- DL manuals
- Kawasaki
- Other
- FJ180V -
- Service Manual
Kawasaki FJ180V - Service Manual
Summary of FJ180V -
Page 1
4-stroke air-cooled gasoline engine.
Page 3: Quick Reference Guide
Quick reference guide general information 1 j periodic maintenance 2 j fuel system 3 j cooling system 4 j engine top end 5 j lubrication system 6 j camshaft/crankshaft 7 j electrical system 8 j troubleshooting 9 j this quick reference guide will assist you in locating a desired topic or pro- cedure....
Page 5: Fj180V
Fj180v 4-stroke air-cooled 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 or otherwise, without the prior written permission of quality assura...
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 grease and dirty oil should be cleaned off. Deteriorated grease has lost its lubricative quality and may contain abrasive foreign particles. Don’t use just any oil or grease. Some oils and greases in particular should be used only in certain applications and ...
Page 12
1-4 general information model identification.
Page 13
General information 1-5 general specifications items fj180v type of engine forced air-cooled, vertical shaft, ohv, 4-stroke gasoline engine bore x stroke 65 mm x 54 mm (2.56 in x 2.13 in) piston displacement 179 ml (10.9 cu. In) direction of rotation counterclockwise facing the pto shaft compression...
Page 14
1-6 general information torque and locking agent the following tables list the tightening torque for the major fasteners, and the parts requiring use of a non-permanent locking agent or liquid gasket. Letters used in the "remarks" column mean: l : apply a non-permanent locking agent to the threads. ...
Page 15
General information 1-7 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-clea...
Page 17: Periodic Maintenance
Periodic maintenance 2-1 2 periodic maintenance table of contents periodic maintenance chart ...................................................................................................... 2- 2 specifications .......................................................................................
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 specifications item standard fuel system high idle speed 3200 r/min (rpm) air cleaner: type dual stage filtration system pre-cleaner foam element second-stage cleaner paper element engine top end valve clearance intake exhaust 0.10 ~ 0.15 mm (0.004 ~ 0.006 in.) valve seating...
Page 20
2-4 periodic maintenance special tools valve seat cutter, 45 - f27.5: 57001–1114 valve seat cutter, 32 - f25.0: 57001–1118 valve seat cutter, 32 - f28.0: 57001–1119 valve seat cutter holder bar: 57001–1128 valve seat cutter holder - f6.0: 57001–1360
Page 21
Periodic maintenance 2-5 periodic maintenance procedures fuel system high idle speed adjustment caution do not adjust high idle speed with the air cleaner removed. • start and warm up the engine throughly. Warning always keep your hands clear of the moving parts. • move the throttle lever at a dash ...
Page 22
2-6 periodic maintenance periodic maintenance procedures fuel filter inspection • visually insect the fuel filter [a]. If the filter is clear with no signs of dirt or other contami- nation, it is ok and need not be replaced. If the filter is dark or looks dirty, replace with a new one. Also check th...
Page 23
Periodic maintenance 2-7 periodic maintenance procedures air element installation • install: foam element paper element • install the hollow [a] of the air cleaner case and projection [b] of the air cleaner body are fitting. • move the holders [a]. Air element cleaning and inspection note in dusty a...
Page 24
2-8 periodic maintenance periodic maintenance procedures air cleaner housing (case and body) inspection • clean the housing with detergent and water and dry thor- oughly. • check the housing for deformation or other damage. The housing must seal well and permit only filtered air to reach the carbure...
Page 25
Periodic maintenance 2-9 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 (when cold) intake, exhaust 0.10 ~ 0.1...
Page 26
2-10 periodic maintenance periodic maintenance procedures note the valve stem and guide must be in good condition or this check will not be valid. Good [a] too wide [b] too narrow [c] uneven [d] if the valve seating pattern is not correct, repair the seat. Valve seating surface width (std) inlet, ex...
