PDF Service Manual Kawasaki FH451V FH500V FH531V FH601V FH641V FH680V FH721V Engine - 473 KB
This is the factory service manual for the Kawasaki FH series of 4-stroke V-twin gasoline engines, including the FH451V through FH721V models.
It contains detailed instructions for every aspect of service, from basic tune-ups to complete overhauls.
This manual is the ultimate resource for mechanics who need to maintain, troubleshoot, and repair these reliable Kawasaki engines.
PDF Viewer
Viewer loads when you scroll here
SHARE THIS MANUAL
Download the PDF Manual
PDF viewer loading area
Text Preview from This Manual
The text below was extracted from the visible preview pages to help you confirm the manual contents before download.
--- Page 1 ---
FH451V,FH500V,FH531V
FH601V,FH641V,FH680V
FH721V
4βstroke 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 Department/Consumer Products & Machinery Group/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.
Β© Kawasaki Heavy Industries, Ltd., 1999, 2000 Third Edition (1) : Nov. 20, 2000 (K)
--- Page 3 ---
GENERAL INFORMATION 1-7
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 (β’) 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.
FH451V, FH500V, FH531V
OPERATION INTERVAL
Daily First Every Every Every Every Every
8 hr. 25 hr. 50 hr. 100 hr. 200 hr. 300 hr.
Check or clean air intake screen
β’
Check and add engine oil
β’
Check for fuel and oil leakage
β’
Check for loose or lost nut and screw
β’
Check battery electrolyte level
β’
Clean air cleaner foam element (1)
β’
Clean air cleaner paper element (1)
β’
Clean dust and dirt from cylinder and
cylinder head fins (1) β’
Tighten nut and screws
β’
Change engine oil
β’ β’
Clean and re-gap spark plugs
β’
Change Oil filter
β’
Change air cleaner paper element (1)
β’
Check and adjust vlave clearance
β’
Clean and lap valve seating surface
β’
Clean combustion chamber
β’
(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.
--- Page 4 ---
FUEL SYSTEM 2-3
Exploded View
[FH451V, FH500V, FH531V]
1. Pilot Screw
2. Pilot Air Jet
3. Main Air Jet
4. Main Jet
5. Pilot Jet
6. Solenoid Valve
T1: 0.7 N1m (0.07 kg1m, 6 in1lb)
T2: 1.0 N1m (0.10 kg1m, 9 in1lb)
T3: 1.3 N1m (0.13 kg1m, 11 in1lb)
T4: 1.7 N1m (0.17 kg1m, 15 in1lb)
T5: 2.0 N1m (0.20 kg1m, 17 in1lb)
T6: 3.4 N1m (0.35 kg1m, 30 in1lb)
T7: 3.9 N1m (0.40 kg1m, 35 in1lb)
T8: 6.9 N1m (0.70 kg1m, 61 in1lb
T9: 7.8 N1m (0.80 kg1m, 69 in1lb)
T10: 8.8 N1m (0.90 kg1m, 78 in1lb)
--- Page 5 ---
FUEL SYSTEM 2-13
Carburetor
Fuel Shut Off Solenoid Valve (Electric Starter Model)
To avoid after firing when stopping the engine, a solenoid actuated
fuel shut off solenoid valve [A] is installed in the carburetor bowl. The
valve shuts off the fuel supply to the valve seat [B] simultaneously when
the switch key turned to the βOFFβ position.
The valve opens automatically when the switch key is turned to the
βRunβ position.
Low Idle Speed Adjustment
β’ Disconnect all possible external loads from the engine.
β’ Start the engine and warm it up thoroughly.
Always keep your hands clear of the moving parts.
β’ Movethe throttle lever on dash to the idle position, and hold the throttle
lever on the carburetor in closed position (turn the governor arm
clockwise all the way) and adjust the low idle speed screw [A] until the
engine idles at specified speed. - FH451V, 500V, 531V.
