rod into the cylinder....

  • Page 73

    Engine top end 5-17 cylinder, piston piston ring and ring groove wear • clean the piston (see piston cleaning in this chapter). • visually inspect the piston rings and ring grooves. If the piston rings are worn unevenly or damaged, replace them. If the ring grooves are worn unevenly or damaged, re- ...

  • Page 74

    5-18 engine top end cylinder, piston piston pin, piston pin hole, and connecting rod wear • remove the piston pin (see piston removal in this chap- ter). • measure the diameter of the piston pin with a micrometer at several points. If the outside diameter is less than service limit, replace the pist...

  • Page 75

    Engine top end 5-19 muffler muffler assembly removal • remove: muffler cover screws [a] muffler cover [b] • unscrew the exhaust pipe flange nuts [a], and the spring washers [b] to remove the muffler assembly [c]. Use a penetrating oil if necessary to break threads loose. • remove the gasket. • do no...

  • Page 76

    For kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com easymotoculture.

  • Page 77: Lubrication System

    Lubrication system 6-1 6 lubrication system table of contents exploded view........................................................................................................................ 6-2 specifications ........................................................................................

  • Page 78

    6-2 lubrication system exploded view for kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com easymotoculture.

  • Page 79

    Lubrication system 6-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 engine oil drain bolt 32 3.3 24 r: replacement parts for kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com easymotoculture.

  • Page 80

    6-4 lubrication system specifications item standard engine oil type sf, sg, sh or sj class viscosity sae 10w-30 capacity 0.26 ∼ 0.46 l (0.27 ∼ 0.49 us qt) level operating range (grid area (between l and h)) on dipstick for kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Co...

  • Page 81

    Lubrication system 6-5 lubrication method as shown in the right figure the revolution of the crank- shaft causes the splash arm [a] that is provided at the big end of the connecting rod to pick up the engine oil from the crankshaft chamber and splash it in a spray form to lubri- cate the internal pa...

  • Page 82

    6-6 lubrication system engine oil caution engine operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure. Before starting the engine for the first time, add oil: the engine is shipped dry. Preoil the engine to force all air f...

  • Page 83: Camshaft/crankshaft

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

  • Page 84

    7-2 camshaft/crankshaft exploded view for kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com easymotoculture.

  • Page 85

    Camshaft/crankshaft 7-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 crankcase cover bolts 8.8 0.90 78 in·lb s 2 connecting rod big end cap bolts 9.0 0.90 80 in·lb o 3 rocker arm bolts 23 2.3 17 hg: apply high-temperature grease. O: apply engine oil. R: replacement parts s: follow the...

  • Page 86

    7-4 camshaft/crankshaft specifications item service limit camshaft, tappet cam lobe height: exhaust 25.06 mm (0.9866 in.) inlet 25.06 mm (0.9866 in.) camshaft journal diameter: pto side 11.94 mm (0.4701 in.) flywheel side 13.93 mm (0.5484 in.) camshaft bearing inside diameter: crankcase 14.08 mm (0....

  • Page 87

    Camshaft/crankshaft 7-5 special tool bearing driver set: 57001-1129 for kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com easymotoculture.

  • Page 88

    7-6 camshaft/crankshaft crankcase crankcase cover removal • drain the engine oil (see oil change in the periodic main- tenance chapter). • unscrew the mounting bolts [a] and remove the crankcase cover [b] from the crankcase. ○ there are two dowel pins on the crankcase mating sur- face. A wooden or p...

  • Page 89

    Camshaft/crankshaft 7-7 crankcase • be sure to replace any oil seal removed with a new seal. ○ install the oil seal so that the marks [a] face out. ○ thoroughly pack high-temperature grease to 60% volume into the space [b] between the seal lip [d] and dust lip [c]. Press in the new oil seal using a ...

  • Page 90

    7-8 camshaft/crankshaft crankcase crankcase assembly • be sure to replace any oil seal removed with a new seal. ○ install the oil seal so that the marks [a] face out. ○ thoroughly pack high-temperature grease to 60% volume into the space [b] between the seal lip [d] and dust lip [c]. Press in the ne...

  • Page 91

    Camshaft/crankshaft 7-9 crankcase crankcase cleaning • remove: camshaft and tappets (see camshaft, tappet removal in this chapter) connecting rod and piston (see piston removal in the engine top end chapter) crankshaft (see crankshaft removal in this chapter) • clean up the crankcase with a high-fla...

  • Page 92

    7-10 camshaft/crankshaft breather the function of the breather is to create a negative pressure 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 prevent blow-by gases fro...

  • Page 93

    Camshaft/crankshaft 7-11 camshaft, tappet camshaft, tappet removal • drain the engine oil (see oil change in the periodic main- tenance chapter). • remove: muffler assembly (see muffler assembly removal in the engine top end chapter) crankcase cover (see crankcase cover removal in this chapter) rock...

  • Page 94

    7-12 camshaft/crankshaft camshaft, tappet • install the push rods (see push rod installation in the engine top end chapter). • mount the rocker arms on the push rods, and install the valve clearance adjusting nuts and locknuts. Torque - valve clearance locknuts: 6.9 n·m (0.70 kgf·m, 61 in·lb) • adju...

