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Kawasaki FX1000V - Service Manual

Manual is about: 4-Stroke Air-Cooled V-Twin Gasoline Engine

Summary of FX1000V -

  • Page 1

    Fx921v fx1000v 4-stroke air-cooled v-twin gasoline engine service manual for kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com.

  • Page 2

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

  • 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.

  • Page 5: Fx921V

    Fx921v fx1000v 4-stroke air-cooled v-twin gasoline engine service manual all rights reserved. No parts of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior writte...

  • 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 fx921v, fx1000v 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. For kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymow...

  • Page 13

    General information 1-5 general specifications item fx921v, fx1000v type forced air-cooled, vertical shaft, ohv 6 valves, 4-stroke gasoline engine. Cylinder layout 90° v-twin bore × stroke 89.15 mm × 80 mm (3.5 in. × 3.15 in.) displacement 999 cm³ (61 cu. In.) direction of rotation counterclockwise ...

  • Page 14

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

  • 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 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: eo: apply oil to the threads. L: apply a non-permanent...

  • Page 18

    2-4 periodic maintenance torque and locking agent torque fastener n·m kgf·m ft·lb remarks electrical system ignition coil bolts 6.9 0.70 61 in·lb stator coil screws 3.4 0.35 30 in·lb flywheel bolt 56 5.7 41 regulator screws 3.5 0.36 31 in·lb spark plugs 22 2.2 16 fan housing bolts 5.9 0.60 52 in·lb ...

  • Page 19

    Periodic maintenance 2-5 specifications item standard fuel system idle speed: (1) low idle speed (carburetor idle rpm) 1 450 r/min (rpm) low idle speed (governor idle rpm) 1 550 r/min (rpm) high idle speed 3 600 r/min (rpm) air cleaner: type heavy duty type pre-cleaner primary element second-stage c...

  • Page 20

    2-6 periodic maintenance special tools valve seat cutter, 45° - 27.5: 57001-1114 valve seat cutter, 45° - 35: 57001-1116 valve seat cutter, 32° - 30: 57001-1120 valve seat cutter, 32° - 35: 57001-1121 valve seat cutter holder, 7: 57001-1126 valve seat cutter holder bar: 57001-1128 oil filter wrench:...

  • Page 21

    Periodic maintenance 2-7 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 22

    2-8 periodic maintenance periodic maintenance procedures warning always keep your hands clear of the moving parts. • loosen the locknut [a], and unscrew the high idle set screw [b] few turns. • move the throttle lever on dash to obtain the specified high idle speed and leave it there. High idle spee...

  • Page 23

    Periodic maintenance 2-9 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 t...

  • Page 24

    2-10 periodic maintenance periodic maintenance procedures valve clearance inspection note ○ check the valve clearance when the engine is cold (at room temperature). • remove the rocker cover (see cylinder head assembly removal in the engine top end chapter). • place the piston at the top dead center...

  • Page 25

    Periodic maintenance 2-11 periodic maintenance procedures • holding the adjusting screw with a suitable tool, tighten the adjusting locknut [a] to the specified torque. Torque - valve clearance adjusting locknuts: 9.8 n·m (1.0 kgf·m, 87 in·lb) • do not overtighten the valve clearance adjusting lockn...

  • Page 26

    2-12 periodic maintenance periodic maintenance procedures if the manufacture’s instructions are not available, use the following procedure. Seat cutter operating cares 1. This valve seat cutter is designed only for valve seat re- pair. Do not use the valve seat cutter for other purpose. 2. Do not dr...

  • Page 27

    Periodic maintenance 2-13 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 28

    2-14 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 29

    Periodic maintenance 2-15 periodic maintenance procedures • remove the oil filler cap and pour in the specified type and the amount of oil. 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] 1.7 l (1....

  • Page 30

    2-16 periodic maintenance periodic maintenance procedures oil cooler fin cleaning • clean dirt off the outside fins [a] with brush or with com- pressed air. Electrical system spark plug cleaning and inspection • carefully pull the plug cap from the spark plug, and re- move the spark plug. If the plu...

  • 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 for kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com.

