4-Stroke Air-Cooled V-Twin Gasoline Engine Service

FR651V, FR691V, FR730V
FS651V, FS691V, FS730V
FX651V, FX691V, FX730V
4-Stroke Air-Cooled V-Twin Gasoline Engine
Service Manual
Quick Reference Guide
This quick reference guide will assist
you in locating a desired topic or procedure.
•Bend the pages back to match the
black tab of the desired chapter number 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 the specific topic required.
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
Starter System
8 j
Electrical System
9 j
Troubleshooting
10 j
FR651V, FR691V, FR730V
FS651V, FS691V, FS730V
FX651V, FX691V, FX730V
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 written permission of Quality Assurance Division/Consumer Products & Machinery
Company/Kawasaki Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible
care has been taken to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation
to make such changes to products manufactured previously.
All information contained in this publication is based on the latest product information available at the time
of publication. Illustrations and photographs in this publication are intended for reference use only and may
not depict actual model component parts.
© 2009 Kawasaki Heavy Industries, Ltd.
First Edition (1):Jan. 9, 2009 (K)
LIST OF ABBREVIATIONS
A
ampere(s)
ABDC
AC
ATDC
BBDC
BDC
BTDC
°C
DC
F
°F
ft
g
h
L
after bottom dead center
alternating current
lb
m
min
pound(s)
after top dead center
before bottom dead center
bottom dead center
before top dead center
degree(s) Celsius
direct current
farad(s)
degree(s) Fahrenheit
foot, feet
gram(s)
N
Pa
PS
psi
r
rpm
TDC
TIR
V
W
meter(s)
minute(s)
newton(s)
pascal(s)
horsepower
pound(s) per square inch
revolution
revolution(s) per minute
top dead center
total indicator reading
volt(s)
watt(s)
hour(s)
liter(s)
Ω
ohm(s)
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 Board.
1. Crankcase Emission Control System
A sealed-type crankcase emission control system is used to eliminate blow-by gases. The
blow-by gases are led to the breather chamber through the crankcase. Then, it is led to the air
cleaner.
Oil is separated from the gases while passing through the inside of the breather chamber from
the crankcase, and then returned back to the bottom of crankcase.
2. Exhaust Emission Control System
The exhaust emission control system applied to this engine consists of a carburetor and an
ignition system having optimum ignition timing characteristics.
The carburetor has been calibrated to provide lean air/fuel mixture characteristics and optimum fuel economy with a suitable air cleaner and exhaust system.
TAMPERING WITH EMISSION CONTROL SYSTEM PROHIBITED
Federal law and California State law prohibits the following acts or the causing thereof: (1) the
removal or rendering inoperative by any person other than for purposes of maintenance, repair,
or replacement, of any device or element of design incorporated into any new engine for the
purpose of emission control prior to its sale or delivery to the ultimate purchaser or while it is in
use, or (2) the use of the engine after such device or element of design has been removed or
rendered inoperative by any person.
Among those acts presumed to constitute tampering are the acts listed below:
Do not tamper with the original emission related part:
and internal parts
• Carburetor
Spark
plugs
• Magneto or electronic ignition system
• Fuel filter element
• Air cleaner elements
• Crankcase
• Cylinder heads
• Breather chamber and internal parts
• Inlet pipe and tube
•
Foreword
This manual is designed primarily for use by
trained mechanics in a properly equipped shop.
However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and
repair work. A basic knowledge of mechanics,
the proper use of tools, and workshop procedures must be understood in order to carry out
maintenance and repair satisfactorily. Whenever the owner has insufficient experience or
doubts as to his ability to do the work, all adjustments, maintenance, and repair should be
carried out only by qualified mechanics.
In order to perform the work efficiently and
to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures
before starting work, and then do the work carefully in a clean area. Whenever special tools or
equipment are specified, do not use makeshift
tools or equipment. Precision measurements
can only be made if the proper instruments are
used, and the use of substitute tools may adversely affect safe operation.