Page 27
Periodic maintenance 2-11 periodic maintenance procedures marks stamped on the cutter: the marks stamped on the back of the cutter represent the following. 1 cutter number, selected from 1 to 12 30 cutter angle [a] 37.5 cutter diameter of cutter [b] ks8b manufactured lot number operating procedures:...
Page 28
2-12 periodic maintenance periodic maintenance procedures • use a 32 seat cutter [a] to narrow the seat width to the std width. Turn the seat cutter one turn at a time while pressing down very lightly. Check the seat width after each turn. Caution the 32 cutter removes material very quickly. Check t...
Page 29
Periodic maintenance 2-13 periodic maintenance procedures lubrication system oil level inspection • place the engine on a level surface. • remove the oil filler cap [a] and wipe its dipstick [b] with a clean cloth. • insert the dipstick into gauge hole [c] without screwing it in, then check the oil ...
Page 30
2-14 periodic maintenance 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: sae30, sae10w-30 capacity: [when engine is completely dry] 0.65 l (0.69 us-qt) electrical system spark plug cle...
Page 31: Fuel System
Fuel system 3-1 3 fuel system table of contents exploded view........................................................................................................................... 3- 2 specifications ..................................................................................................
Page 32
3-2 fuel system exploded view.
Page 33
Fuel system 3-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 govenor arm clamp nut 7.8 0.80 69 in·lb 2 fuel tank cover bolts 6.9 0.70 61 in·lb 3 tank drain bolt 6.9 0.70 61 in·lb.
Page 34
3-4 fuel system exploded view.
Page 35
Fuel system 3-5 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 priming nut 1.2 0.12 11 in·lb 2 throttle valve screw 0.7 0.07 6 in·lb 3 main jet 1.1 0.11 9.7 in·lb 4 float chamber mounting bolt 5.4 0.55 48 in·lb 5 drain screw 4.2 0.43 37 in·lb.
Page 36
3-6 fuel system specifications standard item fj180v caburetor specification: make/ type walbro lmj-17a throttle bore diameter 20 mm (0.79 in.) venturi diameter 14 mm (0.55 in.) main jet (mj) #76 pilot jet (pj) #50 pilot air screw turns out (ps) 2 3/4 (idle mixture screw turns out) float level float ...
Page 37
Fuel system 3-7 governor link mechanism control panel assembly removal • remove: air cleaner (see cleaner body removal) recoil starter (see electrical system chapter) fuel tank (see fuel tank removal) control panel mounting bolts [a] • remove the control panel [b] unhooking the governor spring [a] e...
Page 38
3-8 fuel system governor link mechanism governor arm installation • install the governor arm [a] onto the governor shaft [b] temporarily. • be sure the link spring [c] around the throttle link rod [d] is in place and that it pulls the governor arm and throttle lever [e] toward each other. • loosen t...
Page 39
Fuel system 3-9 governor link mechanism governor assembly installation • instal 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 40
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 during moderate to high load conditions. Fuel flows through the main jet and into ...
Page 41
Fuel system 3-11 carburetor high idle speed adjustment refer to high idle speed adjustment in the periodic main- tenance chapter (2nd chapter). High altitude operation at high altitude, the standard carburetor air-fuel mixture will be excessively rich. Performance will decrease, and fuel consumption...
Page 42
3-12 fuel system carburetor • install the primer pipe [a] and drain screw as shown. 90 ~ 100 [b] fuel system cleanliness inspection refer to fuel system cleanliness inspection in the peri- odic maintenance chapter (2nd chapter). Carburetor removal warning gasoline is extremely flammable and can be e...
Page 43
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 throttle valve for assembling them. • repla...
Page 44
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 appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasolin...
Page 45
Fuel system 3-15 carburetor carburetor inspection warning gasoline is extremely flammable and can be explo- sive under certain. Turn the engine switch stop position. 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 46
3-16 fuel system priming pump priming pump removal • remove the tube [a] from the priming pump. • remove the nut [b] and washer [c]. • remove the priming pump from the intake manifold. • inspect the priming pump for damages. If a damage is present in the priming pump, replace it. Priming pump instal...
