Kawasaki Manual 99924 2078 01

Quick Reference Guide
General Information Periodic Maintenance Fuel System Cooling System Engine Top End Lubrication System Camshaft/Crankshaft Starter System Electrical System Troubleshooting 1 j 2 j 3 j 4 j 5 j 6 j 7 j 8 j 9 j 10 j
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.
FH451V, FH500V, FH531V FH541V, FH580V, FH601V FH641V, FH661V, FH680V FH721V
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 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.
2006 Kawasaki Heavy Industries, Ltd.
1 Edition (1):Mar. 31, 2006 (K)
LIST OF ABBREVIATIONS
A ABDC AC ATDC BBDC BDC BTDC C DC F F ft g h L ampere(s) after bottom dead center alternating current 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) hour(s) liter(s) lb m min N Pa PS psi r rpm TDC TIR V W pound(s) 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) 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:
Carburetor and internal parts Spark plugs electronic ignition system Magneto or Fuel filter element Air cleaner elements Crankcase Cylinder heads and internal parts Breather chamber 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. Dont take shortcuts. Remember to keep complete records of maintenance and repair with dates and any new parts installed. operations. If you want spark plug information, for example, go to the Periodic Maintenance Chart first. The chart tells you how frequently to clean and gap the plug. Next, 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 Spark Plug 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.
This note symbol indicates points of par-
NOTE
ticular interest for more efficient and convenient operation.
How to Use This Manual

In preparing this manual, we divided the product into its major systems. These systems became the manuals chapters. All information for a particular system from adjustment through disassembly and inspection is located in a single chapter. The Quick Reference Guide shows you all of the products system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents. The Periodic Maintenance Chart is located in the General Information chapter. The chart gives a time schedule for required maintenance
Indicates a procedural step or work to be done.
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.
Indicates a procedural sub-step or how to do
GENERAL INFORMATION 1-1
General Information
Table of Contents
Before Servicing ..................................................................................................................... Model Identification................................................................................................................. General Specifications............................................................................................................ 1-2 1-4 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 material and perfectly smooth to avoid oil or compression leaks. (9) Liquid Gasket, Non-Permanent Locking Agent Follow manufacturers 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 Lockn 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 When installing a ball bearing, the bearing race which is affected by friction should be pushed by a suitable driver. This prevents severe stress on the balls and races, and prevents races and balls from being dented. Press a ball bearing until it stops at the stop in the hole or on the shaft. (12)Oil Seal and Grease Seal Replace any oil or grease seals that were removed with new ones, as removal generally damages seals.

Before Servicing
When pressing in a seal which has manufacturers 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 Replace any circlips and retaining rings that were removed with new ones, as removal weakens and deforms them. When installing circlips and retaining rings, take care to compress or expand them only enough to install them and no more. (15)Cotter Pin Replace any cotter pins that were removed with new ones, as removal deforms and breaks them. (16)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. Dont 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. (17)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.
(18)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. (19)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
(20)Specifications Specification terms are defined as follows: Standards show dimensions or performances which brand-new parts or systems have. Service Limits indicate the usable limits. If the measurement shows excessive wear or deteriorated performance, replace the damaged parts.

Model Identification
Electric Starter Model-FH500V
Recoil Starter Model-FH500V
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.


Heavy Duty Air Cleaner Type

General Specifications
FH451V, FH500V, FH601V, FH641V, FH541V, FH580V FH721V FH531V FH661V, FH680V Type Forced air-cooled, vertical shaft, OHV, 4-stroke gasoline engine. Cylinder Layout 90 V-Twin 68 mm 68 mm 74 mm 68 mm 75.2 mm 76 mm Bore Stroke (2.68 in. 2.68 in.) (2.91 in. 2.68 in.) (2.96 in. 2.99 in.) Displacement 494 mL (30.1 cu. in.) 585 mL (35.6 cu. in.) 675 mL (41.19 cu. in.) Direction of Rotation Counterclockwise facing the PTO shaft Compression Release Automatic compression release Low Idle Speed 1 550 rpm 3 600 rpm High Idle Speed Ignition System Transistorized-fly wheel magneto RFI Per Canada and U.S.A. requirements Starting System Electric starter and/or recoil starter Charging System 12 V - 13 amps with regulator Spark Plug CHAMPION RCJ8Y NGK BPR4ES Carburetor Float type, fixed main jet Float type, fixed main jet, two barrel Fuel Pump Diaphragm type pulse pump Air Cleaner Dual stage element, dry type/Heavy duty type Governor Flyweight all speed governor Lubrication System Pressure feed by positive displacement pump Oil Filter Cartridge type full flow filter Oil Pressure Switch ON-OFF switch (Option) 1.9 L Oil Capacity (when 1.8 L (1.9 US-qt) (2.0 US-qt) engine is completely dry) Cooling System Forced air cooling by fan Dimensions 425 mm 359 mm 425 mm 359 mm 458 mm 430 mm 381 mm (L W H ) 324 mm 324 mm Electric Starter Model (16.7 in. 14.1 in. (16.7 in. 14.1 in. (18.0 in. 16.9 in. 15.0 in.) 12.8 in.) 12.8 in.) Recoil Starter Model 425 mm 359 mm 425 mm 359 mm 361 mm 361 mm (16.7 in. 14.1 in. (16.7 in. 14.1 in. 14.2 in.) 14.2 in.) Dry Weight Electric Starter Model 34 kg (75 lbs) 34 kg (75 lbs) 40.5 kg (89.3 lbs) 41.2 kg (90.8 lbs) Recoil Starter Model 32 kg (71 lbs) 32 kg (71 lbs) Item 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 ..................................................................................... Housing (Cap and Body) Inspection ................................................................................. Engine Top End ................................................................................................................... Cylinder Head Cleaning and Inspection............................................................................ Valve Clearance Inspection .............................................................................................. Valve Clearance Adjustment............................................................................................. Valve Seat Inspection ....................................................................................................... Valve Seat Repair ............................................................................................................. Lubrication System .............................................................................................................. Oil Level Inspection........................................................................................................... Oil Change ........................................................................................................................ Oil Filter Replacement ...................................................................................................... Oil Cooler Cleaning........................................................................................................... Electrical System ................................................................................................................. Spark Plug Cleaning and Inspection................................................................................. Spark Plug Gap Inspection ............................................................................................... 2-2 2-4 2-9 2-10 2-11 2-11 2-11 2-11 2-13 2-13 2-15 2-15 2-15 2-16 2-17 2-17 2-18 2-20 2-20 2-21 2-22 2-22 2-22 2-22 2-22
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.
FH451V, FH500V, FH531V, FH541V, FH580V

OPERATION Check and clean air inlet screen Check and add engine oil Check for fuel and oil leakage Check for loose or lost nuts and screws Check battery electrolyte level Clean air cleaner foam element (1) Clean air cleaner paper element (1) Clean cylinder and cylinder head fins (1) Tighten nut and screws Change engine oil Clean and re-gap spark plugs Change oil filter Change air cleaner paper element (1) Replace air cleaner element (Heavy duty air cleaner model) (1) Check and adjust valve clearance Clean and lap valve seating surface Clean combustion chambers (1): Service more frequently under dusty conditions. INTERVAL Every Every Every Every Every First Every Every Daily 100 200 250 300 500 8 hr. 25 hr. 50 hr. hr. hr. hr. hr. hr.
: 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 Chart FH601V, FH641V, FH661V, FH680V, FH721V
OPERATION Check and clean air inlet screen Check and add engine oil Check for fuel and oil leakage Check for loose or lost nuts and screws Check battery electrolyte level Clean air cleaner foam element (1) Clean air cleaner paper element (1) Replace air cleaner paper element (1) Replace air cleaner primary element (Heavy duty air cleaner model) (1) Check air cleaner secondary element (Heavy duty air cleaner model) (1) Replace air cleaner secondary element (Heavy duty air cleaner model) (1) Clean cylinder and cylinder head fins (1) Tighten nut and screws Change engine oil Clean and re-gap spark plugs Check and clean oil cooler fins (FH721V model) Change oil filter Check and adjust valve clearance Clean and lap valve seating surface Clean combustion chambers (1): Service more frequently under dusty conditions. INTERVAL Every Every Every Every Every First Every Every Daily 100 200 250 300 500 8 hr. 25 hr. 50 hr. hr. hr. hr. hr. hr.
: 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.

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: L : Apply a non-permanent locking agent to the threads. M : Apply a molybdenum disulfide lubricant (grease or oil) to the threads, seated surface, or washer. O: Apply oil to the threads, seated surface, or washer. S: Tighten the fasteners following the specified sequence. SS: Apply silicone sealant. FH451V, FH500V, FH531V, FH541V, FH580V FH451V, FH500V, FH531V, FH541V, FH580V Torque Nm kgfm ftlb
Fastener Fuel System Carburetor (FH451V, FH500V, FH531V) Choke Valve Screw Throttle Valve Screws Pilot Jet Main Jet Main Air Jet Main Nozzle Pilot Air Jet Drain Screw Ground Lead Screw (Carburetor Side) Fuel Shut Off Solenoid Valve Float Bowl Mounting Bolt Carburetor (FH541V, FH580V) Throttle Valve Screws Main Jet Fuel Shut off Solenoid Valve Float Chamber Mounting Screw Governor Arm Clamp Nut Governor Shaft Plate Screws Holder Plate Nuts (Air Cleaner, Carburetor Mounting) Inlet Manifold Mounting Bolts Air Cleaner Body Mounting Screws Air Cleaner Body Bracket Bolts (Heavy Duty Air Cleaner Type) Air Cleaner Body Bracket Nuts (Heavy Duty Air Cleaner Type) Control Panel Mounting Bolts Cooling System Engine Shroud Bolt (M8) Engine Shroud Bolts (M6) Plug Bolt (Engine Shroud) Plug Screw (Engine Shroud)
Remarks
0.7 1.0 1.7 0.7 0.7 2.0 0.7 1.3 3.4 6.9 8.8 0.7 2.3 4.5 4.5 7.8 2.0 5.9 5.9 3.4 5.9 9.8 5.9 15 5.9 5.9 3.4
0.07 0.1 0.17 0.07 0.07 0.20 0.07 0.13 0.35 0.70 0.90 0.07 0.23 0.46 0.46 0.80 0.20 0.60 0.60 0.35 0.60 1.0 0.60 1.5 0.60 0.60 0.35
6 inlb 9 inlb 15 inlb 6 inlb 6 inlb 17 inlb 6 inlb 11 inlb 30 inlb 61 inlb 78 inlb 6 inlb 20 inlb 40 inlb 40 inlb 69 inlb 18 inlb 52 inlb 52 inlb 30 inlb 52 inlb 87 inlb 52 inlb 11 52 inlb 52 inlb 30 inlb L

FH451V, FH500V, FH531V, FH541V, FH580V Torque Nm kgfm ftlb 25 6.9 5.9 9.8 28 5.9 15 22 6.9 20 17 39 9.8 3.9 5.9 in the text 25 5.9 3.4 56 5.9 5.9 3.4 7.8 5.9 15 5.9 7.8 22 2.6 0.70 0.60 1.0 2.8 0.60 1.5 2.2 0.70 2.0 1.7 4.0 1.0 0.40 0.60 2.6 0.60 0.35 5.7 0.60 0.60 0.35 0.80 0.60 1.5 0.60 0.80 2.2 19.0 61 inlb 52 inlb 87 inlb 20 52 inlb 11 16 61 inlb 14.5 12.0 29 87 inlb 35 inlb 52 inlb 19.0 52 inlb 30 inlb 41 52 inlb 52 inlb 30 inlb 69 inlb 52 inlb 11 52 inlb 69 inlb 16
Fastener Engine Top End Cylinder Head Bolts Valve Clearance Lock Screws Connecting Rod Big End Cap Bolts (FH541V, FH580V) Rocker Arm Bolts Rocker Cover Mounting Bolts Exhaust Pipe Flange Nuts Spark Plugs Lubrication System Engine Drain Plugs (Plastic) Engine Drain Plug (Metal) Engine Drain Plug Joint (Plastic) Engine Drain Plug Joint (Metal) Oil Pressure Switch Oil Passage Plug Oil Pump Cover Plate Mounting Bolts Oil Filter Camshaft/Crankshaft Crankcase Cover Bolts Breather Chamber Cover Bolts Electrical System Stator Coil Screws Flywheel Bolt Fan Housing Bolts Screen Bolts Regulator Screws Ignition Coil Bolts (Studs) Ignition Coil Bolts (Bolts) Starter Motor Mounting Bolts Recoil Starter Mounting Nuts Recoil Starter Retainer Screw Spark Plugs
Remarks
S O O
SS