To get the longest life out of your engine:
Follow the Periodic Maintenance Chart in the
Service Manual.
Be alert for problems and non-scheduled
maintenance.
Use proper tools and genuine Kawasaki engine parts. Genuine parts provided as spare
parts are listed in the Parts Catalog.
Follow the procedures in this manual carefully. Don’t take shortcuts.
Remember to keep complete records of maintenance and repair with dates and any new
parts installed.
•
•
•
•
•
How to Use This Manual
In this manual, the product is divided into
its major systems and these systems make up
the manual’s chapters. The Quick Reference
Guide shows you all of the product’s system
and assists in locating their chapters. Each
chapter in turn has its own comprehensive Table of Contents.
For, example, if you want ignition coil information, use the Quick Reference Guide to locate
the Electrical System chapter. Then, use the
Table of Contents on the first page of the chapter to find the Ignition Coil section.
Whenever you see these WARNING and
CAUTION symbols, heed their instructions!
Always follow safe operating and maintenance
practices.
WARNING
This warning symbol identifies special
instructions or procedures which, if not
correctly followed, could result in personal injury, or loss of life.
CAUTION
This caution symbol identifies special
instructions or procedures which, if not
strictly observed, could result in damage to or destruction of equipment.
This manual contains four more symbols (in
addition to WARNING and CAUTION) which will
help you distinguish different types of information.
NOTE
This
note
symbol
indicates points of par○
ticular interest for more efficient and convenient operation.
a procedural step or work to be
• Indicates
done.
○Indicates a procedural sub-step or how to do
the work of the procedural step it follows. It
also precedes the text of a WARNING, CAUTION, or NOTE.
Indicates a conditional step or what action to
take based on the results of the test or inspection in the procedural step or sub-step it follows.
In most chapters an exploded view illustration
of the system components follows the Table of
Contents. In these illustrations you will find the
instructions indicating which parts require specified tightening torque, oil, grease or a locking
agent during assembly.
GENERAL INFORMATION 1-1
General Information
Table of Contents
Before Servicing .....................................................................................................................
Model Identification.................................................................................................................
General Specifications............................................................................................................
1
1-2
1-5
1-7
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 included wherever necessary. Nevertheless, even a detailed account has limitations, a certain amount
of basic knowledge is required for successful work.
Especially note the following
(1) Dirt
Before removal and disassembly, clean the engine. Any dirt entering the engine, carburetor, or
other parts, will work as an abrasive and shorten the life of engine. For the same reason, before
installing a new part, clean off any dust or metal filings.
(2) Battery Ground
Remove the ground (–) lead from the battery before performing any disassembly operations on
the equipment. This prevents:
(a)the possibility of accidentally turning the engine over while partially disassembled.
(b)sparks at electrical connections which will occur when they are disconnected.
(c) damage to electrical parts.
(3) Tightening Sequence
Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes
and tighten them to a snug fit. Then tighten them evenly, in a staggered sequence. This is to
avoid distortion of the part and/or causing gas or oil leakage. Conversely when loosening the
bolts, nuts, or screws, first loosen all of them by about a quarter of a turn and then remove them.
Where there is a tightening sequence indication in this Service Manual, the bolts, nuts, or screws
must be tightened in the order and method indicated.
(4) Torque
When torque values are given in this Service Manual, use them. Either too little or too much
torque may lead to serious damage. Use a good quality, reliable torque wrench.
(5) Force
Common sense should dictate how much force is necessary in assembly and disassembly. If
a part seems especially difficult to remove or install, stop and examine what may be causing the
problem. Whenever tapping is necessary, tap lightly using a wooden or plastic-faced mallet. Use
an impact driver for screws (particularly for the removal of screws held by a locking agent) in order
to avoid damaging the heads.
(6) Edges
Watch for sharp edges, especially during major engine disassembly and assembly. Protect your
hands with gloves or a piece of thick cloth when lifting the engine or turning it over.