Page 47
Fuel system 3-17 intake manifold intake manifold removal • unscrew the intake manifold mounting bolts [a]. • remove the breather pipe [b] from the intake manifold. Intake manifold installation • replace the o-ring [a] with a new one. • clean the mating surface of the carburetor and intake manifold. ...
Page 48
3-18 fuel system fuel tank fuel tank removal • remove: air cleaner (see cleaner body removal) recoil starter (see electrical system chapter) oil gauge fuel tank cover bolts [a]. • place a suitable container beneath the fuel hose. • loosen the clamp and remove the fuel hose from the car- buretor. • l...
Page 49
Fuel system 3-19 fuel tank fuel tank cleaning warning clean the fuel tank in a well-ventilated area, and take care that there is no sparks or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or low flash-point solvent to clean the tank. • r...
Page 50
3-20 fuel system fuel filter fuel filter inspection refer to fuel filter inspection in the periodic maintenance chapter (2nd chapter)..
Page 51
Fuel system 3-21 air cleaner element removal refer to air element removal in the periodic mainte- nance chapter (2nd chapter). Element installation refer to air element instalation in the periodic mainte- nance chapter (2nd chapter). Element cleaning and inspection refer to air element cleaning and ...
Page 52
3-22 fuel system air cleaner • move the holders [a]. Housing (case and body) inspection refer to air cleaner housing (case and body) inspection in the periodic maintenance chapter (2nd chapter)..
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.
Page 55
Cooling system 4-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 flywheel bolt 42 4.3 31 2 fuel tank cover bolts 6.9 0.70 61 in·lb.
Page 56
4-4 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 cracks, ...
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.
Page 59
Engine top end 5-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 cylinder head bolts 22 2.2 16 s 2 valve clearance lock screws 6.9 0.70 61 in·lb 3 connecting rod big end cap bolts 5.9 0.60 52 in·lb o 4 rocker arm bolts 28 2.8 20 5 spark plug 22 2.2 16 6 rocker cover mounting bolts 5.9 ...
Page 60
5-4 engine top end specifications item service limit cylinder head: cylinder compression (min) [196 kpa (28.4 psi)] (min) cylinder head warp 0.03 mm (0.001 in.) valves: valve head thickness intake 0.35 mm (0.014 in.) exhaust 0.36 mm (0.014 in.) valve stem runout intake, exhaust 0.05 mm (0.002 in.) v...
Page 61
Engine top end 5-5 special tools compression gauge: 57001–221 piston ring compression: 57001–1095 piston ring compression belt, f55 ~ f67: 57001–1096 compression gauge adapter m14 ×1.25 : 57001–1159.
Page 62
5-6 engine top end cylinder head compression measurement • before measuring compression, do the following. 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. Stop the engine. • disconnect the spark pl...
Page 63
Engine top end 5-7 cylinder head cylinder head assembly removal • remove: air cleaner (see fuel system chapter) recoil starter (see electrical system chapter) fuel tank (see fuel system chapter) muffler (see muffler removal) fan housing (see flywheel removal) intake manifold and carburetor (see fuel...
Page 64
5-8 engine top end cylinder head push rod removal • set at t.D.C of power stroke in. • remove the rocker cover (see cylinder head assembly removal). • loosen the valve clearance adjusting nuts [a]. • move the rocker arms [b] to clear the push rod upper ends. • pull out the push rods. Note mark the p...
Page 65
Engine top end 5-9 cylinder head valve mechanism removal/installation • remove the cylinder head assembly (see cylinder head assembly removal). Note when removing the valve mechanism parts, note their position so that they may be reinstalled in their original position during assembly. • remove: valv...
Page 66
5-10 engine top end cylinder head rocker arm inspection • clean and inspect the rocker arm where it touches the push rod and valve stem. If the contact points [a] are worn or damaged, replace the rocker arm..
Page 67
Engine top end 5-11 valves valve clearance inspection refer to valve clearance inspection in the periodic main- tenance chapter (2nd chapter). Valve clearance adjustment refer to valve clearance adjustment in the periodic maintenance chapter (2nd chapter). Valve seat inspection refer to valve seat i...