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 dia (mm) 4 5 6 8 Nm 2.0 3.4 5.9 15 Torque kgfm 0.20 0.35 0.60 1.5 ftlb 17 inlb 30 inlb 52 inlb 11

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: L: Apply a non-permanent locking agent to the threads. M: Apply a molybdenum disulfide lubricant (grease or oil) to the threads, seated surface, or washer. O: Apply oil to the threads, seated surface, or washer. S: Tighten the fasteners following the specified sequence. SS: Apply silicone sealant. FH601V, FH641V, FH661V, FH680V, FH721V FH601V, FH641V, FH661V, FH680V, FH721V Torque Nm kgfm ftlb 1.0 1.0 19 2.0 20 3.9 7.8 2.0 5.9 5.9 5.9 9.8 5.9 15 5.9 3.4 25 6.9 21 0.10 0.10 1.9 0.20 2.0 0.40 0.80 0.20 0.60 0.60 0.60 1.0 0.60 1.5 0.60 0.35 2.6 0.70 2.1 8.9 inlb 8.9 inlb 14 18 inlb 15 35 inlb 69 inlb 18 inlb 52 inlb 52 inlb 52 inlb 87 inlb 52 inlb 11 52 inlb 30 inlb 19 61 inlb 15 S O
Fasteners Fuel System Choke Valve Screw Throttle Valve Screws Pilot Jet Main Jet Main Jet, Plug Main Nozzle Main Air Jet Pilot Air Jet Drain Screw (Carburetor) Ground Lead Screw (Carburetor Side) Fuel Shut Off Solenoid Valve (Carburetor) Float Bowl Mounting Screw (Carburetor) Governor Arm Clamp Nut Governor Shaft Plate Screws Inlet Pipe Mounting Bolts and Nuts Inlet Manifold Mounting Bolts Air Cleaner Body Mounting Screws Air Cleaner Body Bracket Bolts (Heavy Duty Air Cleaner Type) Air Cleaner Body Bracket Nuts (Heavy Duty Air Cleaner Type) Control Panel Mounting Bolts Cooling System Engine Shroud Bolt (M8) Engine Shroud Bolts (M6) Plug Bolt (Engine Shroud) Plug Screw (Engine Shroud) Engine Top End Cylinder Head Bolts Valve Clearance Lock Screws Connecting Rod Big End Cap Bolts (For M7 P1.0 screw thread spec.)
Remarks
L L

FH601V, FH641V, FH661V, FH680V, FH721V Torque Nm kgfm ftlb 9.8 1.0 87 inlb 28 5.9 15 22 6.9 20 17 39 9.8 3.9 5.9 in the text 44 25 5.9 3.4 56 5.9 5.9 3.4 7.8 5.9 15 22 2.8 0.60 1.5 2.2 0.70 2.0 1.7 4.0 1.0 0.40 0.60 4.5 2.6 0.60 0.35 5.7 0.60 0.60 0.35 0.80 0.60 1.5 2.2 20 52 inlb 11 16 61 inlb 14.5 12 29 87 inlb 35 inlb 52 inlb 33 19.0 52 inlb 30 inlb 41 52 inlb 52 inlb 30 inlb 69 inlb 52 inlb 11 16
Fasteners Connecting Rod Big End Cap Bolts (For M6 P1.0 screw thread spec.) Rocker Arm Bolts Rocker Cover Mounting Bolts Exhaust Pipe Flange Nuts Spark Plugs Lubrication System Engine Drain Plugs (Plastic) Engine Drain Plug (Metal) Engine Drain Plug Joint (Plastic) Engine Drain Plug Joint (Metal) Oil Pressure Switch Oil Passage Plug Oil Pump Cover Plate Mounting Bolts Oil Filter Oil Cooler Mounting Joint (FH721V) Camshaft/Crankshaft Crankcase Cover Bolts Breather Chamber Cover Bolts Electrical System Stator Coil Screws Flywheel Bolt Fan Housing Bolts Screen Bolts Regulator Screws Ignition Coil Bolts (Studs) Ignition Coil Bolts (Bolts) Starter Motor Mounting Bolts Recoil Starter Mounting Nuts Recoil Starter Retainer Screw Spark Plugs
Remarks O
SS
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 dia (mm) 4 5 6 8 Nm 2.0 3.4 5.9 15 Torque kgfm 0.20 0.35 0.60 1.5 ftlb 17 inlb 30 inlb 52 inlb 11

Specifications
Item Fuel System Idle Speed: (1) Low Idle Speed High Idle Speed Air Cleaner: Type Pre-cleaner Second-stage cleaner Standard
1 550 r/min (rpm) 3 600 r/min (rpm) Dual stage filtration system Foam element Paper element FH451V, FH500V, FH531V FH601V, FH641V, FH661V, FH680V, FH721V Heavy duty type Paper element Primary element Secondary element FH541V, FH580V
Type Cleaner Pre-cleaner Second-stage cleaner 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
0.10 0.15 mm (0.004 0.006 in.) 45 0.6 0.9 mm (0.024 0.035 in.)
Level Electrical System Spark Plug Spark Plug Gap Item Engine Top End Cylinder Head Warp
SF, SG, SH, SJ or SL class SAE 40, SAE 30, SAE 10W-30/SAE 10W-40, or SAE 5W-20 1.5 L (1.6 US qt) (When the oil filter is not removed) 1.7 L (1.8 US qt) (When the oil filter is removed) except FH721 1.8 L (1.9 US qt) (When the oil filter is removed) FH721 Operating range (grid area) on dipstick CHAMPION RCJ8Y, NGK BPR4ES 0.75 mm (0.030 in.) Service Limit 0.05 mm (0.002 in.)
(1) Idle speeds may vary depending on each equipment. Refer to the equipment specification.

Special Tools
Valve Seat Cutter, 45 57001-1116 35: Valve Seat Cutter, 32 57001-1199 33:
Valve Seat Cutter, 32 57001-1120
30:
Oil Filter Wrench: 57001-1249
Valve Seat Cutter Holder Bar: 57001-1128
Valve Seat Cutter Holder, 57001-1360
6:

Periodic Maintenance Procedures Fuel System
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
external loads from Disconnect all possibleengine thoroughly. the engine. Start and warm up the
NOTE
WARNING
Always keep your hands clear of the moving parts. the throttle lever at a idle position, and Movethe throttle lever on thedash to the in closed position hold carburetor (turn the governor arm clockwise all the way) and adjust the low idle speed screw [A] until the engine idles at specified speed.
For FH601V, FH641V, FH661V, FH680V, FH721V model; adjust the low idle speed screw [C] with Phillips Head
Screwdriver [D] until the engine idles at specified speed.
Low Idle Speed (Carburetor idle rpm) 1 450 rpm
the low Release the throttle lever and adjustobtain theidle speed set screw [A] on the control plate to specified governor low idle speed.
Low Idle Speed (Governor idle rpm) 1 550 rpm
High Idle Speed Adjustment
High idle speed adjustment should be made after the

low idle speed adjustment is performed.
NOTE
CAUTION
Do not adjust high idle speed with the air cleaner removed.
Start and warm up the engine thoroughly.

Periodic Maintenance Procedures WARNING
Always keep your hands clear of the moving parts. the high idle Move the throttle lever at a dash towith the panel position and match the lever hole position hole by
inserting 6 mm dia. pin or bolt [A]. Loosen two M6 control panel mounting bolts [B] enough to move the control panel assembly. Carefully move the control panel assembly right side [C] up or down to obtain the specified high idle speed.
High Idle Speed 3 600 rpm
Tighten the M6 Mounting bolts.
6 mm dia. pin bolt. Remove thehigh idle speed,orand readjust the high idle Check the speed if necessary.
Torque - Control Panel Mounting Bolts: kgfm, 52 inlb)
5.9 Nm (0.60
CAUTION
Be sure to make the low idle speed and high idle speed respectively correspond to those of the equipment.

Periodic Maintenance Procedures
Fuel System Cleanliness Inspection
WARNING
Gasoline is extremely flammable and can be explosive 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 pilot light. the air Cleaner Removesuitablecleaner (see Airunder the Body Removal). Place a container [A] drain screw (B) on the carburetor. a to drain the Turn out the drain screw or few turnsaccumulated carburetor and check if water dirt has in the
carburetor. For FH541V, FH580V model; remove the float bowl to drain the carburetor and check if water or dirt has accumulated in the carburetor. Tighten the drain screw.
Torque - [FH451V, FH500V, FH531V] Drain Screw: 1.3 Nm (0.13 kgfm, 11 inlb) [FH601V, FH641V, FH661V, FH680V, FH721V] Drain Screw: 2.0 Nm (0.20 kgfm, 18 inlb)
FH541V, FH580V Forfloat bowl mounting model; tighten the solenoid valve or screw.
Torque - Solenoid Valve: 4.5 Nm (0.46 kgfm, 40 inlb) Float Bowl Mounting Screw: 4.5 Nm (0.46 kgfm, 40 inlb)
or dirt found, If any waterCleaning)isand fuelclean the carburetor (see Carburetor tank. And check the fuel filter.
Element Cleaning and Inspection

Standard Type FH451V, FH500V, FH531V, FH541V, FH580V Models
In dusty areas, clean the elements more frequently than the recommended intervals.
WARNING
Because of the danger of highly flammable liquids, do not use gasoline or a low-flash point solvent to clean the element. and paper Remove the foam element[A] in thebath of element. and Clean the foam element a detergent water, and dry the element by air thoroughly before installation.
NOTE

by tapping on a Clean the paper element [A]the element itisgently dirty, flat surface to remove dust. If very replace it with a new one.
CAUTION
Do not use compressed air to clean the paper element. Do not oil the paper element or the foam element.
FH601V, FH641V, FH661V, FH680V, FH721V 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.
Heavy Duty Air Cleaner Type For FH541V and FH580V Models This air cleaner element is not recommended to be cleaned, and the air cleaner element should be replaced with a new one at the maintenance time as shown in the maintenance chart.
Operating in dusty condition may require more frequent

maintenance than above. the element Removechapter). (see Element Removal in the Fuel System Replace the element [A] every 250 hrs.
NOTE
CAUTION
Do not wash air cleaner element. Do not oil air cleaner element. Do not use pressurized air to clean air cleaner element. FH601V, FH641V, FH661V, FH680V, FH721V Models 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.
Operating in dusty condition may require more frequent

maintenance than above. the elements Removechapter). (see Element Removal in the Fuel System Replace the primary element [A] every 250 hrs.
NOTE

element [A] Replace the secondary is checked. with a new one if dirty when primary element 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.
Housing (Cap and Body) Inspection
Clean the housing with detergent and water and dry the housing thoroughly. deformation or other damage. Check the housing forand permit only filtered air to reach Seal the housing well
the carburetor. If the housing is damaged, replace the housing with a new one. Check that no foreign material obstructs the air passage.
Engine Top End

Cylinder Head Cleaning and Inspection
Scrape the carbon deposits from the cylinder head and the exhaust port with a suitable tool [A]. gouging, use that material To avoidcylinder head scrapersexhaust pipe.will not damage the and the the head in a bath Cleanwith compressed air.of high-flash point solvent and dry it
WARNING
Clean the cylinder head in a well ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Do not use gasoline or a low-flash point solvent to clean the cylinder head. A fire or explosion could result.
Lay a straight edge [A] across the mating surface of the cylinder head at several different points, and measure
the warp by inserting a thickness gauge [B] between the straight edge and the cylinder head. If the warp exceeds the service limit, repair the mating surface. Replace the cylinder head with a new one if the mating surface is badly damaged or warped.
Cylinder Head Warp Service Limit: 0.05 mm (0.002 in.)

head for other damage. Check the cylinderto the eyecracks ordetected by coating Cracks not visible may be the suspected area with mixture of 25% kerosene and
and inspect the Cleanrod and the valve rocker arm where it touches the push stem.
75% light engine oil. Wipe the area dry and immediately apply a coating of zinc oxide dissolved in wood alcohol. If a crack is present, the coating will become discolored at the detected area. If a crack is present in the cylinder head, replace it with a new one. Inspect the mating surface for burrs or nicks.
If the contact points [A] are worn or damaged, replace the rocker arm with a new one.
Valve Clearance Inspection
Check the valve clearance when the engine is cold (at room temperature).
cover Head Removal). Remove the rockerthe top (see Cylinder(TDC) of the compiston at dead center Place thestroke by turning the crankshaft clockwise facing pression the flywheel. No.1 Cylinder: The left projection [A] on the flywheel is faced with the right leg [B] on the #1 ignition coil [C] as shown in the figure. Check the inlet and exhaust valves are closed completely, if they are not closed, turn the flywheel one turn (360) clockwise and face the left projection with the right leg again. No.2 Cylinder: The left projection [A] on the flywheel is faced with the right leg [B] on the #2 ignition coil [C] as shown in the figure. Follow No.1 Cylinder alignment.
NOTE
Checkathe valve clearance. measure the valve clearance Using thickness gauge [A],
between the rocker arm [B] and the valve stem end. If the valve clearance is no correct, adjust it.
Valve Clearance (when cold) Inlet, Exhaust 0.10 0.15 mm (0.004 0.006 in.)