  • Page 95

    Camshaft/crankshaft 7-13 camshaft, tappet the acr weight installation • align the pin hole of the acr weight [a] and that of the camshaft gear. • insert the pin [b] from the weight side and caulk it on the reverse end. Caulking diameter: 4.4 ∼ 4.6 (0.173 ∼ 0.181 in.) [d] • hook the spring [c] on the...

  • Page 96

    7-14 camshaft/crankshaft crankshaft, connecting rod connecting rod removal • remove: piston (see piston removal in the engine top end chap- ter) connecting rod installation • install: piston (see piston installation in the engine top end chapter) crankshaft removal • drain the engine oil (see oil ch...

  • Page 97

    Camshaft/crankshaft 7-15 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 98

    7-16 camshaft/crankshaft crankshaft, connecting rod connecting rod big end bearing/crankpin wear • apply a thin film of engine oil on the thread of the cap bolts. • install the cap bolts and tighten the bolts to the speci- fied torque (see piston installation in the engine top end chapter). • measur...

  • Page 99: Electrical System

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

  • Page 100

    8-2 electrical system exploded view for kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com easymotoculture.

  • Page 101

    Electrical system 8-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 recoil starter mounting stud bolts 7.8 0.80 69 in·lb l 2 fan housing bolts 8.8 0.90 78 in·lb 3 recoil starter retainer screw 3.4 0.35 30 in·lb 4 spark plug 23 2.3 17 5 flywheel bolt 25 2.5 18 6 recoil starter mounting ...

  • Page 102

    8-4 electrical system specifications item standard service limit ignition system ignition coil: primary winding resistance about 1.3 Ω – – – secondary winding resistance about 15.5 kΩ – – – spark plug ngk b6hs/br6hs – – – plug gap 0.6 ∼ 0.7 mm (0.02 ∼ 0.03 in.) – – – for kawasaki discount parts call...

  • Page 103

    Electrical system 8-5 special tools hand tester: 57001-1394 pulley holder: 57001-1528 for kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com easymotoculture.

  • Page 104

    8-6 electrical system wiring diagram for kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com easymotoculture.

  • Page 105

    Electrical system 8-7 precautions there are a number of important precautions that are musts when servicing electrical systems. Learn and ob- serve all the rules below. ○ the electrical parts should never be struck sharply, as with a hammer, or allowed to fall on a hard surface. Such a shock to the ...

  • Page 106

    8-8 electrical system charging, ignition system flywheel removal • remove: fuel tank (see fuel tank removal in the fuel system chapter) air cleaner body (see air cleaner body removal in the fuel system chapter) carburetor (see carburetor removal in the fuel system chapter) recoil starter (see recoil...

  • Page 107

    Electrical system 8-9 charging, ignition system • remove: woodruff key [a] flywheel installation • using a cleaning fluid, clean off any oil or dirt on the fol- lowing portions and dry them with a clean cloth. Crankshaft tapered portion [a] flywheel tapered portion [b] ○ treat deoiling the tapered p...

  • Page 108

    8-10 electrical system charging, ignition system the ignition system is the voltage-interruption method which interrupts the primary current con- ducted by turning the flywheel and generates the high secondary voltage, and therefore this system is basically the same as the traditional system of mech...

  • Page 109

    Electrical system 8-11 charging, ignition system ignition coil removal • remove: fan housing (see flywheel removal in this chapter) spark plug cap bolts [a] ignition coil [b] ignition coil installation • install ignition coil [a] on the crankcase. Tighten bolt (1) first, then tighten bolt (2). While...

  • Page 110

    8-12 electrical system charging, ignition system spark plug installation • screw the spark plug gently into the plug hole with the plug installed in the plug wrench. • tighten the plug. Torque - spark plug: 23 n·m (2.3 kgf·m, 17 ft·lb) • fit the plug cap securely. • pull up the spark plug cap lightl...

  • Page 111

    Electrical system 8-13 starter system recoil starter removal • remove: recoil starter mounting nuts [a] recoil starter [b] recoil starter installation • install the recoil starter and tighten the mounting nuts. Torque - recoil starter mounting nuts: 6.9 n·m (0.70 kgf·m, 61 in·lb) recoil starter disa...

  • Page 112

    8-14 electrical system starter system warning when removing the reel [a], be careful that the re- coil spring [b] under the reel may fly out and cause injury. The spring is under great pressure. Note ○ there should be no spring tension on the reel when removing it. If tension is felt, push the reel ...

  • Page 113

    Electrical system 8-15 starter system • install: ratchets [a] • if the friction spring is removed, install the friction spring on the ratchet guide [a]. • install the ratchet guide. • tighten the screw [b]. Torque - recoil starter retainer screw: 3.4 n·m (0.35 kgf·m, 30 in·lb) • turn the reel two tu...

  • Page 114

    For kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com easymotoculture.

  • Page 115: Troubleshooting

    Troubleshooting 9-1 9 troubleshooting table of contents engine troubleshooting guide ............................................................................................... 9-2 for kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com easymotoculture.

  • Page 116

    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 117

    Troubleshooting 9-3 engine troubleshooting guide for kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com easymotoculture.

  • Page 118

    9-4 troubleshooting engine troubleshooting guide for kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com easymotoculture.

  • Page 119

    Troubleshooting 9-5 engine troubleshooting guide for kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com easymotoculture.

  • Page 120

    Part no.99924-2070-01 printed in japan for kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com easymotoculture.