  • Page 33

    Fuel system 3-3 exploded view torque no. Fastener n·m kg·m ft·lb remarks 1 carburetor and inlet pipe mounting bolts 5.9 0.60 52 in·lb 2 carburetor and inlet pipe mounting nuts 5.9 0.60 52 in·lb 3 air creaner bracket mounting nuts 19.6 2.00 14.4 4 air creaner mounting bracket bolt 19.6 2.00 14.4 5 fu...

  • Page 34

    3-4 fuel system specifications item standard carburetor specifications: make/type fx921v nikki 621300-021 fx1000v nikki 621300-011 throttle bore diameter 30 mm (1.2 in.) venturi diameter 23 mm (0.90 in.) main jet (mj) l: #134 r: #140 pilot jet (pj) #52 main air jet (maj) 1.4 pilot air jet (paj) 1.1 ...

  • Page 35

    Fuel system 3-5 governor link mechanism control panel assembly removal • remove: air cleaner (see air cleaner body and bracket removal) clamp [a] breather hose [b] inlet pipe mounting bolts [c] and nuts [d] ground lead [e] inlet pipe [f] • remove the control panel assembly [a] while unhooking the go...

  • Page 36

    3-6 fuel system governor link mechanism governor arm removal • remove: control panel assembly (see control panel assembly removal) solenoid valve connector [a] • loosen the clamp nut [b] and take off the governor arm [c]. • unhook the throttle link rod spring [d] end loop and clear the throttle link...

  • Page 37

    Fuel system 3-7 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 operate freely. Governor assembly inspection • visually check all governor parts for wear or da...

  • Page 38

    3-8 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 39

    Fuel system 3-9 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 40

    3-10 fuel system carburetor fuel shut off solenoid valve 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 main jets [b] simultaneously when the switch key turned to the...

  • Page 41

    Fuel system 3-11 carburetor • remove the float assembly [a] from the float chamber. • remove: pin [a] float [b] float valve [c] spacer [d] o-ring [e] • use the rod to push the main jet “l” [a] and “r” [b] out from the bottom side of the spacer [c]. • replace the main jet [a] with a new one for altit...

  • Page 42

    3-12 fuel system carburetor carburetor removal warning gasoline is extremely flammable and can be ex- plosive under certain conditions. Turn the ignition switch off. Do not smoke. Make sure the area is well- ventilated and free from any source of flame or sparks; this includes any appliance with a p...

  • Page 43

    Fuel system 3-13 carburetor • install the throttle link rod [a] and spring [b] to the throttle shaft lever clip [c]. Note ○ take care not to bend the throttle link rod during instal- lation. • make sure that the link spring around the throttle link rod is inplace and that it pulls the governor arm a...

  • Page 44

    3-14 fuel system carburetor • replace the pilot screw [a] in accordance with the follow- ing procedure if necessary. ○ remove the pilot screw plug [b] (material: stainless steel) as follows: punch a hole in the plug and pry it out with an awl or other suitable tool. ○ turn in the pilot screw and cou...

  • Page 45

    Fuel system 3-15 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 46

    3-16 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 47

    Fuel system 3-17 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. Fuel shut off solenoid valve test • un...

  • Page 48

    3-18 fuel system inlet manifold inlet manifold removal • remove: fan housing (see flywheel and stator coil removal in the electrical system chapter) carburetor (see carburetor removal) • cut off the bands [a] holding the wire lead and/or harness. • unscrew the inlet manifold bolts in the order shown...

  • Page 49

    Fuel system 3-19 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 removal • remove: fuel tubes [a] breather tube [b] bolts [c] fuel pump [d] fuel pump installation • connect the fuel tubes [a] and breather tube [b]...

  • Page 50

    3-20 fuel system fuel pump, fuel filter fuel filter removal/installation • remove: clamp [a] fuel filter [b] • when install the fuel filter, arrow mark [c] faces fuel pump side. Fuel filter inspection • visually inspect the fuel filter [a]. If the filter is clear with no signs of dirt or other conta...

  • Page 51

    Fuel system 3-21 air cleaner element removal • while pulling up the two knobs [a], turn the cap [b] to counterclockwise. • align the arrow mark [a] and unlock mark [b] to remove the cap. • remove: primary element [a] • remove: secondary element [a] element installation • slide the secondary element ...