Valve Clearance Adjustment
change the Since valve repairs as specified.valve clearance, adjust the valve clearance the cylinder and install the cylinder head Assemble on the block head Cylinder Head Installation). assembly (see direction Turn the crankshaft in properstroke (asuntil the piston is at the TDC of the compression described above). the Loosennuts lock screws [A] and the valve clearance adjusting [B]. Insert a 0.10 mm (0.04 in.) thickness gauge [C] between the rocker arm and valve stem. Tighten the adjusting nut until the thickness gauge begins to bind between the rocker arm and valve stem end. Sweep the thickness gauge during this adjustment.
Valve Clearance (when cold) Inlet, Exhaust: 0.10 0.15 mm (0.004 0.006 in.)
Holding the adjusting nut with a spanner, tighten the lock screw to the specified torque.
lock screws. Do not overtighten the valve clearancemeasure the valve After the valve clearance adjustment, clearance again. Readjust the valve clearance if necessary.
Torque - Valve Clearance Lock Screws: kgfm, 61 inlb) 6.9 Nm (0.70
Valve Seat Inspection
Remove the valve (see Valve Mechanism Removal/Installation). damage. Inspect the valve seats for distorted beyond reconditionIf the seats are warped or
ing, replace the cylinder head with a new one. Pitted or worn valve seats can be refaced. Lap the valves to the seats after refacing. Coat the valve seat with machinists dye. Push the valve into the guide. Rotate the valve against the seat with a lapping tool. Pull the valve out, and check the seating pattern on the valve head. It must be the correct width [A] and even all the way around.
The valve stem and guide must be in good condition or

this check will not be valid. If the valve seating pattern is not correct, repair the seat.
Valve Seating Surface Width (STD) [FH451V, FH500V, FH531V, FH541V, FH580V] Inlet, Exhaust 0.6 0.9 mm (0.024 0.035 in.) [FH601V, FH641V, FH661V, FH680V, FH721V] Inlet Exhaust 0.8 1.4 mm (0.03 0.05 in.) 1.1 1.6 mm (0.04 0.06 in.)
NOTE

Valve Seat Repair
Follow the manufactures instructions for use of valve seat cutters

Special Tools Inlet Valve: Valve Seat Cutter Valve Seat Cutter Exhaust Valve: Valve Seat Cutter Valve Seat Cutter Valve Seat Cutter Holder Valve Seat Cutter Holder Bar: 45 32 6 30 30 57001-1187 57001-1120 57001-1360 57001-1128 45 32 35 33 57001-1116 57001-1199
If the manufactures instructions are not available, use the following procedure. Seat Cutter Operating Cares 1. This valve seat cutter is designed only for valve seat repair. Do not use the valve seat cutter for other purpose. 2. Do not drop or hit the valve seat cutter, or the diamond particles may fall off. 3. Be sure to apply engine oil to the valve seat cutter before grinding the seat surface. Also wash off ground particles sticking to the cutter with washing oil.
Do not use a wire brush to remove the metal particles

from the cutter. It will take off the diamond particles. 4. Setting the valve seat cutter holder [A] in position, operate the cutter [B] with one hand [C]. Do not apply too much force to the diamond portion.
NOTE
Prior to grinding, apply oil to the cutter, and during the operation wash off any ground particles sticking to the cutter with washing oil.
5. After use, wash the cutter with washing oil and apply thin layer of engine oil before storing. Marks Stamped on the Cutter The marks stamped on the back of the cutter represent the following.
1 32 37.5 KS8B Cutter number, selected from 1 to 12 Cutter angle [A] Cutter diameter [B] Manufactured lot number
NOTE

Operating Procedures Clean the seat area carefully. Recondition the valve seats with the valve seat cutters (45, 32) and lap the valves. Check the seats for good contact all the way around with machinists dye. Measure the seat width [A]. If it is greater than the STD width, reface the seating surface. If the valve seating pattern is not correct, repair the seat.
the seat machinists Coat 45 cutterwith to the holderdye. slide it into the valve Fit a [A] and guide. enough material to produce a smooth and concentric seat.
Resurface the valve seat with a 45 cutter, removing only

CAUTION
Do not grind the seat too much. Overgrinding will reduce valve clearance by sinking the valve into the head. If the valve sinks too far into the head, it will be impossible to adjust the clearance, and the cylinder head must be replaced. Do not turn the cutter counterclockwise or drop it against the seat, or it will be dulled. 32 Use awidth.seat cutter [A] to narrow the seat width to the STD
Turn the seat cutter one turn at a time while pressing down
very lightly. Check the seat width after each turn.
CAUTION
The 32 cutter removes material very quickly. Check the seat width frequently to prevent over grinding.
Keep the seat width as close as possible to the STD

width. seat with Make a light contact on the valvethe edge ofthe 45 cutter to remove any possible burrs at the seat. After resurfacing the seat, inspect for even valve seating. Apply a machinists dye to the valve face, insert the
NOTE
valve, and snap it closed against the seat several times. The valve surface should show good contact all the way around. Be sure the valve seat is centered on the valve face. The position of the valve in the seat is evident after lapping the valve. If the seat does not make proper contact, lap the valve into seat with a vacuum cap tool.

Coat the valve face sparingly with a fine lapping compound. the vacuum cap tool [A], to of UseRotate the valve in a circulargrip the toplap the valve [B]. motion to the valve
to the seat. Lift the valve slightly from the seat every 8 to 10 strokes, continue lapping operation until a uniform ring appears around entire surface of the valve face.
completed, wash When lapping iscompound. Dry theall parts in solvent to remove lapping 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. When the engine is assembled, be sure to adjust the valve clearances (see Valve Clearance Adjustment).
Lubrication System
Oil Level Inspection
engine on a level Place thethe oil filler cap [A] surface. its dipstick [B] with Remove and wipe a clean cloth. Insert the dipstick into tube [C] without screwing it in, then check the oil level.
oil level should Thethe dipstick [D]. be the operating range [A] (grid area) on If the oil level is ADD range [B], add enough engine oil to bring oil level to the operating range [A].
CAUTION
Do not add more oil above the operating range. Excess oil will cause a smoking condition.
Use the same type and make of oil that is already in the
engine.
If the engine oil type and make are unknown, use any
NOTE
brand of the specified oil to top up the level in preference to running the engine with the oil level low. Then at your earliest convenience, change the oil completely.
If the oil level is FULL range [C], drain the excess oil by loosening the drain plug. Oil Level Gauge: Before 2002/2 produce model [E] Oil Level Gauge: On and after 2002/2 produce model [F]

Oil Change
the oil after Change oil every 100first 8 hours of operation. Thereafter change hours of operation. and warm Start the engine.up the engine to drain the oil easily. Stop Place the engine on a level surface. Place a suitable container under the engine. Remove the oil drain plug [A] and drain the oil.
WARNING
Be careful of hot oil when draining. It may be hot enough to burn you severely. the O-ring [B] Checkthe O-ring withat the oil drainitplug for damage. Replace a new one if is damaged. If the oil drain plug joint is removed, tighten it.
Torque - Oil Drain Plug Joint (Plastic) :17 Nm (1.7 kgfm, 12.0 ftlb) Oil Drain Plug Joint (Metal) :39 Nm (4.0 kgfm, 29 ftlb) Torque - Oil Drain Plug (Plastic) : 6.9 Nm (0.70 kgfm, 61 inlb) Oil Drain Plug (Metal) : 20 Nm (2.0 kgfm, 14.5 ftlb)
Install the oil drain plug with the O-ring and tighten it.
the oil Removeamount filler cap and pour in the specified type and the of oil.
Engine Oil : Grade: Viscosity: Capacity: SF, SG, SH, SJ or SL Class SAE40, SAE30, SAE10W-30/SAE10W-40, or SAE5W-20 [When the oil filter is not removed] 1.5 L (1.6 US qt) [When the oil filter is removed] 1.7 L (1.8 US qt) except FH721V 1.8 L (1.9 US qt) FH721V
the O-ring [A] the Checkthe O-ring with onnew oil fillerit cap for damage. Replace a one if is damaged. When checking the oil level, do not turn oil filler cap on threads.
Some
NOTE
increase in oil consumption may be expected when a multi grade engine oil (10W-30/10W-40, 5W-20) is used. Check the oil level more frequently than recommended interval.

Oil Filter Replacement
engine oil Drain thethe oil filter(see Oil Change).filter wrench [B] or Remove [A] with the oil strap wrench.
When unscrewing the oil filter, place a suitable container
Special Tool - Oil Filter Wrench: 57001-1249
beneath the oil drip tray to receive oil from the oil filter and oil passages in the engine.
filter [A] a one. Replace the oil of enginewithto newseal [B]. Apply light film oil the Install the oil filter. Turn the filter until the seal contacts mounting surface [C]
of the engine. Then turn the filter BY HAND (S) 3/4 turn more. Run the engine at slow idle speed for 2 minutes. While running the engine, check for oil leaks around it. Stop the engine and check the oil level (see Oil Level Inspection).
Oil Cooler Cleaning
Clean dirt off the outside fins with brush or with compressed air.
Electrical System
Spark Plug Cleaning and Inspection
Carefully pull the plug cap from the spark plug, and remove the spark plug.
If the plug is oily or has carbon built up on it, clean the plug using a high-flash point solvent and a wire brush or other suitable tools. If the spark plug electrodes are corroded or damaged, or if the insulator is cracked replace the plug with a new one. Use the standard spark plug or its equivalent. Insulator [A] Center Electrode [B] Plug Gap [C] Side Electrode [D]
Spark Plug Gap Inspection
gap with a wire-type thickness gauge. Measure thenot correct, carefully bend the side electrode If the gap is with a suitable tool to obtain the correct gap.
Spark Plug Gap Standard: 0.75 mm (0.030 in.)
FUEL SYSTEM 3-1
Fuel System
Table of Contents
Exploded View........................................................................................................................ Specifications ......................................................................................................................... Governor Link Mechanism...................................................................................................... Control Panel Assembly Removal .................................................................................... Control Panel Assembly Installation ................................................................................. Governor Arm Removal .................................................................................................... Governor Arm Installation ................................................................................................. Governor Assembly Removal ........................................................................................... Governor Assembly Installation ........................................................................................ Governor Assembly Inspection ......................................................................................... Governor Shaft Removal .................................................................................................. Governor Shaft Installation ............................................................................................... Carburetor .............................................................................................................................. Fuel and Air Flow .............................................................................................................. Fuel Shut Off Solenoid Valve (Electric Starter Model) ...................................................... Low Idle Speed Adjustment .............................................................................................. High Idle Speed Adjustment ............................................................................................. High Altitude Operation..................................................................................................... Main Jet Replacement ...................................................................................................... Fuel System Cleanliness Inspection ................................................................................. Carburetor Removal.......................................................................................................... Carburetor Installation....................................................................................................... Carburetor Disassembly/Assembly-FH451V, FH500V, FH531V....................................... Carburetor Disassembly/Assembly-FH541V, FH580V ..................................................... Carburetor Disassembly/Assembly-FH601V, FH641V, FH661V, FH680V, FH721V ......... Carburetor Disassembly/Assembly-FH680V and FH721V Late Models........................... Carburetor Cleaning.......................................................................................................... Carburetor Inspection ....................................................................................................... Fuel Shut Off Solenoid Valve Test (Electric Starter Model)............................................... Inlet Manifold .......................................................................................................................... Inlet Manifold Removal ..................................................................................................... Inlet Manifold Installation .................................................................................................. Inlet Manifold Inspection ................................................................................................... Fuel Pump, Fuel Filter ............................................................................................................ Fuel Pump Inspection ....................................................................................................... Fuel Filter Inspection......................................................................................................... Air Cleaner (Standard Type)................................................................................................... Element Removal.............................................................................................................. Element Removal.............................................................................................................. Element Installation........................................................................................................... Element Cleaning and Inspection ..................................................................................... Air Cleaner Body Removal................................................................................................ Air Cleaner Body Installation............................................................................................. Air Cleaner (Heavy Duty Type)............................................................................................... Element Removal.............................................................................................................. Element Installation........................................................................................................... Element Cleaning and Inspection ..................................................................................... Air Cleaner Body Removal................................................................................................ Air Cleaner Body Installation............................................................................................. Housing (Cap and Body) Inspection ................................................................................. 3-2 3-14 3-15 3-15 3-15 3-15 3-16 3-16 3-17 3-17 3-17 3-17 3-18 3-18 3-20 3-20 3-20 3-20 3-20 3-21 3-21 3-22 3-24 3-25 3-26 3-27 3-29 3-30 3-31 3-32 3-32 3-32 3-33 3-34 3-34 3-34 3-35 3-35 3-35 3-35 3-35 3-35 3-36 3-38 3-38 3-38 3-38 3-39 3-40 3-41
3-2 FUEL SYSTEM