(7) High-Flash Point Solvent
A high-flash point solvent is recommended to reduce fire danger. A commercial solvent commonly available in North America is Standard solvent (generic name). Always follow manufacturer
and container directions regarding the use of any solvent.
(8) Gasket, O-ring
Do not reuse a gasket or O-ring once it has been in service. The mating surfaces around the
gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks.
(9) Liquid Gasket, Non-Permanent Locking Agent
Follow manufacturer’s directions for cleaning and preparing surfaces where these compounds
will be used. Apply sparingly. Excessive amounts may block engine oil passages and cause
serious damage. An example of a non-permanent locking agent commonly available in North
America is Loctite Lock’n Seal (Blue).
(10)Press
A part installed using a press or driver, such as a journal, should first be coated with oil on its
outer or inner circumference so that it will go into place smoothly.
(11) Ball Bearing, Needle Bearing
Do not remove a ball bearing or a needle bearing unless it is absolutely necessary. Replace any
ball or needle bearings that were removed with new ones. Install bearings with the manufacturer
and size marks facing out, applying pressure evenly with a suitable driver to the end of the race
that contacts the press fit portion, and press it evenly over the base component.
GENERAL INFORMATION 1-3
Before Servicing
(12)Oil Seal and Grease Seal
Replace any oil or grease seals that were removed with new ones, as removal generally damages seals.
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.
(13)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 friction.
(14)Circlip, Retaining Ring and Cotter Pin
When installing circlips and retaining rings, take care to compress or expand them only enough
to install them and no more. Install the circlip with its chamfered side facing load side as well.
Replace any circlips, retaining rings, and cotter pins that were removed with new ones, as removal weakens and deforms them. If old ones are reused, they could become detached while
running, leading to a problem.
(15)Lubrication
Engine wear is generally at its maximum while the engine is warming up and before all the
rubbing surfaces have an adequate lubricative film. During assembly, oil or grease (whichever
is more suitable) should be applied to any rubbing surface which has lost its lubricative film. Old
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 may be harmful if used in an application for which they are not intended.
This manual makes reference to molybdenum disulfide grease (MoS2) in the assembly of certain
engine parts. Always check manufacturer recommendations before using such special lubricants.
(16)Electrical Wires
All the electrical wires are either single-color or two-color and, with only a few exceptions, must
be connected to wires of the same color. On any of the two-color wires there is a greater amount
of one color and a lesser amount of a second color, so a two-color wire is identified by first the
primary color and then the secondary color. For example, a yellow wire with thin red stripes is
referred to as a “yellow/red” wire; it would be a “red/yellow” wire if the colors were reversed to
make red the main color.
(17)Replacement Parts
When there is a replacement instruction, replace these parts with new ones every time they are
removed. There replacement parts will be damaged or lose their original function once removed.
(18)Inspection
When parts have been disassembled, visually inspect these parts for the following conditions
or other damage. If there is any doubt as to the condition of them, replace them with new ones.
Abrasion
Bent
Color change
Crack
Dent
Deterioration
Hardening
Scratch
Seizure
Warp
Wear
(19)Service Data
Service Data terms are defined as follows:
“Standards” show dimensions or performances which brand-new parts or systems have.
1-4 GENERAL INFORMATION
Before Servicing
“Service Limits” indicate the usable limits. If the measurement shows excessive wear or deteriorated performance, replace the damaged parts.
GENERAL INFORMATION 1-5
Model Identification
FX Models
FR Models
1-6 GENERAL INFORMATION
Model Identification
FS Models
Cylinder Number Designation:
No.1 Cylinder is the left-hand cylinder viewed from the inlet pipe.
No.2 Cylinder is the right-hand cylinder viewed from the inlet pipe.