  • Page 52

    3-22 fuel system air cleaner • turn the cap to the clockwise until the lock mark [a]. Element cleaning and inspection air cleaner elements are not recommended to be cleaned, and each air cleaner element should be replaced with new ones. • refer to the element cleaning and inspection in the pe- riodi...

  • Page 53

    Fuel system 3-23 air cleaner • set the air cleaner body [a] onto the lower bracket so that the air inlet duct [b] is facing upward. • install the inlet hose [c], and tighten the clamp [d]. • install the upper bracket [e]. • tighten: torque - air cleaner mounting bracket bolt [f]: 19.6 n·m (2.00 kgf·...

  • Page 54

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

  • Page 55: Cooling System

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

  • Page 56

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

  • Page 57

    Cooling system 4-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 engine shroud bolts 5.9 0.60 52 in·lb 2 cooling fan screen bolts 5.9 0.60 52 in·lb 3 cooling fan plate mounting stud bolts 5.9 0.60 52 in·lb 4 guard mounting bolts 5.9 0.60 52 in·lb 5 fan housing bolts 5.9 0.60 52 in·lb f...

  • Page 58

    4-4 cooling system cooling fan cooling fan removal • refer to the flywheel and stator coil removal in the elec- trical system chapter. Cooling fan installation • refer to the flywheel and stator coil installation in the electrical system chapter. Cooling fan inspection • remove the fan housing (see ...

  • Page 59

    Cooling system 4-5 engine shroud engine shroud removal/installation • remove: fan housing (see flywheel and stator coil removal in the electrical system chapter) carburetor (see carburetor removal in the fuel system chapter) governor arm (see governor arm removal in the fuel system chapter) rocker c...

  • Page 60

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

  • Page 61: Engine Top End

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

  • Page 62

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

  • Page 63

    Engine top end 5-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 cylinder head bolts 46 4.7 34 s 2 rocker case bolts 5.9 0.60 52 in·lb 3 exhaust pipe nuts 22 2.2 16.2 4 valve clearance adjusting locknuts 9.8 1.0 87 in·lb 5 connecting rod big end cap bolts 20.6 2.10 15.2 eo eo: apply en...

  • Page 64

    5-4 engine top end specifications item service limit cylinder head: cylinder compression (min) 555 kpa (80 psi) @ engine oil temperature 50 ∼ 60°c (122 ∼ 144°f), cranking speed 500 rpm/5 seconds cylinder head warp 0.05 mm (0.002 in.) valves: valve head thickness inlet, exhaust 0.4 mm (0.016 in.) val...

  • Page 65

    Engine top end 5-5 specifications item standard valve clearance: inlet, exhaust 0.10 ∼ 0.15 mm (0.0039 ∼ 0.059 in.) valve seating surface angle: inlet, exhaust 45° valve seating surface width: inlet 0.7 ∼ 1.1 mm (0.028 ∼ 0.043 in.) exhaust 1.0 ∼ 1.5 mm (0.039 ∼ 0.059 in.) valves guide inside diamete...

  • Page 66

    5-6 engine top end special tools piston ring pliers: 57001-115 compression gauge, 20 kgf/cm²: 57001-221 piston ring compressor grip: 57001-1095 compression gauge adapter, m14 × 1.25: 57001-1159 piston ring compressor belt, 80 ∼ 91: 57001-1320 for kawasaki discount parts call 606-678-9623 or 606-561-...

  • Page 67

    Engine top end 5-7 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 68

    5-8 engine top end cylinder head cylinder head assembly removal • remove: inlet manifold (see inlet manifold removal in the fuel system chapter) spark plug • unscrew the rocker cover bolts [a], and remove the cover [b] and the gasket. • when removing the #1, #2 cylinder head, set each pis- ton at th...

  • Page 69

    Engine top end 5-9 cylinder head cylinder head assembly installation • clean the mating surfaces of the cylinder heads and cylin- ders. • install the push rods in their original positions on each cylinder (see push rod installation). • install the knock pins [a] • set each piston at the t.D.C [a] of...