Exploded View
[FH451V, FH500V, FH531V]
FUEL SYSTEM 3-3

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 7. Out Vent Tube (Before 2003/5 Product model) T1: 0.7 Nm (0.07 kgfm, 6 inlb) T2: 1.0 Nm (0.10 kgfm, 9 inlb) T3: 1.3 Nm (0.13 kgfm, 11 inlb) T4: 1.7 Nm (0.17 kgfm, 15 inlb) T5: 2.0 Nm (0.20 kgfm, 17 inlb) T6: 3.4 Nm (0.35 kgfm, 30 inlb) T7: 5.9 Nm (0.60 kgfm, 52 inlb) T8: 6.9 Nm (0.70 kgfm, 61 inlb) T9: 8.8 Nm (0.90 kgfm, 78 inlb)
3-4 FUEL SYSTEM

Exploded View
[FH541V, FH580V]
FUEL SYSTEM 3-5

Exploded View
[FH541V, FH580V] 1. Pilot Screw 2. Main Jet 3. Solenoid Valve T1: 0.7 Nm (0.07 kgfm, 6 inlb) T2: 2.3 Nm (0.23 kgfm, 20 inlb) T3: 4.5 Nm (0.46 kgfm, 40 inlb) T4: 3.4 Nm (0.35 kgfm, 30 inlb) T5: 5.9 Nm (0.60 kgfm, 52 inlb) L: Apply non-permanent locking agent.
3-6 FUEL SYSTEM

Exploded View
[Heavy Duty Air Cleaner Type]
FUEL SYSTEM 3-7

Exploded View
[Heavy Duty Air Cleaner Type] 1. Pilot Screw 2. Main Jet 3. Solenoid Valve T1: 0.7 Nm (0.07 kgfm, 6 inlb) T2: 2.3 Nm (0.23 kgfm, 20 inlb) T3: 4.5 Nm (0.46 kgfm, 40 inlb) T4: 5.9 Nm (0.60 kgfm, 52 inlb) T5: 9.8 Nm (1.0 kgfm, 87 inlb) L: Apply non-permanent locking agent.
3-8 FUEL SYSTEM

Exploded View
[FH601V, FH641V, FH661V, FH680V, FH721V]
FUEL SYSTEM 3-9

Exploded View
[FH601V, FH641V, FH661V, FH680V, FH721V] 1. Pilot Screw 2. Pilot Air Jet 3. Main Air Jet 4. Main Jet 5. Pilot Jet 6. Solenoid Valve 7. Out Vent Tube (Before 2003/5 Product model) T1: 1.0 Nm (0.10 kgfm, 9 inlb) T2: 3.9 Nm (0.40 kgfm, 35 inlb) T3: 2.0 Nm (0.20 kgfm, 18 inlb) T4: 19 Nm (1.9 kgfm, 14 ftlb) T5: 20 Nm (2.0 kgfm, 15 ftlb) T6: 5.9 Nm (0.60 kgfm, 52 inlb)
3-10 FUEL SYSTEM

Exploded View
[Heavy Duty Air Cleaner Type]
FUEL SYSTEM 3-11

Exploded View
[Heavy Duty Air Cleaner Type] 1. Main Jet 2. Pilot Screw 3. Solenoid Valve R: Replacement Parts T1: 1.0 Nm (0.10 kgfm, 9 inlb) T2: 3.9 Nm (0.40 kgfm, 35 inlb) T3: 2.0 Nm (0.20 kgfm, 18 inlb) T4: 2.5 Nm (0.25 kgfm, 22 inlb) T5: 6.9 Nm (0.70 kgfm, 61 inlb) T6: 9.8 Nm (1.0 kgfm, 87 inlb) T7: 5.9 Nm (0.60 kgfm, 52 inlb)
3-12 FUEL SYSTEM

Exploded View
FUEL SYSTEM 3-13

Exploded View
[FH451V, FH500V, FH531V] T1: 5.9 Nm (0.60 kgfm , 52 inlb) T2: 2.0 Nm (0.20 kgfm , 17 inlb) T3: 7.8 Nm (0.80 kgfm , 69 inlb) [FH541V, FH580V] T1: 5.9 Nm (0.60 kgfm , 52 inlb) T2: 2.0 Nm (0.20 kgfm , 17 inlb) T3: 7.8 Nm (0.80 kgfm , 69 inlb) [FH601V, FH641V, FH661V, FH680V, FH721V] T1: 5.9 Nm (0.60 kgfm , 52 inlb) T2: 2.0 Nm (0.20 kgfm , 17 inlb) T3: 7.8 Nm (0.80 kgfm , 69 inlb) A: Separate Choke Type B: Associate Choke Type O: Apply engine oil. 1. Fuel Tube for FH680V Late Model 2. Fuel Tube for FH680V Early Model
3-14 FUEL SYSTEM

Specifications
Standard Item Carburetor Specifications: Make/Type Throttle Bore Diameter Venturi Diameter Main Jet (MJ) Pilot jet (PJ) Main air jet (MAJ) Pilot air jet (PAJ) Pilot Air Screw Turns out (PS) (Idle Mixture Screw Turns Out) Float Level Idle Speed: (1) Low Idle Speed High Idle Speed Air Cleaner: Standard Model: Type Pre-cleaner Second-stage cleaner Heavy Duty Model: Type Cleaner Pre-cleaner Second-stage cleaner Fuel: Fuel Requirement Fuel Pump: Type Governor: Type FH451V, FH500V FH531V FH541V FH601V, FH641V, FH580V FH661V, FH680V, FH721V
MIKUNI B24T1 24 mm (0.94 in.) 16 mm (0.63 in.) 18 mm (0.71 in.) #125 #116.3 #48.8 1.7 1.2 2 1/4 #43.8 1.4 0.8 1 3/8
Walbro LMF 16 mm (0.63 in.) #100 #48 #150 #170 2 1/2
18 mm (0.71 in.) #105 #50 #110 #140 1 7/8
Nikki 621266 26 mm (1.02 in.) 21 mm (0.83 in.) *18 mm (0.71 in.) L: #122, R: #128 *L: #104, R: #108 L: #46, R: #44 *#52 1.7, * 1.6 1.1, * 1.4 L: 2 1/4, R: 1 1/4 *L: 3, R: 2 1/4
Float parallel to carburetor body 1 550 r/min (rpm) 3 600 r/min (rpm)
Dual stage filtration system Foam element Paper element Heavy duty type Paper element Primary element Secondary element
Unleaded regular grade gasoline Pulse-diaphragm pump Flyweight all speed governor
(1) Idle speeds may vary depending on each equipment. Refer to the equipment specification. *: For FH680V and FH721V Late Models
FUEL SYSTEM 3-15

Governor Link Mechanism
Control Panel Assembly Removal
Remove: (see Air Cleaner Body Removal) Air Cleaner

Air Cleaner Mount Bracket Bolts [A] Air Cleaner Mount Bracket [B] Ground Lead (Electric Starter Model) Control Panel Mounting Bolts [C]
panel [A] while unhooking Remove the control [B] endassemblythe panel bracket. the governor spring loop at Clear the choke link rod lower end [C] from the choke lever.
Control Panel Assembly Installation
control panel Before installing the[A] and engineassembly, check to see that the choke lever speed control lever [B] move smoothly in all directions. If any part is worn or damaged, replace the control panel assembly with a new one. After installation, adjust the low idle speed and high idle speed to the specifications (see Low Idle Speed and High Idle Speed adjustment in the Periodic Maintenance chapter).
separate choke type; Forshown in the figure. the control panel assembly is as
Governor Arm Removal
Remove: Panel Assembly Control Loosen the clamp nut [A] and take off the governor arm [B]. throttle link rod spring Unhook thelink rod lower end [D]. [C] end loop and clear the throttle
3-16 FUEL SYSTEM

FH580V For FH541V, figure. model; shown in the the governor arm is as
Governor Arm Installation
Install the governor arm [A] onto the governor shaft [B] temporarily. link spring [C] link rod [D] Beinsure theand that it pulls around the throttleand throttle is place the governor arm
lever [E] each other. Loosen the clamp nut [F] on the governor arm enough to move the governor shaft. Turn the top end of the governor arm counterclockwise to fully open the carburetor [G] throttle valve and hold it there. Turn the governor shaft counterclockwise fully to the end of its travel. Tighten the clamp nut.
Torque - Governor Arm Clamp Nut: 7.8 Nm (0.80 kgfm, 69 inlb)
the governor shaft the governor Be sureapproximately 7 mm extension from shown in the arm is (0.3 in) [H] as
figure. Install the control panel assembly, and connect the governor arm with the governor spring.
Governor Assembly Removal
Remove the crankcase cover (see Camshaft/Crankshaft chapter). Remove the push rod (see Engine Top End chapter). Remove the camshaft [A].
Remove: [A] Washer

Snap Ring [B] Sleeve [C] Governor Plate [D] Snap Ring [B] Steel Balls [E] Ball Guide [F] Ball Plate [G]
FUEL SYSTEM 3-17

Governor Assembly Installation
the groove Fit the snap ring [A] intoby hand andsecurely. the steel Turn the governor plate balls and governor plate move freely.check that
Governor Assembly Inspection
Visually check all governor parts for wear or damage.