GENERAL INFORMATION 1-7
General Specifications
Item
Type of Engine
Cylinder Layout
Bore × Stroke
Piston Displacement
Direction of Rotation
Compression Release
Low Idle Speed
High Idle Speed
Ignition System
RFI
Starting System:
FR and FS Models
FX Models
Charging System:
FS and FX Models
FR Models
Spark Plug
Carburetor:
FR and FS Models
FX Models
Fuel Pump
Air Cleaner:
FR Models
FS Models
FX Models
Governor
Lubrication System
Oil Filter
Oil Capacity (when engine
is completely dry)
Cooling System
Dimensions (L × W × H ):
FR Models
FS Models
FX Models
Dry Weight (without muffler):
FR Models
FS Models
FX Models
FR651V,FR691V,FR730V, FS651V,FS691V, FS730V,
FX651V, FX691V, FX730V
Forced air-cooled, vertical shaft, OHV, 4-stroke gasoline engine
90 V-Twin
78 mm × 76 mm (3.07 in. × 2.99 in.)
726 cm³ (44.3 cu in.)
Counterclockwise facing the PTO shaft
Automatic compression release
1 550 r/min (rpm)
3 600 r/min (rpm)
Transistorized-flywheel magneto
Per Canada and U.S.A. requirements
Electric starter
Shift type electric starter
12 V - 15 amps with regulator
12 V - 3.6 amp without regulator
NGK BPR4ES
Float type, fixed main jet, internally vented, single barrel
Float type, fixed main jet, internally vented, two barrel
Diaphragm type pulse pump
Single stage element, dry type
Dual stage element, dry type
Dual stage element, heavy duty type
Flyweight all speed governor
Pressure feed by positive displacement pump
Cartridge type full flow filter
2.0 L (2.1 US qt)
Forced air cooling by fan
481 mm × 424 mm × 380 mm (18.9 in. × 16.7 in. × 15.0 in.)
481 mm × 424 mm × 380 mm (18.9 in. × 16.7 in. × 15.0 in.)
478 mm × 424 mm × 549 mm (18.8 in. × 16.7 in. × 21.6 in.)
40.0 kg (88.2 lb)
41.0 kg (90.4 lb)
46.0 kg (101.4 lb)
Specifications are subject to change without notice.
PERIODIC MAINTENANCE 2-1
Periodic Maintenance
Table of Contents
Periodic Maintenance Chart ...................................................................................................
Torque and Locking Agent......................................................................................................
Specifications .........................................................................................................................
Special Tools ..........................................................................................................................
Periodic Maintenance Procedures..........................................................................................
Fuel System.........................................................................................................................
Low Idle Speed Adjustment ..............................................................................................
High Idle Speed Adjustment .............................................................................................
Fuel System Cleanliness Inspection .................................................................................
Element Cleaning and Inspection .....................................................................................
Air Cleaner Housing (Cap and Body) Inspection ..............................................................
Engine Top End ...................................................................................................................
Cylinder Head Cleaning ....................................................................................................
Valve Clearance Inspection ..............................................................................................
Valve Clearance Adjustment.............................................................................................
Valve Seat Inspection .......................................................................................................
Valve Seat Repair .............................................................................................................
Lubrication System ..............................................................................................................
Engine Oil Level Inspection ..............................................................................................
Engine Oil Change............................................................................................................
Oil Filter Replacement ......................................................................................................
Electrical System .................................................................................................................
Spark Plug Cleaning and Inspection.................................................................................
Spark Plug Gap Inspection ...............................................................................................
2-2
2-3
2-5
2-6
2-7
2-7
2-7
2-7
2-8
2-9
2-10
2-10
2-10
2-10
2-11
2-12
2-12
2-15
2-15
2-15
2-16
2-17
2-17
2-17
2
2-2 PERIODIC MAINTENANCE
Periodic Maintenance Chart
To ensure satisfactory operation over an extended period of time, any engine requires normal maintenance regular intervals. The Periodic Maintenance Chart below shows periodic inspection and
maintenance items and suitable intervals. The bullet mark ( ) designates that the corresponding item
should be performed at that interval.
Some adjustments require the use of special tools or other equipment. An electronic tachometer
will facilitate setting idle and running speeds.