  • Page 70

    5-10 engine top end cylinder head push rod removal • set each piston at the t.D.C of the compression stroke. • remove the rocker covers and rocker arm (see cylinder head assembly removal). • pull out the push rods [a] note ○ mark the push rods to reinstall in their original position during assembly....

  • Page 71

    Engine top end 5-11 cylinder head • support the valve head in the combustion chamber with a suitable block. • to remove the collets [a], push down the valve retainer [b] with thumbs and remove the collets. • remove the spring [c] and the valve [d] . • remove the stem seals [a]. Note ○ remove the ste...

  • Page 72

    5-12 engine top end cylinder head rocker arm inspection • measure the diameter [a] of the rocker shafts with a mi- crometer at several points of bearing the rocker arm. If the outside diameter is less than the service limit, re- place the rocker shaft. Rocker shafts outside diameter service limit (i...

  • Page 73

    Engine top end 5-13 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 74

    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 75

    Engine top end 5-15 cylinder, piston piston removal • split the crankcase (see crankcase cover removal in the camshaft/crankshaft chapter). • remove the camshaft (see camshaft, tappet removal in the camshaft/crankshaft chapter). • turn the crankshaft to expose the connecting rod cap bolts [a]. • rem...

  • Page 76

    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 77

    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 78

    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 molybdenum disulfide oil solution oil to the inner surface [a] of the connecting rod big end [b] ...

  • Page 79

    Engine top end 5-19 cylinder, piston • clean the piston ring grooves [a] with a broken piston ring or other suitable tools. Caution be careful not to widen the ring grooves. Damaged ring grooves will require piston replacement. Piston ring and ring groove wear • clean the piston (see piston cleaning...

  • Page 80

    5-20 engine top end cylinder, piston piston ring end gap • remove the piston rings. • push each ring (one at a time) in the cylinder bore to a point close to the bottom of the cylinder bore. ○ use the piston to push it in to be sure it is square. • measure the gap [a] between the ends of the ring [b...

  • Page 81

    Engine top end 5-21 cylinder, piston piston diameter • measure the outside diameter [a] of the piston 7 mm (0.28 in.) [b] up from the bottom of the piston at a right angle to the direction of the piston pin hole. If the measured outside diameter is less than the service limit, replace the piston wit...

  • Page 82

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

  • Page 83: Lubrication System

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

  • Page 84

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

  • Page 85

    Lubrication system 6-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 oil filter joint pipe 6.9 0.70 61 in·lb 2 oil pump cover plate bolts 5.9 0.60 52 in·lb 3 oil filter 11.8 1.2 104 in·lb r 4 engine oil drain plugs 6.9 0.70 61 in·lb eo 5 oil filler mounting bolt 5.9 0.60 52 in·lb 6 oil...

  • Page 86

    6-4 lubrication system engine oil flow chart for kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com.

  • Page 87

    Lubrication system 6-5 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 1.7 l (1.8 us qt) when the oil filter is removed 1.9 l (2.0 us qt) level operating range (grid area) ...

  • Page 88

    6-6 lubrication system special tools oil pressure gauge, 10 kgf/cm²: 57001-164 oil pressure gauge adapter, pt 1/8: 57001-1033 for kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com.

  • Page 89

    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. Engine oil level inspection • refer to the engine oil level inspection in the p...

  • Page 90

    6-8 lubrication system pressurized lubrication system the engine lubrication circuit is a pressurized system consisting of a positive displacement pump which picks up oil through a filter screen from the crankcase. The oil is pumped to a replaceable oil filter cartridge, through the engine’s oil pas...

  • Page 91

    Lubrication system 6-9 oil pump, relief valve oil pump, relief valve removal • remove: crankshaft (see crankshaft removal in the camshaft/crankshaft chapter) bolts [a] • take out the pump cover plate [b] , pump gear [c] and pump shaft [d] as a set. • remove the pins [a], oil pump cover plate [b] and...

  • Page 92

    6-10 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, outer and inner rotor, and cover plate. If there is any damage or uneven wear, replace them with new ones. ○ check the clea...