Governor Shaft Removal
If any parts are worm or damaged, replace them with new ones.
Split the crankcase (see Camshaft/Crankcase chapter). Unscrew the governor shaft plate screws [A], and pull out the governor shaft [B].
Remove the governor shaft only if the replacement of
the governor shaft is necessary. the oil new one only Replace leakagesealitwith abeen damaged.if the lip shows signs of or has [A]. Be Assemble the oil sealengine. sure that the seal lip must face the inside of the in 0 1.0 mm Press thethe oil seal cover surface(0.04 in.) [B] flush or below crankcase [C].
NOTE
Governor Shaft Installation
engine oil to Apply the governor the governor shaft. crankcase. Insert the governorshaft into the [A] to the shaft [B] as Install shaft plate shown in the figure.
Check that the governor shaft moves freely in its operating range.
If the oil seal is removed, install the governor shaft first,
then install the oil seal.
Torque - Governor Shaft Plate Screws: 2.0 Nm (0.20 kgfm, 17 inlb)
NOTE
3-18 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 main jet and into the main nozzle, where it is joined by air from the main air passage (main air jet). The resulting mixture flows out of the main nozzle end into the carburetor bore, where it is atomized by the high speed air flow, and carried into the engine. Main Fuel Flow
FUEL SYSTEM 3-19

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 there is very little air flow through the carburetor bore; so little that it is not enough to draw fuel through the main system of the carburetor and to atomize it. Instead, the fuel is drawn through the pilot system, since the nearly closed throttle valve [K] causes high speed air flow through the pilot outlet and bypass holes (even at low engine speed). Fuel flow in the pilot system is metered by the pilot jet. Air for better atomization is admitted via the pilot air jet in the mouth of the carburetor. The fuel/air mixture passes into the bore of the carburetor side stream of the throttle valve through the bypass holes and pilot outlet. While the throttle valve is almost closed, it covers the small bypass holes opening into the bore from the pilot system. As the throttle valve begins to open, it uncovers the bypass holes, allowing more fuel/air mixture to flow. The extra flow is needed because the engine starts to run faster as the throttle is opened. The pilot screw controls the amount of fuel/air mixture allowed through the pilot outlet, but does not meter the bypass holes. A moderate amount of air comes in around the throttle valve at an idle, so adjusting the pilot screw changes the fuel/air ratio. Turning the pilot screw (idle mixture screw) out (counterclockwise) enriches the mixture; turning it in (clockwise) leans the mixture. Pilot Fuel Flow
3-20 FUEL SYSTEM

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 OFF position. The valve opens automatically when the switch key is turned to the Run position.
Low Idle Speed Adjustment
Refer to the Low Idle Speed Adjustment in the Periodic Maintenance chapter.
High Idle Speed Adjustment
Refer to the High Idle Speed Adjustment in the Periodic Maintenance chapter.
High Altitude Operation
At high altitude, the standard carburetor air-fuel mixture will be excessively rich. Performance will decrease, and fuel consumption will increase. High altitude performance can be improved by installing a smaller diameter main-jet in the carburetor and adjusting the idle speed.
The main jet high altitude kits are available for the equipHigh Altitude Main Jet
NOTE
ment used in the high altitude. The main jet numbers are stamped on the ends of the main jets.
Main Jet No. FH451V FH531V FH541V FH580V FH500V #125 #120 #116.3 #113.8 #111.3 #100 #98 #96 #105 #100 #98 FH601V FH641V FH680V FH661V FH721V FH680V and FH721V Late Models
Altitude
0 1 000 m (0 3 000 ft) 2 000 m (6 000 ft) and higher
L: #122 R: #128 L: #104 R: #108 L: #119 R: #125 L: #101 R: #105 L:# 116 R: #122 L: #98 R: #102
1 000 2 000 m (3 000 6 000 ft) #122.5
Main Jet Replacement
level surface. Place the engine (equipment) on aequipment. Close the fuel shut off valve in the Drain the fuel in the carburetor completely by unscrewing the drain screw at the bottom of the float chamber. Carburetor Removal). Remove the carburetor (seebolt [A] and take off the float Unscrew the float chamber bowl [B]. Starter model, unscrew For Electric the valve and gasket. the solenoid valve and take off
FUEL SYSTEM 3-21

Carburetor
screwdriver, carefully replace Using a proper standard tip one for expected altitude. the main jet (A) with a new jet to the Tighten the main Assemblyspecified torque (see Carburetor Disassembly Notes). Install the float chamber, gasket and float bowl bolt. For Electric Stater model, install the float chamber, gasket and solenoid valve.
For FH601V, FH641V, FH661V, FH680V, FH721V model; note the following.
Remove the carburetor (see Carburetor Removal). Unscrew the main jet plugs [C] and take off the main jet Make sure that L [L] or R [R] mark on the float shows
plugs and gaskets. the main jet position. Using a proper standard tip screwdriver, carefully replace the main jet [D] with a new one for expected altitude. Tighten the main jet to the specified torque (see Carburetor Disassembly/Assembly). Install the gasket and the main jet plug.
Torque - Main Jet Plug: 19 Nm (1.9 kgfm, 14 ftlb)
Fuel System Cleanliness Inspection
the Fuel System Cleanliness Inspection in the Refer to Maintenance chapter. Periodic
Carburetor Removal
WARNING
Gasoline is extremely flammable and can be explosive 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 pilot light.
Remove: and Related Parts (see Air Cleaner Body) Air Cleaner Turn the fuel shut off valve to the OFF position. Drain the carburetor. Disconnect the fuel tube at the fuel inlet joint [A] of the carburetor. model, disconnect the solenoid For Electric Starterremove the ground terminal. valve lead terminal and link [B] at Unhook the throttlelong springplier. the throttle shaft lever top end [C] with a nose the [D] Unhook theirthrottlewhileand choke link rods [E] at the top ends of arms pulling off the carburetor.
3-22 FUEL SYSTEM

Carburetor
For FH541V, FH580V model; see the figure.
For FH601V, FH641V, FH661V, FH680V, FH721V model; note the following.
a long nose plier. Unhook the link clip [F] and remove the throttle link rod [D] and choke link rods [E] at the ends of their arms while pulling off the carburetor.
Unhook the throttle link spring [B] at the link clip [F] with
Carburetor Installation
the surfaces of the Cleanand matingnew gaskets. carburetor and inlet manifold, fit the the new gaskets, the insulator, Install the inlet manifold,gasket and the inlet pipe in the the carburetor, the new sequence as shown.
For FH451V, FH500V, FH531 model; Inlet Manifold [A]

Gaskets [B] Insulator [C] Carburetor [D] Gasket [E] Stud Bolt [F]
For FH541V, FH580V model; Inlet Manifold [A]

Gaskets [B] Insulator [C] Carburetor [D] Gasket [E] Stud Bolt [F]
FUEL SYSTEM 3-23

Carburetor
For FH601V, FH641V, FH661V, FH680V, FH721V model; Inlet Manifold [A]
Gaskets [B] Insulator [C] Carburetor [D] Gasket [E]
the Air Cleaner Body Installation). Installcare air cleaner (see throttle link rod and choke link Take not to bend the rods during installation. Make sure that the link spring around the throttle link rod is in place and that it pulls the governor arm and carburetor throttle shaft lever toward each other.
Be sure that the fuel tube clip ends [A] face horizontal direction.
WARNING
Improper installation of the fuel inlet hose clamp can result in gasoline leakage and potential fire hazard. Be sure the clip ends of the hose clamp face in a horizontal direction. In a vertical position (see illustration), the clip ends [A] can come into contact with the inlet pipe and become loose.
Adjust: Pilot Screw Carburetor

Idle Speed
3-24 FUEL SYSTEM

Carburetor
Carburetor Disassembly/Assembly-FH451V, FH500V, FH531V
and assembly. Refer to the illustration for disassembly plugs) in the carpassage plugs (Ball There are severalnot remove them. buretor body. Do Before disassembly, mark the out side of choke valve and throttle valves for assembling them. pilot screw with new one Replace thewith the following aprocedure. if necessary in accordance
Carefully mark the position of the pilot screw limiter on
the carburetor body so that it can be installed and set to its original position later. Remove the limiter. Be careful not to turn the pilot screw at this point. Turn the pilot screw clockwise and count the number of turns until screw is gently seated in the pilot passage. Record the number of turns needed to close the screw. Turn out the pilot screw to replace it with a new one. Install the new pilot screw until the screw is gently seated. Then open the screw the same number of turns as recorded prior to removal. Align the limiter with the mark on the carburetor body to install, taking care not to turn the pilot screw. Install the choke valve and throttle valve on the shaft as the outside mark of them facing outside. Drive the float pin into the carburetor body. The big diameter side of the float pin must face the engine flange side. The fuel inlet valve seat is pressed into the carburetor body and is not replaceable. Assemble carburetor parts with recommended tightening torque (see Exploded View).
1. Limiter 2. Pilot Screw 3. Spring 4. Low Idle Speed Screw 5. Spring 6. Seal 7. Ring 8. Throttle Shaft 9. Throttle Valve 10. Screws 11. Pilot Jet 12. Screw 13. Choke Valve 14. Choke Shaft 15. Spring 16. Collar 17. Main jet 18. Float 19. Main Nozzle 20. Valve Seat
21. Float Bowl 22. Gasket 23. Bolt (Other than Solenoid Valve Type) 24. Gasket 25. Solenoid Valve (Electric Starter Model) 26. Drain Screw 27. Gasket 28. Float Pin 29. Snap Ring 30. Float Valve 31. Main Air Jet 32. Air Jet 33. Washer 34. E Type Circlip 35. Cap 36. Ground Lead (Electric Starter Model)
FUEL SYSTEM 3-25

Carburetor
Carburetor Disassembly/Assembly-FH541V, FH580V
and assembly. Refer to the illustration for disassembly plugs) in the carpassage plugs (Ball There are severalnot remove them. buretor body. Do Before disassembly, mark the out side of choke valve and throttle valves for assembling them. pilot screw with new one Replace thewith the following aprocedure. if necessary in accordance
Carefully mark the position of the pilot screw limiter on
the carburetor body so that it can be installed and set to its original position later. Remove the limiter. Be careful not to turn the pilot screw at this point. Turn the pilot screw clockwise and count the number of turns until screw is gently seated in the pilot passage. Record the number of turns needed to close the screw. Turn out the pilot screw to replace it with a new one. Install the new pilot screw until the screw is gently seated. Then open the screw the same number of turns as recorded prior to removal. Align the limiter with the mark on the carburetor body to install, taking care not to turn the pilot screw. Install the choke valve and throttle valve on the shaft as the outside mark of them facing outside. Drive the float pin into the carburetor body. The big diameter side of the float pin must face the choke value side. Assemble carburetor parts with recommended tightening torque (see Exploded View). 1. Limiter 2. Pilot Screw 3. Spring 4. Spacer 5. Low Idle Speed Screw 6. Spring 7. Screws 8. Throttle Valve 9. Throttle Shaft 10. Dust Seal 11. Choke Valve 12. Choke Shaft 13. Dust Seal 14. Solenoid Valve (Electric Starter Model) 15. Gasket 16. Float Bowl 17. Gasket 18. Float Pin 19. Float 20. Main Jet 21. Main Nozzle 22. Float Valve 23. Gasket 24. Screw (Other than Solenoid Valve Type)
3-26 FUEL SYSTEM

Carburetor
Carburetor Disassembly/Assembly-FH601V, FH641V, FH661V, FH680V, FH721V
and assembly. Refer to the illustration for disassembly plugs) in the carpassage plugs (Ball There are severalnot remove them. buretor body. Do Before disassembly, mark the out side of choke valve and throttle valves for assembling them. 1. Plug Pilot Screw 2. Pilot Screw 3. Low Idle Speed Screw 4. Spring 5. Seal 6. Collar 7. Throttle Valve 8. Screws 9. Throttle Shaft 10. Choke Valve 11. Choke Shaft 12. Seal 13. Float Valve 14. Float Pin 15. Float 16. Gasket 17. Float Bowl 18. Screw 19. Clamp 20. Plug Main Jet 21. Gasket 22. Main Jet: L 23. Main Jet: R 24. Slow Jet 25. Drain Screw 26. Spring 27. Gasket 28. Solenoid Valve
FUEL SYSTEM 3-27

Carburetor
Carburetor Disassembly/Assembly-FH680V and FH721V Late Models
and assembly. Refer to the illustration for disassembly plugs) in the carpassage plugs (Ball There are severalnot remove them. buretor body. Do Before disassembly, mark the out side of choke valve and throttle valves for assembling them. 1. Plug Pilot Screw 2. Pilot Screw 3. Gasket 4. Cover Plate 5. Screws 6. Low Idle Speed Screw 7. Spring 8. Seal 9. Collar 10. Throttle Valve 11. Screws 12. Throttle Shaft 13. Choke Valve 14. Choke Shaft 15. Seal 16. Main Jet (L) 17. Main Jet (R) 18. O-rings 19. Gasket 20. O-ring 21. Spacer 22. Pin 23. Float Valve 24. Float 25. O-ring 26. Gasket 27. Screws 28. Gasket 29. Solenoid Valve 30. Drain Screw 31. Spring
3-28 FUEL SYSTEM

Carburetor
pilot screw [A] with a new one Replace the with the following procedure. if necessary in accordance
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 count the number of turns until it seats fully but not tightly, then remove the screw. This is to set the screw to its original position when assembling. Turn in the new pilot screw [A] fully but not tightly, then back it out the same number of turns counted during disassembly. Install a new pilot screw plug [B] in the pilot screw hole by pressing with the rod [C], and apply a small amount of a bonding agent [D] around the plug to fix the plug. Install the choke valve and throttle valve on the shaft as the outside mark of them facing outside, and apply a small amount of a bonding agent to the valve screw threads.
CAUTION
Do not apply too much bonding agent to the valve. Screws themselves may be fixed. carburetor body. The big Drive the float pin into thethe throttle shaft lever side.side of the float pin must face The fuel inlet valve seat is pressed into the carburetor body and is not replacable. parts Assemble carburetor View). with specified tightening torque (see Exploded
FUEL SYSTEM 3-29