β’ Adjust the low idle speed screw [C] with Phillips Screwedriver [D] until
the engine idles at specified speed.β FH601V, 641V, 680V, 721V.
Idle Speed (Carburetor idle rpm)
1450 rpm
β’ Release the throttle lever and adjust the low idle speed set screw [B]
on the control plate to obtain the specified governed low idle speed.
Low Idle Speed (Governed idle rpm)
1550 rpm
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.
β’ Start and warm up the engine thoroughly.
--- Page 6 ---
FUEL SYSTEM 2-23
Intake Manifold
Intake Manifold Inspection
β’ Cracksnot
Inspect the intake manifold for cracks or porous casting.
β’ area with mixture
visible to the eye may be detected by coating the suspected
of 25% kerosene and 75% light engine oil.
β’ dissolved
Wipethe area dry and immediately apply a coating of zinc oxide
in wood alcohol. If a cracks is present, the coating will become
discolored at the defective area.
If a crack is present in the intake manifold, replace it.
β’ Inspect the gasket surfaces for burns and nicks.
--- Page 7 ---
COOLING SYSTEM 3-5
Cooling Fan
Screen Clearance Adjustment
β’ Checkclearance between screen [A] and fan housing [B]. If clearance
is less than 1 mm, add proper number of spacer [C] between screen
and bracket comp [D] to adjust clearance [G] 1 3 mm.
F: Screws
G: Clearance 1 3 mm
--- Page 8 ---
ENGINE TOP END 4-9
Cylinder Head
Compression Measurement
β’ Before measuring compression, do the following.
Be sure the battery is fully charged.
Thoroughlywarm up the engine so that engine oil between the piston
and cylinder wall will help seal compression as it does during normal
running.
Stop the engine.
β’ Disconnect
plugs.
the spark plug caps of each cylinder and remove the spark
β’ Attach the compression gauge assembly firmly into one plug hole.
Special Tool - Compression Gauge: 57001β221 [A]
Compression Gauge Adapter: 57001β1159 [B]
β’ Ground the spark plugs to the engine.
To avoid fire, do not ground the spark plugs in proximity to the
plug holes. Keep the plugs as far away as possible from the plug
holes.
β’ starter
Withthe throttle fully open, turn engine over sharply with the recoil
several times until the compression gauge stops rising; the
compression is the highest reading obtainable. (Recoil Model)
Cylinder Compression (MIN) 390 kPa (57 psi)
β’ Using the starter motor, turn the engine over with the throttle fully open
until the compression gauge stops rising; (Electric Starter Model).
Cylinder Compression (MIN) 390 kPa (57 psi)
β’ Repeat the measurement to the other cylinder.
If the compression is higher than the specified value, the piston rings,
cylinder and valves are probably in good condition.
If the compression is too high, check the following.
1. Carbon build-up on the piston crown and cylinder head - clean off
any carbon on the piston crown and cylinder head.
2. Cylinder head gasket - use only the proper gasket. The use of a
gasket of incorrect thickness will change the compression.
3. Valve guides and piston rings - rapid carbon accumulation in the
combustion chamber may be caused by worn valve guides and/
or worn piston oil rings. This may be indicated by white exhaust
smoke.
If cylinder compression is lower than the (MIN), check the following:
1. Gas leakage around the cylinder head - replace the damaged
gasket and check and check the cylinder head warp.
2. Condition of the valve seating.
3. Valve clearance.
4. Piston/cylinder wear, piston seizure.
5. Piston ring, piston ring groove.
--- Page 10 ---
ENGINE TOP END 4-19
Cylinder, Piston
Piston Removal
β’ Split the crankcase (see Camshaft/Crankshaft chapter).
β’ Turn the the
Remove camshaft (see Camshaft/Crankshaft chapter).
β’ Remove the bolts andto take
crankshaft expose the connecting rod cap bolts [A].