  • Page 93

    Lubrication system 6-11 oil pump, relief valve • measure the outside [a] diameter of the pump shaft with a micrometer at several points. If the diameter is less than the service limit, replace the pump shaft with a new one. Pump shaft outside diameter service limit: 10.923 mm (0.43004 in.) • measure...

  • Page 94

    6-12 lubrication system oil screen oil screen removal • remove the oil pump cover plate (see oil pump, relief valve removal). • remove the oil screen [a]. Oil screen installation • clean the oil screen thoroughly whenever it is removed for any reason. • insert the oil screen [a] in position and inst...

  • Page 95: Camshaft/crankshaft

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

  • Page 96

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

  • Page 97

    Camshaft/crankshaft 7-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 oil passage plugs 3.9 0.40 34 in·lb l 2 crankcase cover bolts 46 4.7 34 s 3 connecting rod big end cap bolts 20.6 2.10 15.2 eo 4 breather valve mounting screws 2.0 0.20 18 in·lb 5 breather chamber cover bolts 5.9 0.6...

  • Page 98

    7-4 camshaft/crankshaft specifications item service limit camshaft, tappet: cam lobe height: inlet 34.49 mm (1.358 in.) exhaust 35.11 mm (1.382 in.) camshaft journal diameter pto side 19.98 mm (0.7866 in.) camshaft bearing inside diameter crankcase 20.14 mm (0.7929 in.) crankshaft, connecting rod: c...

  • Page 99

    Camshaft/crankshaft 7-5 special tools and sealant oil seal & bearing remover: 57001-1058 bearing driver set: 57001-1129 kawasaki bond (liquid gasket - gray): 92104-1063 for kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com.

  • Page 100

    7-6 camshaft/crankshaft crankcase crankcase cover removal • set the engine on a clean surface while parts are being removed. • drain the oil (see engine oil change in the periodic main- tenance chapter). • remove: ignition coils (see ignition coil removal in the electrical system chapter) flywheel a...

  • Page 101

    Camshaft/crankshaft 7-7 crankcase • be sure to replace the ball bearing with a new one if re- moved. • press the ball bearing [a] until bottom surface [b] of the crankcase cover. Special tool - bearing driver set: 57001-1129 • apply engine oil to the ball bearing. • be sure to replace any oil seal w...

  • Page 102

    7-8 camshaft/crankshaft crankcase • check to see that the dowel pins [a] are in place on the crankcase. • install the crankcase cover and tighten the crankcase cover bolts following the tightening sequence as shown. Torque - crankcase cover bolts: 46 n·m (4.7 kgf·m, 34 ft·lb) ○ do not turn one screw...

  • Page 103

    Camshaft/crankshaft 7-9 crankcase • be sure to replace the bearings and snap ring with new ones if removed. • install the bearings [a] so that the bearing notch direction and depth as shown. • install the new snap rings [b]. [c]: 80° [d]: 100° [e]: 3.0 ∼ 3.2 mm (0.118 ∼ 0.126 in.) • be sure to repla...

  • Page 104

    7-10 camshaft/crankshaft crankcase crankcase and crankcase cover cleaning • remove: oil pump and relief valve (see oil pump, relief valve removal in the lubrication system chapter) camshaft and tappets (see camshaft, tappet removal) crankshaft (see crankshaft removal) breather pipes and cover (see b...

  • Page 105

    Camshaft/crankshaft 7-11 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-...

  • Page 106

    7-12 camshaft/crankshaft breather breather valve removal • remove: inlet manifold (see inlet manifold removal in the fuel system chapter) bolts [a] breather chamber cover [b] • remove: screws [a] breather valve [b] breather valve installation • install the breather valve. • tighten: torque - breathe...

  • Page 107

    Camshaft/crankshaft 7-13 breather breather pipe removal • remove: camshaft (see camshaft, tappet removal) bolts [a] breather pipe cover [b] • remove: upper breather pipe [a] • remove: lower breather pipe [a] breather pipe installation • install the lower and upper breather pipes so that fit the proj...