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 gasoline or low-flash point solvents to clean the carburetors.
CAUTION
Do not use compressed air on an assembled carburetor, or the floats may be crushed by the pressure. Remove as many rubber or plastic parts as possible from the carburetor before cleaning the carburetor with a cleaning solution. This will prevent from damage or deterioration of the parts. The carburetor body has plastic parts that cannot be removed. Do not use a strong carburetor cleaning solution which could attack these parts; instead, use a mild high-flash point cleaning solution safe for plastic parts. Do not use wire or any other hard instrument to clean carburetor parts, especially jets, as they may be damaged. the carburetor. Disassemble the carburetor metal parts in a carburetor Immerse all cleaning solution and clean them. Rinse the parts in water and dry them with compressed air. Do notoruse rags or paper to dry parts. Lint may plug the holes passages. Blow air through the holes and fuel passages with the compressed air. All holes must be open. Assemble the carburetor.
3-30 FUEL SYSTEM

Carburetor
Carburetor Inspection
WARNING
Gasoline is extremely flammable and can be explosive 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 light. for Flange Inspect the carburetor body anddamage.burns andsealing surfaces should be smooth free of nicks.
Replace the gasket with a new one if necessary. Turn the throttle and choke shafts to check that the throttle and choke butterfly valves move smoothly. If the valves do not move smoothly, replace the carburetor body and/or throttle shaft and choke shaft assembly with new ones. Check the gasket on the carburetor body. If the gasket is not in good condition, replace it with a new one. Check the other parts of the carburetor for any wear or damage. Replace the part with a new one if necessary. Clean and check the float level as follows.
CAUTION
Do not push down on the float during float level checking.
With the float [A] assembly installed onto the carburetor body [B], hold the carburetor upside down at eye level.
Gently support the float with a finger and bring it down slowly so that the float arm tab [C] just touches the float valve [D]. The float lower surface [E] should be parallel with the carburetor body mating surfaces [F]. If the float position is not correct, replace the float with a new one.
float valve wear or Inspect thebe smooth, for excessivegrooves, damage. The tip should without any scratches, or tears. The rod at the other end of the needle should move smoothly when pushed in and released. If either the needle or the seat is worn or damaged, replace the float assembly and carburetor body as a set with a new one.
FUEL SYSTEM 3-31

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.
FH601V, FH641V, FH661V, FH680V, For pilot screw is as shown in the figure. FH721V model; the
Fuel Shut Off Solenoid Valve Test (Electric Starter Model)
Unscrew athe fuel shut off valve and remove the valve.the Connect 12 VDC source to the solenoid as shown in figure.
If the actuated solenoid plunger (Needle Valve) does not pop out when the Test Voltage is applied, replace it with a new one.
If necessary, push the plunger slightly for the plunger to withdraw.
NOTE
3-32 FUEL SYSTEM

Inlet Manifold
Inlet Manifold Removal
Remove: (see Air Cleaner Body Removal) Air Cleaner

Engine Upper Cover Cut off the band [A] and release the harness and/or lead from the inlet manifold. Unscrew the manifold mounting bolts [B].
up middle section [A] then Then liftinginletthe inlet manifold carburetor [B] as shown pull out the manifold from the in the figure.
Inlet Manifold Installation
gaskets with new ones. Replace the inlet manifold of the cylinders and inlet manClean the mating surfaces ifolds and fit new gaskets [A]. [B] Distance (FH451V, FH500V, FH531V): 6 mm (0.24 in.) [B] Distance (FH541V, FH580V): 0 mm (0 in.) [B] Distance (FH601V, FH641V, FH661V, FH680V, FH721V): 12 mm (0.47 in.) the surfaces of the carburetor and inlet man Cleanand mating the new gaskets [A] and insulator [B] in ifolds install
the sequence as shown in the figure. Install the inlet manifold. Tighten the mounting bolts.
Torque - Inlet Manifold Mounting Bolts: kgfm, 52 inlb) 5.9 Nm (0.60
[A] around Install and tighten the bandharness [D]. the manifold [B] and the lead [C] and/or the
Position the lead and/or the harness on top of the manifold
as shown in the figure. Cut the excessive band off. Install the other removed parts in the reverse order of the disassembly.
FUEL SYSTEM 3-33

Inlet Manifold
Inlet Manifold Inspection
the inlet manifold for cracks casting. Inspect not visible to the eye may beor porous by using a Cracks detected metal crack detection system (Visual color check: commonly found at automotive parts stores). If a crack is present in the inlet manifold, replace it with a new one. Inspect the gasket surfaces for burns and nicks.
3-34 FUEL SYSTEM

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 Inspection
Check the vent hole [A] and the filter [B] for plugging or clogging.
If the vent hole and the filter are plugged or clogged, remove the foreign material from them.
Fuel Flow Test:
WARNING
Gasoline is extremely flammable and can be explosive 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 pilot light. the fuel pump outlet nozzle Disconnectsuitable hose [A] to the outletfrom the tube. Connect a nozzle. Run the lower end of the hose into a container. Start the engine. Check the fuel flow. If fuel flow is none or little, replace the fuel pump with a new one. Check the tubes and the fuel filter for clogging or damage. Replace the clogged or damaged tubes of fuel filter with new ones.
Fuel Filter Inspection
fuel filter [A]. Visually inspect thewith no signs of dirt or other contamiIf the filter is clear nation, replacement of the fuel filter is not necessary. If the filter is dark or looks dirty, replace it with a new one. Also check the rest of the fuel system for contamination.
FUEL SYSTEM 3-35

Air Cleaner (Standard Type)
Element Removal
FH451V, FH500V, FH531V, FH541V, FH580V Pull the hooks [A] to outside and remove the air cleaner cover [B].
Remove: [A] Wing Bolt

Foam Element [B] Paper Element [C]
Element Removal
FH601V, FH641V, FH661V, FH680V, FH721V Remove Air Cleaner Case Nut Air Cleaner Case Wing Nut [A] Foam Element [B] Paper Element [C]
Element Installation
correctly cleaner body. Install the elementthe paper on the airinto the air cleaner Be sure to install element body. Be sure to install the foam element on the paper element.
to the Element Cleaning Refer Maintenance chapter. and Inspection in the Periodic
Air Cleaner Body Removal

FH451V, FH500V, FH531V, FH541V, FH580V Remove the elements (see Element Removal). Remove the air cleaner body mounting screws [A], the holder plate nuts [B] and the holder plate [C].
3-36 FUEL SYSTEM

[A] off the Pull the breather tube air cleaner pipe at the back of the body, and remove the body [B].
FH601V, FH641V, FH661V, FH680V, FH721V Remove the element (see Element Removal). Remove the clamp [A], and pull off the breather tube [B]. Loosen the nuts [C] and remove the solenoid valve lead [D]. Unscrew the bolts [E] and remove the inlet pipe [F].
Air Cleaner Body Installation

FH451V, FH500V, FH531V, FH541V, FH580V Connect the breather tube from the crankcase to the pipe at the back of the air cleaner body. Tighten the holder plate nuts and the air cleaner body mounting screws.
Torque - Holder Plate Nuts: 5.9 Nm (0.60 kgfm, 52 inlb) Air Cleaner Body Mounting Screws 3.4 Nm (0.35 kgfm, 30 inlb)
FH601V, FH641V, FH661V, FH680V, FH721V Replace the inlet pipe gaskets with new ones. Clean the mating surfaces of the carburetor and the inlet pipe. Install the inlet pipe and solenoid valve lead. Tighten the mounting bolts and nuts.
the sleeve inlet pipe. Install in the sleeveon the the inlet pipe [B] fixing the groove Press [A] to [C] to the projection [D] as shown in the figure. Connect the breather tube to the pipe at the inlet pipe and clip it with a clamp.
Torque - Inlet Pipe Mounting Bolts and Nuts: 5.9 Nm (0.60 kgfm, 52 inlb)
FUEL SYSTEM 3-37

3-38 FUEL SYSTEM

Air Cleaner (Heavy Duty Type)
Element Removal
retaining clamps Unhook the twocleaner body. [A] and remove the cap [B] from the air
Remove: Element [A] Primary

Secondary Element [B]
For FH541V, FH580V Remove: Element [A]
Element Installation
secondary element Slide thethe air cleaner body. and primary element into place in Install the cap [A] direction as shown. Mark [B]
Upside [C] Fasten the two retaining clamps [D].
For FH541V, FH580V Slide the element into place in the air cleaner body. Install the cap [A] direction as shown. Mark [B] Upside [C] 15 [D] Fasten the two retaining clamps [E].
to the Element Cleaning Refer Maintenance chapter. and Inspection in the Periodic
FUEL SYSTEM 3-39

Air Cleaner Body Removal
Remove the air cleaner elements (see Element Removal). Loosen the clamps [A], and remove the inlet hose [B]. [C]. Remove the boltcleaner body [D] from the arrow side [E] Take out the air in the figure.
Air Cleaner Body Bracket Bolts [F] Air Cleaner Body Bracket [G]
For FH541V,FH580V Clamps [A] Inlet Hose [B] Bolt [C] Air Cleaner Body [D] Arrow Side [E] Air Cleaner Body Bracket Bolts [F] Air Cleaner Body Bracket [G]
3-40 FUEL SYSTEM

Air Cleaner Body Installation
air cleaner Install thetorque. body bracket with the bolts to the specified the body Setinlet air cleanerfacing [A] onto the bracket so that the air duct [B] is upward. Install the inlet hose [C], and position the clamps [D] pinch heads as shown.
Torque - Air Cleaner Body Bracket Bolts: 5.9 Nm (0.60 kgfm, 52 inlb)
Install the air cleaner body clamp bolt [A] as shown and tighten it.
Collar [B] Spring [C] Nut [D] Install the air cleaner elements (see Element Installation). Install the cap as shown.
For FH541V,FH580V Air Cleaner Body [A] Air Inlet Duct [B] Inlet Hose [C] Clamps [D]
FUEL SYSTEM 3-41

Air Cleaner Body Clamp Bolt [A] Collar [B] Spring [C] Nut [D] 15 [E]
Housing (Cap and Body) Inspection
the Housing Refer to Maintenance (Cap and Body) Inspection in the Periodic chapter.
COOLING SYSTEM 4-1
Cooling System
Table of Contents
Exploded View........................................................................................................................ Cooling Fan ............................................................................................................................ Cooling Fan Removal ....................................................................................................... Cooling Fan Installation .................................................................................................... Cooling Fan Inspection ..................................................................................................... Screen Clearance Adjustment .......................................................................................... 4-2 4-4 4-4 4-4 4-4 4-4
4-2 COOLING SYSTEM

Exploded View
COOLING SYSTEM 4-3

Exploded View
[FH451V, FH500V, FH531V] T1: 3.9 Nm (0.40 kgfm, 35 inlb) T2: 5.9 Nm (0.60 kgfm, 52 inlb) T3: 17 Nm (1.7 kgfm, 12.0 ftlb) T4: 56 Nm (5.7 kgfm, 41 ftlb) T5: 7.8 Nm (0.80 kgfm, 69 inlb) [FH541V, FH580V] T1: 3.9 Nm (0.40 kgfm, 35 inlb) T2: 5.9 Nm (0.60 kgfm, 52 inlb) T3: 17 Nm (1.7 kgfm, 12.0 ftlb) T4: 56 Nm (5.7 kgfm, 41 ftlb) T5: 7.8 Nm (0.80 kgfm, 69 inlb) [FH601V, FH641V, FH661V, FH680V, FH721V] T1: 3.9 Nm (0.40 kgfm, 35 inlb) T2: 5.9 Nm (0.60 kgfm, 52 inlb) T3: 17 Nm (1.7 kgfm, 12.0 ftlb) T4: 56 Nm (5.7 kgfm, 41 ftlb) T5: 7.8 Nm (0.80 kgfm, 69 inlb) 1. Stud (Before 2002/4 Product Model) 2. Stud (On and after 2002/5 Product Model) 3. Cooling Fan (Late Model) 4. Cooling Fan (Early Model) A: Recoil Starter Model B: Electric Starter Model
4-4 COOLING SYSTEM

Cooling Fan
Cooling Fan Removal
Refer to the Flywheel Removal in Electrical System chapter.

Cooling Fan Installation
Refer to the Flywheel Installation in Electrical System chapter.