•
OPERATION
Check or clean air inlet screen
(1)
Check and add engine oil
Check for fuel and oil leakage
Check for loose or lost nuts and
screws
Check battery electrolyte level
INTERVAL
First Every Every Every Every Every Every
Daily
8 hr. 25 hr. 100 hr. 200 hr. 250 hr. 300 hr. 500 hr.
•
•
•
•
•
Replace air cleaner primary
element (Heavy Duty Air
Cleaner) (FX Models) (1)
Check air cleaner secondary
element (Heavy Duty Air
Cleaner) (FX Models) (1)
Replace air cleaner secondary
element (Heavy Duty Air
Cleaner) (FX Models) (1)
Clean air cleaner foam element
(FS Models) (1)
Clean air cleaner paper element
(FR and FS Models) (1)
Replace air cleaner paper
element (FR and FS Models) (1)
Clean dust and dirt from cylinder
and cylinder head fins (1)
•
•
•
•
•
•
Tighten nuts and screws
Change engine oil
•
Clean and re-gap spark plugs
Change oil filter
Check and adjust valve
♦
clearance
Clean and lap valve seating
♦
surface
♦Clean combustion chambers
•
•
•
•
•
•
•
•
(1): Service more frequently under dusty conditions.
♦: These items must be performed with the proper tools. See your authorized Kawasaki Engine
Dealer for service, unless you have the proper equipment and mechanical proficiency.
PERIODIC MAINTENANCE 2-3
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:
EO: Apply oil to the threads.
L: Apply a non-permanent locking agent to the threads.
Lh: Left-hand threads.
S: Tighten the fasteners following the specified sequence.
Fastener
Fuel System
Carburetor and Inlet Pipe Mounting Nuts
Control Panel Mounting Bolt
Governor Arm Clamp Nut
Governor Arm Joint Bolt
Governor Shaft Plate Screws
Inlet Manifold Bolts
FX Models
Air Cleaner Bracket Mounting Bolts
Air Cleaner Holder Bracket Bolts
Carburetor and Inlet Pipe Mounting Bolts
Choke Valve Screws
Cover Plate Screw
Drain Screw
Float Chamber Mounting Screws
Throttle Valve Screws
FR and FS Models
Control Panel and Inlet Pipe Mounting Bolt
Main Jet
Solenoid Valve
Throttle Valve Screws
FR651V, FR691V, FS651V, FS691V Models
Throttle Lever Mounting Screw
Cooling System
Cooling Fan Plate Mounting Bolts
Cooling Fan Screen Bolts
Flywheel Bolt
FX Models
Engine Shroud Bolts
Fan Housing Bolts
Guard Mounting Bolts
FR and FS Models
Engine Shroud Bolts
Fan Housing Bolts
Engine Top End
Connecting Rod Big End Cap Bolts
Cylinder Head Bolts (L = 50 mm)
N·m
Torque
kgf·m
5.9
5.9
7.8
5.9
2.0
5.9
0.60
0.60
0.80
0.60
0.20
0.60
52
52
69
52
18
52
5.9
5.9
5.9
0.60
0.60
0.60
52 in·lb
52 in·lb
52 in·lb
0.93
2.4
2.0
3.9
0.93
0.095
0.24
0.20
0.40
0.095
8.2 in·lb
21 in·lb
18 in·lb
35 in·lb
8.2 in·lb
5.9
2.3
4.5
0.68
0.60
0.23
0.46
0.069
52 in·lb
20 in·lb
40 in·lb
6.0 in·lb
L
0.68
0.069
6.0 in·lb
L
8.8
5.9
56
0.90
0.60
5.7
78 in·lb