β’ off the connecting rod caps [B]. NOTE
Note the position of the connecting rod caps for reinstalling the
caps.
β’ Push the connecting rod end into the cylinder, and pull the piston and
connecting rod out of the cylinder.
CAUTION
Note a location of the arrow match mark [A] on the piston head
in relation to K Mark [B] on the connecting rod.
No.1 cyl. K Mark on the connecting rod is face to face with
No.2 cyl. K Mark on the connecting rod.
Keep parts together as a set.
β’ Remove
[B].
one of the piston pin snap rings [A] with needle nose pliers
β’ Remove the piston by pushing the piston pin [A] out the side from
which the snap ring was removed.
β’ Remove the top and second rings with piston ring pliers. Special
Tool - Piston Ring Pliers: 57001β115
β’ Ifwiththeyour
special tool is not available, carefully spread the ring opening
thumbs and then push up on the opposite side of the ring
[A] to remove it.
β’ Remove the 3-piece oil ring with your thumbs in the same manner.
--- Page 11 ---
LUBRICATION SYSTEM 5-1
Lubrication System
Table of Contents
Exploded View....................................................................................................................................................................5-2
Engine Oil Flow Chart ........................................................................................................................................................5-4 5
Specifications .....................................................................................................................................................................5-5
Engine Oil, Oil Filter, and Oil Cooler..................................................................................................................................5-6
Oil Level Inspection .....................................................................................................................................................5-6
Oil Change...................................................................................................................................................................5-6
Oil Filter Removal ........................................................................................................................................................5-7
Oil Filter Installation.....................................................................................................................................................5-7
Oil Cooler Removal .....................................................................................................................................................5-7
Oil Cooler Installation ..................................................................................................................................................5-7
Pressurized Lubrication System.........................................................................................................................................5-8
Oil Pressure Measurement..........................................................................................................................................5-8
Oil Pressure Switch Inspection ...................................................................................................................................5-8
Oil Pump, Relief Valve .......................................................................................................................................................5-9
Oil Pump, Relief Valve Removal .................................................................................................................................5-9
Oil Pump, Relief Valve Installation ..............................................................................................................................5-9
Oil Pump, Relief Valve Inspection ...............................................................................................................................5-9
Oil Screen.........................................................................................................................................................................5-12
Oil Screen Removal...................................................................................................................................................5-12
Oil Screen Installation ...............................................................................................................................................5-12
Cleaning and Inspection............................................................................................................................................5-12
--- Page 12 ---
LUBRICATION SYSTEM 5-11
Oil Pump, Relief Valve
If cleaning does not solve the problem, replace the relief valve parts. If
necessary, put the ball in position and lightly tap the ball with a suitable
tools to form a perfect seat.
β’ Measure free length [A] of the spring with a vernier caliper.
If the free length of the spring is less than the service limit, replace
the spring.
Relief Valve Spring Free Length
Service Limit: 19.50 mm (0.77 in.)
--- Page 13 ---
CAMSHAFT/CRANKSHAFT 6-9
Breather
Breather Element Removal - FH451V, 500V, 531V
β’ Remove the bolts [A] and breather chamber cover [B].
β’ Remove the element [A].
β’ Check to see that the plate [B] is in place under the element [A].
d
Breather Element Installation - FH451V, 500V, 531V
β’ Apply sealant [A] to the mating surface of the crankcase. Sealant -
Kawasaki Bond (Silicone Sealant) : 56019-120
β’ Install
bolts.
a new gasket and the breather chamber cover, and tighten the
Torque - Breather Chamber Cover Bolts: 5.9 N1m (0.6 kg1m, 52 in1lb)
Breather Valve Inspection - FH601V, 641V, 680V, 721V
β’ Unscrew the mounting screw (A), and remove the plate (B) and the
breather valve (C).
β’ Inspect the breather valve (C) for breakage, hair crack or distortion,
replace it if necessary.