Cooling Fan Inspection
the blades [B]. Visually inspect crack, warp[A] in the cooling fan the coolIf they have any or damage, replace ing fan with a new one. If any mud or dust have stuck to the cooling fan, clean it. Wash the cooling fan in detergent and water.
CAUTION
Do not clean the cooling fan in oil solvent. It may be damage by oil solvent.
Screen Clearance Adjustment
fan Check the clearance between the screen1[A] and thein.), housing [B]. If the clearance is less than mm (0.04 add proper number of the spacer [C] between the screen and the bracket comp [D] to adjust the clearance [G] 1 3 mm (0.04 0.12 in.). Screws [F] Clearance 1 3 mm (0.04 0.12 in.) [G]
ENGINE TOP END 5-1
Engine Top End

Table of Contents
Exploded View........................................................................................................................ Specifications ......................................................................................................................... Cylinder Head......................................................................................................................... Compression Measurement.............................................................................................. Cylinder Head Assembly Removal ................................................................................... Cylinder Head Assembly Installation ................................................................................ Push Rod Removal ........................................................................................................... Push Rod Installation ........................................................................................................ Push Rod Inspection......................................................................................................... Valve Mechanism Removal/Installation ............................................................................ Valves ..................................................................................................................................... Cylinder Head Cleaning and Inspection............................................................................ Valve Clearance Inspection .............................................................................................. Valve Clearance Adjustment............................................................................................. Valve Seat Inspection ....................................................................................................... Valve Seat Repair ............................................................................................................. Valve Head Thickness ...................................................................................................... Valve Stem Runout ........................................................................................................... Valve Stem Diameter ........................................................................................................ Valve Guide Inside Diameter ............................................................................................ Valve Spring Inspection .................................................................................................... Cylinder, Piston....................................................................................................................... Piston Removal................................................................................................................. Piston Installation.............................................................................................................. Piston/Cylinder Seizure..................................................................................................... Piston Cleaning................................................................................................................. Piston Ring and Ring Groove Wear.................................................................................. Piston Ring End Gap ........................................................................................................ Piston Pin, Piston Pin Hole, and Connecting Rod Wear................................................... Piston Diameter ................................................................................................................ Cylinder Inside Diameter................................................................................................... Cylinder Boring and Honing .............................................................................................. Muffler/Exhaust Pipe Installation ............................................................................................ Muffler/Exhaust Pipe Removal.......................................................................................... Muffler/Exhaust Pipe Installation....................................................................................... Inspection.......................................................................................................................... 5-2 5-6 5-9 5-9 5-10 5-10 5-11 5-11 5-12 5-12 5-13 5-13 5-13 5-13 5-13 5-13 5-13 5-13 5-13 5-14 5-14 5-15 5-15 5-16 5-18 5-19 5-19 5-20 5-20 5-21 5-21 5-22 5-24 5-24 5-24 5-25
5-2 ENGINE TOP END

Exploded View
ENGINE TOP END 5-3

Exploded View
[FH451V, FH500V, FH531V] T1: 5.9 Nm (0.60 kgfm, 52 inlb) T2: 6.9 Nm (0.70 kgfm, 61 inlb) T3: 25 Nm (2.6 kgfm, 19.5 ftlb) T4: 28 Nm (2.8 kgfm, 20 ftlb) T5: 22 Nm (2.2 kgfm, 16 ftlb) [FH541V, FH580V] T1: 9.8 Nm (1.0 kgfm, 87 inlb) T2: 6.9 Nm (0.70 kgfm, 61 inlb) T3: 25 Nm (2.6 kgfm, 19.5 ftlb) T4: 28 Nm (2.8 kgfm, 20 ftlb) T5: 22 Nm (2.2 kgfm, 16 ftlb) [FH601V, FH641V, FH661V, FH680V, FH721V] T1: 21 Nm (2.1 kgfm, 15 ftlb) (For M7 P1.0 screw thread spec.) T1: 9.8 Nm (1.0 kgfm, 87 inlb) (For M6 P1.0 screw thread spec.) T2: 6.9 Nm (0.70 kgfm, 61 inlb) T3: 25 Nm (2.6 kgfm, 19.5 ftlb) T4: 28 Nm (2.8 kgfm, 20 ftlb) T5: 22 Nm (2.25 kgfm, 16 ftlb) G: Apply grease. O: Apply engine oil. S: Follow the specified tightening sequence.
5-4 ENGINE TOP END

Exploded View
ENGINE TOP END 5-5

Exploded View
[FH451V, FH500V, FH531V] T2: 15 Nm (1.5 kgfm, 11.0 ftlb) [FH541V, FH580V] T2: 15 Nm (1.5 kgfm, 11.0 ftlb) [FH601V, FH641V, FH661V, FH680V, FH721V] T2: 15 Nm (1.5 kgfm, 11.0 ftlb) 1. Muffler Comp for Late Models. 2. Muffler Comp for Early Models.
5-6 ENGINE TOP END

Specifications
Item Cylinder Head Cylinder Compression (MIN) Cylinder Head Warp Valves Valve Head Thickness Inlet, Exhaust Valve Stem Runout Inlet, Exhaust Valve Stem Diameter Inlet Exhaust Valve Clearance Inlet, Exhaust Valve Seating Surface Angle Inlet, Exhaust Valve Seating Surface Width Inlet, Exhaust Valve Guide Inside Diameter Inlet, Exhaust Valve Spring Free Length Inlet, Exhaust Rocker Arm Push Rod Runout Inlet, Exhaust Cylinder, Piston Piston Diameter Piston Ring/Groove Clearance Top Second Piston Ring Thickness Top, Second Piston Ring End Gap Top Second Oil Piston Pin Outside Diameter Piston Pin Hole Inside Diameter Connecting Rod Small End Inside Diameter Cylinder Inside Diameter: Standard Cylinder 0.50 mm Oversize Cylinder Inside Diameter Out Round Service Limit FH451V, FH500V, FH531V [390 kPa (57 psi)] (MIN) 0.05 mm (0.002 in.) FH541V, FH580V
0.35 mm (0.014 in.) 0.05 mm (0.002 in.) 5.95 mm (0.0234 in.) 5.93 mm (0.0233 in.) (Standard) 0.10 0.15 mm (0.004 0.006 in.) (Standard) 45 (Standard) 0.6 0.9 mm (0.024 0.035 in.) 6.08 mm (0.239 in.) 31.0 mm (1.22 in.) 0.5 mm (0.02 in.) 67.79 mm (2.669 in.) 0.15 mm (0.006 in.) 0.12 mm (0.005 in.) 1.40 mm (0.055 in.) 0.70 mm (0.028 in.) 0.78 mm (0.031 in.) 1.05 mm (0.041 in.) 15.96 mm (0.628 in.) 16.08 mm (0.633 in.) 16.05 mm (0.632 in.) 68.10 mm (2.681 in.) 68.60 mm (2.701 in.) 0.056 mm (0.0022 in.)
73.79 mm (2.905 in.) 74.10 mm (2.917 in.) 74.60 mm (2.937 in.)
ENGINE TOP END 5-7

Specifications
Item Cylinder Head Cylinder Compression (MIN) Cylinder Head Warp Valves Valve Head Thickness Inlet, Exhaust Valve Stem Runout Inlet, Exhaust Valve Stem Diameter Inlet Exhaust Valve Clearance Inlet, Exhaust Valve Seating Surface Angle Inlet, Exhaust Valve Seating Surface Width Inlet Exhaust Valve Guide Inside Diameter Inlet, Exhaust Valve Spring Free Length Inlet, Exhaust Rocker Arm Push Rod Runout Inlet, Exhaust Cylinder, Piston Piston Diameter Piston Ring/Groove Clearance Top Second Piston Ring Thickness Top, Second Piston Ring End Gap Top Second Oil Piston Pin Outside Diameter Piston Pin Hole Inside Diameter Connecting Rod Small End Inside Diameter Cylinder Inside Diameter: Standard Cylinder 0.50 mm Oversize Cylinder Inside Diameter Out Round Service Limit FH601V, FH641V, FH661V, FH680V, FH721V [390 kPa (57 psi)] (MIN) 0.05 mm (0.002 in.)
0.35 mm (0.014 in.) 0.05 mm (0.002 in.) 5.95 mm (0.0234 in.) 5.93 mm (0.0233 in.) (Standard) 0.10 0.15 mm (0.004 0.006 in.) (Standard) 45 (Standard) 0.8 1.4 mm (0.03 0.06 in.) 1.1 1.6 mm (0.04 0.06 in.) 6.08 mm (0.239 in.) 31.0 mm (1.22 in.) 0.5 mm (0.02 in.) 74.99 mm (2.952 in.) 0.18 mm (0.007 in.) 0.16 mm (0.006 in.) 1.40 mm (0.055 in.) 0.65 mm (0.026 in.) 0.78 mm (0.031 in.) 1.05 mm (0.041 in.) 15.96 mm (0.628 in.) 16.08 mm (0.633 in.) 16.05 mm (0.632 in.) 75.28 mm (2.964 in.) 75.78 mm (2.983 in.) 0.056 mm (0.0022 in.)
5-8 ENGINE TOP END

Specifications
Special Tools - Piston Ring Pliers: 57001-115 Compression Gauge, 20 kgf/cm: 57001-221 Piston Ring Compressor Grip: 57001-1095 Piston Ring Compressor Belt, 67 79: 57001-1097 Compression Gauge Adapter, M14 1.25: 57001-1159 Valve Seat Cutter Holder Bar: 57001-1128 Valve Seat Cutter Holder, 6: 57001-1360 Valve Seat Cutter, 45 - 35: 57001-1116 Valve Seat Cutter, 32 - 33: 57001-1199 Valve Seat Cutter, 45 - 30: 57001-1187 Valve Seat Cutter, 32 - 30: 57001-1120
ENGINE TOP END 5-9

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 running. Stop the engine. Disconnect the spark plug caps of each cylinder and remove the spark plugs. Attach the compression gauge assembly firmly into one plug hole.
Special Tools - Compression Gauge, 20 kgf/cm: 57001-221 [A] Compression Gauge Adapter, M14 1.25: 57001-1159
Ground the spark plugs to the engine.

WARNING
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. Run Open the throttle fully. timesthe engine by pulling the recoil starter grip several until the compression gauge stops rising. Read the highest compression value. (Recoil starter model) the throttle fully. Openswitch key several Run the engine by turning the engine times until the compression gauge stops rising. Read the highest compression value. (Electric starter model) the Repeat the measurement onthan other cylinder.value, the If the compression is higher the specified 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 - worn valve guides and/or worn piston oil rings may cause rapid carbon accumulation in the combustion chamber. This may be indicated by white exhaust smoke. If the cylinder compression is lower than the (MIN), check the following: 1. Gas leakage around the cylinder head - replace the damaged gasket with a new one 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.
Cylinder Compression (MIN) 390 kPa (57 psi) Cylinder Compression (MIN) 390 kPa (57 psi)
5-10 ENGINE TOP END

Cylinder Head
Cylinder Head Assembly Removal
Remove: and Carburetor (see Fuel System chapter) Air Cleaner

Muffler (see Muffler Exhaust Pipe Removal) Inlet Manifold (see Fuel System chapter) Spark Plug Unscrew the rocker cover mounting bolts [A], and remove the cover [B] and the gasket.
removing the #1, When the top dead center#2 cylinder head, set each piston at (T.D.C) [A] of the compression stroke.
Loosen the cylinder head bolts 1/4 turn in the sequence as shown in the figure.
CAUTION
If the above procedure is not followed, the cylinder head may be warped during removal. the sequence until all Repeatcylinder head assembly.bolts are removed and lift off the
Mark the push rods to reinstall in their original position during assembly.
Cylinder Head Assembly Installation
NOTE
Clean the mating surfaces of the cylinder heads and cylinders. their original Install the push rods in Installation). positions on each cylinder (see Push Rod Install the knock pins.the T.D.C [A] of the compression Set each piston at stroke. the cylinder head Put new gaskets and the cylinder heads assemblies on each cylinder, then let with push rods
aligned under the rocker arms.
As the head gaskets are coated with sealing agents, be

careful not to damage the surfaces.
NOTE
ENGINE TOP END 5-11

Cylinder Head
Tighten the cylinder head bolts following the tightening sequence in the figure.
Torque - Cylinder Head Bolts: 25 Nm (2.6 kgfm, 19.0 ftlb)
CAUTION
A torque wrench must be used to assure proper torque. Improper tightening of the head bolts may result in warping of the cylinder head. and adjust Check the gasketsthe valve clearance. Install and rocker covers.
Install the other removed parts.