52 in·lb
41
5.9
5.9
5.9
0.60
0.60
0.60
52 in·lb
52 in·lb
52 in·lb
8.8
8.8
0.90
0.90
78 in·lb
78 in·lb
9.8
46
1.0
4.7
87 in·lb
34
ft·lb
in·lb
in·lb
in·lb
in·lb
in·lb
in·lb
Remarks
Lh
S
EO
S
2-4 PERIODIC MAINTENANCE
Torque and Locking Agent
Fastener
46
14.7
5.9
Torque
kgf·m
4.7
1.5
0.60
ft·lb
34
11
52 in·lb
22
11
2.2
1.1
16
97 in·lb
6.9
5.9
0.70
0.60
61 in·lb
52 in·lb
5.9
0.60
52 in·lb
8.8
0.90
78 in·lb
9.8
27.4
3.9
3.9
5.9
1.0
2.8
0.40
0.40
0.60
87 in·lb
20
35 in·lb
35 in·lb
52 in·lb
2.0
0.20
18 in·lb
19.6
2.0
14
3.95
0.40
35 in·lb
56
5.9
22
3.4
5.7
0.60
2.2
0.35
41
52 in·lb
16
30 in·lb
N·m
Cylinder Head Bolts (L = 60 mm)
Rocker Arm Bracket Bolts
Rocker Cover Bolts
Spark Plugs
Valve Clearance Adjusting Locknuts
Lubrication System
Engine Oil Drain Plug
Oil Pump Cover Plate Bolts
FX Models
Oil Filler Mounting Bolt
FR and FS Models
Oil Filler Mounting Bolt
Camshaft/Crankshaft
Connecting Rod Big End Cap Bolts
Crankcase Cover Bolts
Crankcase Cover Oil Passage Plugs
Crankcase Oil Passage Plugs
Breather Chamber Cover Bolts
Breather Valve Mounting Screw
Starter System
Starter Motor Mounting Bolts
FR and FS Models
Starter Motor Through Bolts
Electrical System
Flywheel Bolt
Ignition Coil Bolts
Spark Plugs
Stator Coil Screws
Remarks
S
L
EO
S
L
L
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-cleaned threads.
Basic Torque for General Fasteners
Threads Diameter
(mm)
4
5
6
8
10
N·m
2.0
3.4
5.9
15
20
Torque
kgf·m
0.20
0.35
0.60
1.5
2.0
ft·lb
17 in·lb
30 in·lb
52 in·lb
11
15
PERIODIC MAINTENANCE 2-5
Specifications
Item
Fuel System
Idle Speed (1):
Low Idle Speed (Carburetor idle rpm)
Low Idle Speed (Governor idle rpm)
High Idle Speed
Air Cleaner:
Type:
FR Models
FS and FX Models
Pre-cleaner:
FR Models
FS Models
FX Models
Second-stage cleaner:
FS Models
FX Models
Engine Top End
Valve Clearance:
Inlet, Exhaust
Valve Seating Surface Angle:
Inlet, Exhaust
Valve Seating Surface Width:
Inlet
Exhaust
Lubrication System
Engine Oil:
Type
Viscosity
Capacity
Level
Electrical System
Spark Plug
Spark Plug Gap
Standard
1 450 r/min (rpm)
1 550 r/min (rpm)
3 600 r/min (rpm)
Single stage filtration system
Dual stage filtration system
Paper element
Foam element
Paper element
Paper element
Foam element
0.05 ∼ 0.10 mm (0.0020 ∼ 0.0039 in.)
45°
1.2 ∼ 1.8 mm (0.047 ∼ 0.071 in.)
0.8 ∼ 1.6 mm (0.031 ∼ 0.063 in.)
SF, SG, SH, SJ or SL class
SAE 40, SAE 30, SAE 10W-30/SAE 10W-40, or
SAE 5W-20
1.8 L (1.9 US qt) (When the oil filter is not removed)
2.1 L (2.2 US qt) (When the oil filter is removed)
Operating range (grid area (ADD and FULL)) on dipstick
NGK BPR4ES
0.7 ∼ 0.8 mm (0.028 ∼ 0.031 in.)
(1) Idle speeds may vary depending on each equipment. Refer to the equipment specification.