β’ Inspect the plate (B) for damage or rough contact surface, replace it
if necessary.
β’ Inspect the valve seating surface. The surface should be free of nicks
or burrs.
β’ Be sure the drain hole on the breather chamber does not accumulate
with slugs before installing the breather valve.
β’ Align center of the valve seat with center of the breather valve and
the plate, then tighten the mounting screw.
NOTE
Themounting screw is a self-tapping one. Be aware that misthreading
or overtightening screw will strip the female threads and ruin the
hole.
--- Page 14 ---
ELECTRICAL SYSTEM 7-3
Exploded View
[FH451V, FH500V, FH531V]
T1: 3.9 N1m (0.40 kg1m, 35 in1lb)
T2: 5.9 N1m (0.60 kg1m, 52 in1lb)
T3: 7.8 N1m (0.80 kg1m, 69 in1lb)
T5: 56 N1m (5.7 kg1m, 41 ft1lb)
T6: 22 N1m (2.2 kg1m, 16 ft1lb)
[FH601V, FH641V, FH680V, FH721V]
T1: 3.9 N1m (0.40 kg1m, 35 in1lb)
T2: 5.9 N1m (0.60 kg1m, 52 in1lb)
T3: 7.8 N1m (0.80 kg1m, 69 in1lb)
T5: 56 N1m (5.7 kg1m, 41 ft1lb)
T6: 22 N1m (2.2 kg1m, 16 ft1lb)
G: Apply grease.
--- Page 15 ---
ELECTRICAL SYSTEM 7-13
Charging, Ignition System
β’ Remove: Woodruff Key [A]
Stator Coil Lead Connector [B]
Stator Coil Screw [C]
Stator Coil [D]
Flywheel, Stator Coil Installation
β’ Install the stator coil and tighten the screws.
Torque - Stator Coil Screws: 3.4 N1m (0.35 kg1m, 30 in1lb)
β’ Using a cleaning fluid, clean off any oil or dirt on the following portions
and dry them with a clean cloth.
[A] Crankshaft Tapered Portion
[B] Flywheel Tapered Portion
β’ Fit the Woodruff key [C] securely in the slot in the crankshaft before
installing the flywheel.
β’ Install the fan [A] so that two positioning bosses [B] fit around flywheel
ignition magnet [C].
β’ Install the plate [D] so that the notch [E] inserts into the slot in the
flywheel.
β’ Install the screen [A] so that the projections [B] fit into the recess [C]
of the fan.
β’ Install the pulley [A] or bracket so that the tabs of the plate fit into
holes [B] in the pulley.
β’ Put the washer [C] as shown.
β’ Tighten the flywheel bolt [D].
Torque - Flywheel Bolt: 56 N1m (5.7 kg1m, 41 ft1lb)
--- Page 16 ---
ELECTRICAL SYSTEM 7-23
Starter System
β’ Test the armature winding for shorts.
Place the armature on a growler [A].
Hold a thin metal strip (e.g., hack saw blade) on top of the armature.
Turn on the growler and rotate the armature one complete turn.
If the metal strip vibrates, the windings are internally shorted to each
other and the starter motor must be replaced.
Yoke Assembly Inspection
Set the hand tester to the R 2 1 k range and measure the resistance
β’ between the positive brush (es) [A] and brush plate [B].
If the resistance is less than infinite, the positive brush is shorted to
ground. Replace the brush plate assembly.
Positive Brush to Ground Resistance
()
β’ Set the hand tester to the R 2 1 range and measure the resistance
between the negative brush (es) [A] and brush plate [B].
If the meter does not read close to 0 , the brush plate is faulty.
Replace the brush plate assembly.
Negative Brush to Ground Resistance
Close to 0
Pinion Clutch Inspection
β’ Turn the pinion gear by hand. The pinion gear should turn
clockwise freely.
If the pinion clutch does not operate as it should, or if it makes noise,
replace the pinion clutch.