Page 68
5-12 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 guides [b] at three places down the length of the guides. If the measurement is more than the service limit, replace the cylinder head with a new one. Valve...
Page 69
Engine top end 5-13 cylinder, piston piston removal • remove: air cleaner (see fuel system chapter) recoil starter (see electrical system chapter) fuel tank (see fuel system chapter) flywheel (see electrical system chapter) • remove the crankcase cover (see camshaft/crankshaft chapter). • remove the...
Page 70
5-14 engine top end cylinder, piston • carefully spread the ring opening with your thumbs and then push up on the opposite side of the ring [a] to remove it. • remove the 3-piece oil ring with your thumbs in the same manner. Piston installation • install the expander [a] in the piston oil ring groov...
Page 71
Engine top end 5-15 cylinder, piston • apply engine oil to the piston pin. • assemble the piston onto the connecting rod as follows: set the arrow mark [a] on the piston head come reverse side of the “k” mark [b] side the connecting rod, then in- sert the piston pin into the piston pin hole. • insta...
Page 72
5-16 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 cap [c]. • set rod and ...
Page 73
Engine top end 5-17 cylinder, piston piston ring and ring groove wear • clean the piston (see piston cleaning). • 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- place both the p...
Page 74
5-18 engine top end cylinder, piston piston pin, piston pin hole, and connecting rod wear • remove the piston pin. • measure the diameter of the piston pin with a micrometer at several points. If the outside diameter is less than service limit, replace the piston pin. Piston pin outside diameter ser...
Page 75
Engine top end 5-19 cylinder, piston cylinder inside diameter • clean and measure the cylinder inside diameter. Use a dial bore gauge to measure front-to-back and side -to-side at the points shown figure. If any of the cylinder bore measurements is greater than the service limit, replace the cylinde...
Page 76
5-20 engine top end muffler muffler removal • remove: muffler cover self tap bolt [c] muffler cover nuts [a] muffler cover [b] muffler • remove the gasket. • do not use unnecessary force on the muffler when remov- ing the muffler assembly, or they could become damaged or distored. Muffler installati...
Page 77: Lubrication System
Lubrication system 6-1 6 lubrication system table of contents exploded view........................................................................................................................... 6- 2 engine oil flow chart..............................................................................
Page 78
6-2 lubrication system exploded view.
Page 79
Lubrication system 6-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 oil drain plug 22 2.2 16 2 tank drain bolt 6.9 0.70 61 in·lb 3 oil filter cover bolt 6.9 0.70 61 in·lb o: apply engine oil..
Page 80
6-4 lubrication system engine oil flow chart.
Page 81
Lubrication system 6-5 specifications item standard engine oil: type sf, sg, sh or sj class viscosity sae30, sae10w-30 capacity [when engine is completely dry] 0.65 l (0.69 us-qt) level operating range (grid area) on dipstick item service limit oil pump: inner and outer rotor clearance 0.14 mm (0.00...
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 and accident. Before starting the engine for the first time, add oil: the engine is shipped dry. Preoil the engine to fo...
Page 83
Lubrication system 6-7 lubrication system pressure the oil of oil pump is elevate the oil passages of crankcase of thread. Discharge the oil camshaft to side from crank celing side and the revolution of the camshaft to dissemination the oil mist from the crankshaft chamber. Lubrication the piston an...
Page 84
6-8 lubrication system oil pump oil pump removal • remove: air cleaner (see fuel system chapter) recoil starter (see electrical system chapter) fuel tank (see fuel system chapter) flywheel (see electrical system chapter) crankcase cover (see camshaft/crankshaft chapter) camshaft (see camshaft/cranks...
Page 85
Lubrication system 6-9 oil pump • measure the inside diameter [a] of the pump housing with an inside micrometer at several points. If the inside diameter is more than the service limit, re- place the crankcase. Pump housing inside diameter service limit: 23.241 mm (0.915 in.) • measure the depth [b]...