2-6 PERIODIC MAINTENANCE
Special Tools
Valve Seat Cutter, 45° 57001-1116
35:
Valve Seat Cutter, 45° 57001-1187
30:
Valve Seat Cutter, 32° 57001-1121
35:
Valve Seat Cutter, 32° 57001-1199
33:
Valve Seat Cutter Holder Bar:
57001-1128
Valve Seat Cutter Holder,
57001-1360
6:
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
all possible external loads from the engine.
• Disconnect
Start
the
engine
and warm it up thoroughly.
•
WARNING
Always keep your hands clear of the moving parts.
the throttle lever at a dash to the idle position.
• Move
Hold
the
lever on the carburetor in closed position
• (turn the throttle
governor arm clockwise all the way) and adjust
the low idle speed screw [A] until the engine idles at specified speed.
Low Idle Speed (Carburetor idle rpm)
1 450 r/min (rpm)
the throttle lever.
• Release
Loosen
the
[A].
• Adjust the lowlocknut
idle speed set screw [B] on the control plate
• to obtain the specified
governor low idle speed.
Low Idle Speed (Governor idle rpm)
1 550 r/min (rpm)
• Tighten the locknut.
High Idle Speed Adjustment
NOTE
○High idle speed adjustment should be made after the
idle speed adjustment is performed.
CAUTION
Do not adjust high idle speed with the air cleaner
removed.
• Start and warm up the engine thoroughly.
2-8 PERIODIC MAINTENANCE
Periodic Maintenance Procedures
WARNING
Always keep your hands clear of the moving parts.
the locknut [A], and unscrew the high idle set
• Loosen
screw [B] few turns.
the throttle lever on dash to obtain the specified high
• Move
idle speed and leave it there.
High Idle Speed
3 600 r/min (rpm)
the high idle set screw so that the end of it just
• Turn
touches the speed control lever [C], and tighten the lock
•
nut.
Check the idle speed, and readjust the idle speed if necessary.
CAUTION
Be sure to make the idle and fast idle speeds respectively correspond to those of the equipment.
Fuel System Cleanliness Inspection
WARNING
Gasoline is extremely flammable and can be explosive under certain conditions. Turn the engine
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
light.
FX Models
Place a suitable container [A] under the drain screw [B]
on the carburetor.
Turn out the drain screw a few turns to drain the carburetor and check if water or dirt has accumulated in the
carburetor.
Tighten the drain screw.
•
•
•
FR and FS Models
Place a suitable container under the carburetor.
Remove:
Solenoid Valve Connector [A]
Solenoid Valve [B]
Float Chamber [C] and Gasket
Check if water or dirt has accumulated in the carburetor.
Install the removed parts (see appropriate chapters).
•
•
•
•
If any water or dirt is found, clean the carburetor (see
Carburetor Cleaning in the Fuel System chapter) and fuel
tank. And check the fuel filter (see Fuel Filter Inspection
in the Fuel System chapter).
PERIODIC MAINTENANCE 2-9
Periodic Maintenance Procedures
Element Cleaning and Inspection
Air cleaner elements are not recommended to be cleaned,
and each air cleaner element should be replaced with new
ones at the maintenance time as shown in the maintenance
chart.
NOTE
○Operating in dusty condition may require more frequent
maintenance than above.
FX Models
Remove the elements (see Element Removal in the Fuel
System chapter).
Replace the primary element [A] every 250 hrs.
•
•
the secondary element [A] with a new one if dirty
• Replace
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 to
clean air cleaner elements.
FR Models
Remove the paper element (see Air Cleaner Element Removal).
Clean the paper element [A] by tapping it gently on a flat
surface to remove dust. If the element is very dirty, replace it with a new one.
•
•
FS Models
Remove the foam and paper elements (see Air Cleaner
Element Removal).
Clean the foam element [A] in a bath of detergent and
water, and let the element air-dry thoroughly.
Clean the paper element [B] by tapping it gently on a flat
surface to remove dust. If the element is very dirty, replace it with a new one.
•
•
•
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