  • Page 108

    7-14 camshaft/crankshaft camshaft, tappet camshaft, tappet removal • set the engine on a clean surface while parts are re- moved. • drain the oil (see engine oil change in the periodic main- tenance chapter). • remove: crankcase cover (see crankcase cover removal) rocker covers (see cylinder head as...

  • Page 109

    Camshaft/crankshaft 7-15 camshaft, tappet • install the spacer [a] on the camshaft. Camshaft disassembly • remove: governor assembly (see governor assembly removal in the fuel system chapter) spring [a] ○ do not remove the acr (automatic compression release) weight [b]. Camshaft assembly • install t...

  • Page 110

    7-16 camshaft/crankshaft camshaft, tappet • measure pto side camshaft journal diameter [a] at sev- eral 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: 19.98 mm (...

  • Page 111

    Camshaft/crankshaft 7-17 crankshaft, connecting rod connecting rod removal • refer to the piston removal in the engine top end chap- ter. Connecting rod installation • refer to the piston installation in the engine top end chapter. Crankshaft removal • set the engine on a clean surface while parts a...

  • Page 112

    7-18 camshaft/crankshaft crankshaft, connecting rod connecting rod bend/twist • measure the connecting rod bend. ○ select an arbor [a] 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...

  • Page 113

    Camshaft/crankshaft 7-19 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 service limit: 49.0 mm (1.93 in.) connecting rod big end bearing/crankpin wear • ...

  • Page 114

    7-20 camshaft/crankshaft crankshaft, connecting rod crankshaft journal/wear • measure pto side crankshaft journal 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 ...

  • Page 115: Starter System

    Starter system 8-1 8 starter system table of contents exploded view........................................................................................................................ 8-2 specifications ................................................................................................

  • Page 116

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

  • Page 117

    Starter system 8-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 starter motor mounting bolts 19.6 2.00 14.4 g: apply grease. R: replacement parts for kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com.

  • Page 118

    8-4 starter system specifications item standard service limit electric starter system starter motor: carbon brush length (with spring boss) 7.125 mm (0.2805 in.) 4.0 mm (0.16 in.) commutator groove depth (approx.) 0.8 mm (0.03 in.) 0.4 mm (0.016 in.) commutator diameter 29.5 mm (1.16 in.) 29.0 mm (1...

  • Page 119

    Starter system 8-5 special tool needle adapter set: 57001-1457 for kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com.

  • Page 120

    8-6 starter system electric starter system starter motor removal • disconnect the wire. • remove the mounting bolts [a] and pull the starter motor [b] from the engine with the switch lead attached. Starter motor installation • clean the starter motor and engine mounting flanges to ensure good electr...

  • Page 121

    Starter system 8-7 electric starter system • set the hand tester to the r × 1 Ω position and connect the leads as shown. Switch terminal [a] to ground [b] if the tester does not read close to 0 Ω, the solenoid is faulty. Replace it. If the tester reads close to 0 Ω, the solenoid may be good. • check...

  • Page 122

    8-8 starter system electric starter system starter motor disassembly • loosen the terminal nut [a]. • remove the lead [b] from the starter motor to the sole- noid. • unscrew the mounting nuts [a] and remove the solenoid assembly [b]. • remove the through bolts [a] and end cover bolts [b]. • remove t...

  • Page 123

    Starter system 8-9 electric starter system starter motor assembly • apply a small amount of grease to the armature shaft [a] as shown. • do not reuse the snap ring [b]. Replace it with a new one. • inspect the boots [a], rubber insert [b] and grommet [c] for visible damage. If it is damaged, replace...

  • Page 124

    8-10 starter system electric starter system • using the suitable tool (for instance, socket wrench of 22 mm), expand the brushes as shown. • install the brush assembly [a] with the suitable tool in- stalled. • pull out the suitable tool. • fit the notch on the (–) lead grommet [b] and slit on the yo...

  • Page 125

    Starter system 8-11 electric starter system brush spring inspection • inspection the brush springs for pitting, cracks, rusting and burrs. Replace the brush assembly if necessary. • inspect the springs for weakened conditions and distor- tion. Replace the brush assembly if necessary. If the brush sp...