Page 87: Camshaft/crankshaft
Camshaft/crankshaft 7-1 7 camshaft/crankshaft table of contents exploded view........................................................................................................................... 7- 2 specifications ..................................................................................
Page 88
7-2 camshaft/crankshaft exploded view.
Page 89
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 5.9 0.60 52 in·lb o 3 valve clearance lock screws 6.9 0.70 61 in·lb 4 rocker arm bolts 28 2.8 20 g: apply grease. O: apply engine oil. S: f...
Page 90
7-4 camshaft/crankshaft specifications item service limit camshaft, tappet: cam lobe height intake, exhaust 22.060 mm (0.8685 in.) camshaft journal diameter pto side 7.77 mm (0.3059 in.) flywheel side 13.927 mm (0.5483 in.) camshaft hole inside diameter crankcase cover 11.060 mm (0.4354 in.) cranksh...
Page 91
Camshaft/crankshaft 7-5 crankcase crankcase cover removal • drain the oil (see lubrication system chapter). • remove: air cleaner (see fuel system chapter) recoil starter (see electrical system chapter) fuel tank (see fuel system chapter) flywheel (see electrical system chapter) • unscrew the mounti...
Page 92
7-6 camshaft/crankshaft crankcase • install the crankcase cover and tighten the crankcase cover bolts following the tightening sequence shown. Torque - crankcase cover bolts: 8.8 n·m (0.90 kgf·m, 78 in·lb) do not turn one bolt down completely before the others, as it may cause the crankcase cover to...
Page 93
Camshaft/crankshaft 7-7 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. Valve controls direction of air flow caused by piston movement so that air flow from ...
Page 94
7-8 camshaft/crankshaft breather breather chamber cover removal • remove the bolts [a] and breather chamber cover [b]. Breather chamber cover installation • install a new gasket and the breather chamber cover, and tighten the bolts. Breather valve inspection • remove the breather valve [a]. • inspec...
Page 95
Camshaft/crankshaft 7-9 camshaft, tappet camshaft, tappet removal • drain the oil (see lubrication system chapter). • remove: air cleaner (see fuel system chapter) recoil starter (see electrical system chapter) fuel tank (see fuel system chapter) flywheel (see electrical system chapter) crankcase co...
Page 96
7-10 camshaft/crankshaft camshaft, tappet camshaft, tappet installation • apply engine oil to the following. Tappet journal camshaft journal cam lobe surface camshaft gear • install the tappets in those old positions. • align the punch marks [a] on the crankshaft gear and on the camshaft gear. • ins...
Page 97
Camshaft/crankshaft 7-11 camshaft, tappet • inspect the camshaft to make sure that its automatic com- pression reduction (acr) function operates smoothly and does not have any damage or abnormal wear. If acr parts are worn, replace the acr with a new one. When the weight [a] is closed, if the top of...
Page 98
7-12 camshaft/crankshaft 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 • drain the oil (see lubrication system chapter). • remove: air cleaner (see fuel sys...
Page 99
Camshaft/crankshaft 7-13 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 leas...
Page 100
7-14 camshaft/crankshaft crankshaft, connecting rod • measure the crankpin width [a] with a dial caliper. If the crankpin width is more than the service limit, replace the crankshaft. Crankpin width service limit: 24.17 mm (0.95 in.) connecting rod big end bearing/crankpin wear • apply a light film ...
Page 101
Camshaft/crankshaft 7-15 crankshaft, connecting rod crankshaft main journal/wear • measure both journals at several points around the jour- nal 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] ser...
Page 103: Electrical System
Electrical system 8-1 8 electrical system table of contents exploded view........................................................................................................................... 8- 2 specifications ......................................................................................
Page 104
8-2 electrical system exploded view.
Page 105
Electrical system 8-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 flywheel bolt 42 4.3 31 2 recoil starter set screw 1.0 0.10 8.9 in·lb 3 spark plug 22 2.2 16 4 brake arm mounting bolt 9.3 0.95 82 in·lb 5 fuel tank cover bolts 6.9 0.70 61 in·lb 6 recoil starter mounting bolts 6.9 0.7...
Page 106
8-4 electrical system specifications item standard service limit ignition system: ignition coil: primary winding resistance in the text – – – secondary winding resistance in the text – – – spark plug ngk bpr5es – – – plug gap 0.75 mm (0.030 in.) – – –.
Page 107
Electrical system 8-5 special tools hand tester: 57001–1394 bracket holder: 57001–1536.
Page 108
8-6 electrical system wiring diagram.
Page 109
Electrical system 8-7 precautions there are a number of important precautions that must be taken 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 th...
Page 110
8-8 electrical system charging, ignition system flywheel removal • remove: air cleaner (see fuel system chapter) recoil starter (see electrical system chapter) fuel tank (see fuel system chapter) • hold the pulley [b] with a bracket holder [a], remove the flywheel bolt and washer. Special tool - bra...
Page 111
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] degrease the flywheel taper, c...
Page 112
8-10 electrical system charging, ignition system • install the pulley [a] and washer [b]. • tighten the flywheel bolt [c]. Torque - flywheel bolt: 42 n·m (4.3 kgf·m, 31 ft·lb) • install the washer [a] as shown. Flywheel bolt [b] • install the other removed parts..
Page 113
Electrical system 8-11 charging, ignition system circuit composition co: ignition coil core c: condenser d1: diode d2: diode d3: diode e: exciter coil l1: primary coil l2: secondary coil scr: thyristor sp: spark plug action principle (1) fundamental action 1. Genarated positive direction voltage by ...
Page 114
8-12 electrical system charging, ignition system cautions of handling and maintenance (1) do not near the magnet by the heat of fire. (2) ignition timing is no adjustment because of it is fixed. (3) when carry out the spark test, pull the recoil starter knob with strong force. If the flywheel does n...
Page 115
Electrical system 8-13 charging, ignition system ignition coil inspection • remove the ignition coil (see ignition coil removal). • measure the winding resistance as follows. Set the hand tester to the r × 1 k range. Special tool - hand tester: 57001–1394 make the measurements shown in the table. Ig...
Page 116
8-14 electrical system starter system recoil starter removal • remove: recoil starter mounting bolts [a] recoil starter [b] recoil starter installation • install the recoil starter and tighten the mounting bolts. Torque - recoil starter mounting bolts: 6.9 n·m (0.70 kgf·m, 61 in·lb) recoil starter d...
Page 117
Electrical system 8-15 starter system warning when removing the reel [a], be careful that the spi- ral spring [b] in the reel does not fly loose 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 ree...
Page 118
8-16 electrical system starter system • remove the tape. • install: ratchets [a] friction spring [b] • install the ratchet guide [a]. • tighten the set screw [b]. Torque - recoil starter set screw: 1.0 n·m (0.10 kgf·m, 8.9 in·lb) • turn the reel two turns counterclockwise to preload the spiral sprin...
Page 119
Electrical system 8-17 pad brake pad brake assembly removal • remove: air cleaner (see fuel system chapter) recoil starter (see electrical system chapter) fuel tank (see fuel system chapter) pulley (see flywheel removal) fan housing and fan (see flywheel removal) • remove the brake lever assembly mo...
Page 120
8-18 electrical system pad brake • tighten the bolt [a]. • install the lever assembly [b]. • tighten the brake lever assembly mounting bolt [c]. Torque - brake lever assembly mounting bolt: 6.9 n·m (0.70 kgf·m, 61 in·lb) check the lever assembly move smoothly was installed. • install the spring [d]....
Page 121: Troubleshooting
Troubleshooting 9-1 9 troubleshooting table of contents engine troubleshooting guide .................................................................................................. 9- 2.
Page 122
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 123
Troubleshooting 9-3 engine troubleshooting guide.
Page 124
9-4 troubleshooting engine troubleshooting guide.
Page 125
Troubleshooting 9-5 engine troubleshooting guide.