  • Page 126

    8-12 starter system electric starter system • measure the armature winding resistance. ○ set the multimeter selector switch to the r × 1 Ω position and check the resistance between each segment and all the others. If the resistance it too high or even infinite, the armature winding has an open circu...

  • Page 127

    Starter system 8-13 electric starter system pinion clutch inspection • remove the pinion clutch. • turn the pinion gear [a] by hand. The pinion gear should turn counterclockwise freely, but should not turn clock- wise. If the pinion clutch dose not operate as it should, or if it makes noise, replace...

  • Page 128

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

  • Page 129: Electrical System

    Electrical system 9-1 9 electrical system table of contents exploded view........................................................................................................................ 9-2 specifications ..........................................................................................

  • Page 130

    9-2 electrical system exploded view for kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com.

  • Page 131

    Electrical system 9-3 exploded view torque no. Fastener n·m kgf·m ft·lb remarks 1 ignition coil bolts 6.9 0.70 61 in·lb 2 stator coil screws 3.4 0.35 30 in·lb 3 flywheel bolt 56 5.7 41 4 regulator screws 3.5 0.36 31 in·lb 5 spark plugs 22 2.2 16.2 g: apply grease (three bond: tb2585g or equivalent)....

  • Page 132

    9-4 electrical system specifications item standard service limit charging system regulated output voltage 14.1 v dc 15 v dc stator coil resistance 0.01 ∼ 0.1 Ω – – – unregulated stator output 28.4 v ac/3 000 rpm 26 v ac/3 000 rpm regulator resistance in the text ignition system ignition coil: air ga...

  • Page 133

    Electrical system 9-5 special tool hand tester: 57001-1394 for kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com.

  • Page 134

    9-6 electrical system wiring dagram for kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com.

  • Page 135

    Electrical system 9-7 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 136

    9-8 electrical system charging system flywheel and stator coil removal • remove: air cleaner (see air cleaner body and bracket removal in the fuel system chapter) oil cooler (see oil cooler removal in the lubrication system chapter) regulator (see regulator removal) fuel pump (see fuel pump removal ...

  • Page 137

    Electrical system 9-9 charging system • using a suitable flywheel puller [a], remove the flywheel [b]. Caution always use flywheel puller. • remove: woodruff key [a] stator coil screw [b] stator coil [c] flywheel and stator coil installation • install the stator coil and tighten the screws. Torque -...

  • Page 138

    9-10 electrical system charging system • install the guide [a] to the fan housing [b]. • install the fan housing. • tighten: torque - fan housing bolts: 5.9 n·m (0.60 kgf·m, 52 in·lb) • install the screen and guard. • tighten: torque - cooling fan screen bolts: 5.9 n·m (0.60 kgf·m, 52 in·lb) guard m...

  • Page 139

    Electrical system 9-11 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 0.01 to 0.1 Ω if the measured value is not within the specification, re- ...

  • Page 140

    9-12 electrical system charging system regulator resistance • remove the regulator (see regulator removal). • 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. (without charging monitor type …3 b...

  • Page 141

    Electrical system 9-13 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 b: bas...

  • Page 142

    9-14 electrical system ignition system ignition coil removal • remove: fan housing (see flywheel and 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...

  • Page 143

    Electrical system 9-15 ignition system spark plug cleaning and inspection • refer to the spark plug cleaning and inspection in the periodic maintenance chapter. Spark plug gap inspection • refer to the spark plug gap inspection in the periodic maintenance chapter. For kawasaki discount parts call 60...

  • Page 144

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

  • Page 145: Troubleshooting

    Troubleshooting 10-1 10 troubleshooting table of contents engine troubleshooting guide ............................................................................................... 10-2 starter motor troubleshooting guide ...............................................................................

  • Page 146

    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...

  • Page 147

    Troubleshooting 10-3 engine troubleshooting guide for kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com.

  • Page 148

    10-4 troubleshooting engine troubleshooting guide for kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com.

  • Page 149

    Troubleshooting 10-5 engine troubleshooting guide for kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com.

  • Page 150

    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 151

    Part no.99924-2082-01 printed in japan for kawasaki discount parts call 606-678-9623 or 606-561-4983 www.Mymowerparts.Com.