Push Rod Removal
Torque - Rocker Cover Mounting Bolts: kgfm, 52 inlb)
5.9 Nm (0.60
piston at Set eachthe rockerthe T.D.C of the compression stroke. covers (see Cylinder Head Assembly Remove Removal). valve adjusting nuts [A]. Loosen therocker clearanceto clear the push rod upper Move the arms [B] ends. Pull out the push rods.
Mark the push rods to reinstall in their original position

during assembly.
NOTE
Push Rod Installation
at the T.D.C of the compression Set each pistonrods [A] in their original positions stroke. Install the push on each cylinder.
To Install the push rod in a correct position on the tappet
[B], insert the push rod so that the end of the push rod is sliding down [C] along inside wall [D] of the crankcase and position the push rod end on to the tappet. Check that both inlet and exhaust push rods on each cylinder are at lowest position on the cam lobes [E]. If the piston is not at the T.D.C of the compression stroke, turn the flywheel clockwise one turn (360) and reset each piston at the T.D.C of the compression stroke. Be sure the end of the push rods are correctly seated on the tappets. Tighten the valve clearance adjusting nuts. Check and adjust the valve clearance.
5-12 ENGINE TOP END

Cylinder Head
Push Rod Inspection
push rod far apart as Place thedial gaugeon V blocks ashalfway pointpossible, and set a on the rod at a between the blocks. Turn the rod to measure the runout. The difference between the highest and the lowest dial readings is the amount of runout. If the runout exceeds the service limit, replace the rod with a new one.
Rocker Arm Push Rod Runout Service Limit: 0.5 mm (0.02 in.)
Valve Mechanism Removal/Installation
Remove the cylinder head assembly (see Cylinder Head Assembly Removal).
When removing the valve mechanism parts, record their
NOTE
position to reinstall in their original position during assembly.
Remove: Valve Clearance Adjusting Nuts [A]

Rocker Arms [B]
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].
Remove the stem seals only if the replacement of the stem seals is necessary. Valve guide [B] is not replaceable, do not remove it.
NOTE
Installation. Valve engine oil to the valve stems to avoid damaging the Apply
stem seals. Check to see that the valve moves up and down smoothly in the guide . Check the valve seating surface [A] between the valve [B] and the valve seat [C]. Rocker Arm Installation Soak the valve clearance adjusting nuts and the rocker arm in the engine oil. Install the rocker arm.
ENGINE TOP END 5-13

Valves
Cylinder Head Cleaning and Inspection
Refer to the Cylinder Head Cleaning and Inspection in the Periodic Maintenance chapter.
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 the Periodic Maintenance chapter.

Valve Seat Repair
Refer to the Valve Seat Repair in the Periodic Maintenance chapter.

Valve Head Thickness
Remove the valve (see Valve Mechanism Removal/Installation). Measure the valve head thickness. If the valve head thickness (valve margin) [A] is less than
the service limit, replace the valve with a new one.
Valve Head Thickness Service Limit (Inlet, Exhaust): 0.35 mm (0.014 in)
Valve Stem Runout
end of the Support the valve on V blocks at each the stem. stem. Position a dial gauge perpendicular to Turn the valve and read the variation on the dial gauge. If the stem runout is greater than service limit, replace the valve.
Valve Stem Runout Service Limit (Inlet, Exhaust): 0.05 mm (0.002 in.)
Valve Stem Diameter
the diameter [A] in two direc Measureproper angles,ofatthe valve stem positions on the tions at four different stem. If any single measured valve stem diameter is less than the service limit, replace the valve with a new one.
Valve Stem Diameter Service Limit: Inlet: Exhaust: 5.95 mm (0.234 in.) 5.93 mm (0.233 in.)
5-14 ENGINE TOP END

Valves
Valve Guide Inside Diameter
small bore Use a diameter [A]gauge or a micrometer to measure the inside 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 one.
Valve Guide Inside Diameter Service Limit: Inlet, Exhaust 6.08 mm (0.239 in.)
Valve Spring Inspection
the valve spring rusting, and InspectReplace the springfor pitting, cracks, necessary. burns. with a new one if length [A] of the Measure the freefree length is lessspring. service limit, If the measured than the replace the spring with a new one.
Valve Spring Free Length Service Limit: 31.0 mm (1.22 in.)
ENGINE TOP END 5-15

Cylinder, Piston
Piston Removal
Camshaft/Crankshaft chapter). Split the crankcase (see(see Camshaft/Crankshaft chapRemove the camshaft ter). the Turn [A]. crankshaft to expose the connecting rod cap bolts Remove the bolts and take off the connecting rod caps [B].
Record the positions of the connecting rod caps for reinstalling the caps.
NOTE
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 cylinder K Mark on the connecting rod is face to face with No.2 cylinder K Mark on the connecting rod. Keep parts together as a set.
Remove the piston pin snap ring [A] with needle nose pliers [B].
the piston pin [A] Remove frompiston by pushing thewas removed. to the direction which the snap ring
5-16 ENGINE TOP END

Cylinder, Piston
Remove the top and second rings with piston ring pliers.
not available, carefully spread the ring If the special tool isthumbs, then push up to the opposite opening with your
Special Tool - Piston Ring Pliers: 57001-115
side of the ring [A] to remove it. Remove the 3-piece oil ring with your thumbs in the same manner.
Piston Installation
in the piston oil Install the expander [A][B] touch together,ring groove so that the expander ends never overlap
them. Install the upper and lower steel rails. There is no UP or Down to the rails. They can be installed either way.
mix up the top and second Do notthe top and second rings as rings. in the figure. Install shown The rings should turn freely in the grooves. Piston Head [A] Top Ring for FH451V, 500V, 531V, 541V, 580V [B] Second Ring for FH451V, 500V, 531V, 541V, 580V [C] Top Ring for , FH601V, 641V, 661V, 680V, 721V [D] Second Ring for FH601V, 641V, 661V, 680V, 721V [E]
Align the piston and rings with the piston ring end gap as shown in the figure.
Arrow Match Marks [A] Top Ring End Gap, Upper Steel Rail End Gap [B] 30 45 [C] Second Ring End Gap, Lower Steel Rail End Gap [D]
piston Apply engine oil to theonto thepins. Assemble the pistons No.1 cylinder piston; align theconnecting rods as follow: arrow match mark on the piston crown with the K mark on the connecting rod. Both marks must face the PTO side. No.2 cylinder piston; align the arrow match mark on the piston head with K Mark on the connecting rod to face the magnet side. No.1 cylinder Piston [A] No.2 cylinder Piston [B] Arrow Match Marks [C] K Mark [D] Opposite K Mark [E]
ENGINE TOP END 5-17

Cylinder, Piston
only When installing ait.piston pin snap ring, compress itsnap enough to install Do not compress the piston pin
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 the edge of the piston pin hole.
CAUTION
Do not reuse the snap rings, as removal weakens and deforms them. They could fall out and score the cylinder wall. and the cylinder bore. Apply engine oil to the piston skirtgrip [A] and the belt [B], Using the piston ring compressor lightly tap the top of the piston with a plastic mallet [C] to insert the piston and connecting rod into the cylinder.
Special Tools - Piston Ring Compressor Grip: 57001-1095 Piston Ring Compressor Belt, 67 79: 57001-1097
the connecting rod so Insert the piston andthe piston crown facesthat the arrow match mark [A] on the flywheel side [B].
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. oil to Apply engine[B] andthe inner surface [A] of the connecting rod big end caps [C]. Install the connecting rod big end caps on their original position on each connecting rod big ends. layer Apply a thin[E] of of engine oil to the thread [D] and seating surface the cap bolts. Tighten the cap bolts.
Install: (see Camshaft/Crankshaft chapter) Camshaft

Piston/Cylinder Seizure
Torque - [FH451V, 500V, 531V] Connecting Rod Big End Cap Bolts: 5.9 Nm (0.60 kgfm, 52 inlb) [FH541V, 580V] Connecting Rod Big End Cap Bolts: 9.8 Nm (1.0 kgfm, 87 inlb) [FH601V, 641V, 661V, 680V, 721V] Connecting Rod Big End Cap Bolts (For M7 P1.0 screw thread spec.: 21 Nm, 2.1 kgfm, 15 inlb) Connecting Rod Big End Cap Bolts (For M6 P1.0 screw thread spec.: 9.8 Nm, 1.0 kgfm, 87 inlb)
Crankcase Cover (see Camshaft/Crankshaft chapter)
In case of seizure, remove the piston. for damage. inspect the Visually is only light cylinder and piston damaged piston If there damage, repair the
surface with #400 emery cloth. Remove the small aluminum deposits from the cylinder with #400 emery cloth or light honing. If the damage is severe, the both cylinders must be bored to fit bigger size piston and install the oversized pistons.
ENGINE TOP END 5-19

Cylinder, Piston
Piston Cleaning
Remove the piston and the piston rings (see Piston Removal).
CAUTION
Never clean the piston head with the engine assembled. Carbon particles will fall between the piston and cylinder, and damage the crankshaft bearings. head. Scrape the carbon off [A] the piston not gouge the piston Use the scraping tools carefully. Do head. To avoid gouging, use scrapers that material will
not damage the piston head. 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
(see Piston Cleaning). Clean the pistonthe piston rings and ring grooves. Visually inspect If the piston rings are worn unevenly or damaged, replace them with new ones. If the ring grooves are worn unevenly or damaged, replace both the piston and the piston rings with new ones. Check ring grooves for wear by inserting a new ring in the proper groove at several points around the piston. Measure the clearance between the top and second rings and their grooves using a thickness gauge [A] as shown in the figure. If the piston ring/groove clearance is greater than the service limit, replace the piston with a new one.
Service Limit FH451V, FH500V, FH531V Top 0.15 mm (0.006 in.) FH601V, FH641V, FH541V, FH661V, FH680V, FH580V FH721V 0.18 mm (0.007 in.) 0.16 mm (0.006 in.)
Piston Ring/Groove Clearance
Second 0.12 mm (0.005 in.)
The oil ring is a three piece assembled ring.
NOTE
It is difficult to measure the ring groove clearance and the thickness. Visually inspect the oil ring, the ring groove clearance and the oil ring thickness.
5-20 ENGINE TOP END

Cylinder, Piston
Measure the piston ring thickness [A].thickness at several Use a micrometer to measure the ring
Piston Ring Thickness Service Limit Top, Second 1.40 mm (0.055 in.)
points around the rings. If any of the measurement are less than the service limit, replace the entire set of rings with new ones.
When using new rings in a used piston, check if the
NOTE
groove wear is even. The rings should fit perfectly parallel to the groove sides. If not, replace the piston with a new one.
Piston Ring End Gap
piston rings. Remove thering (one at a time) in the cylinder bore to a Push each point close to the bottom of the cylinder bore.
Use the piston to push it in to be sure it is square.
gap [A] Measure thegauge. between the ends of the ring [B] with a thickness If the end gap of any ring is greater than the service limit, replace the entire set of rings with new ones.
Piston Ring End Gap Service Limit FH451V, FH500V, FH531V Top Oil 0.70 mm (0.028 in.) 1.05 mm (0.041 in.) FH601V, FH641V, FH541V, FH661V, FH680V, FH580V FH721V 0.65 mm (0.026 in.)
Second 0.78 mm (0.031 in.)
Piston Pin, Piston Pin Hole, and Connecting Rod Wear
Remove the piston pin.of the piston pin diameter with a Measure theatdiameter points. micrometer several
If the outside diameter is less than service limit, replace the piston pin with a new one.
Piston Pin Outside Diameter Service Limit: 15.96 mm (0.628 in.)
ENGINE TOP END 5-21

Cylinder, Piston
the [A] the piston pin hole Measurepointsinside diameterUse of dial bore gauge. at several on both side. a If the inside diameter is greater than the service limit, replace the piston with a new one.
Piston Pin Hole Inside Diameter Service Limit: 16.08 mm (0.633 in.)
inside diameter [A] Measure theseveral points. Use aof the connecting rod small end at dial bore gauge. If the inside diameter is more than the service limit, replace the connecting rod with a new one.
Connecting Rod Small End Inside Diameter Service Limit: 16.05 mm (0.632 in.)
Piston Diameter
the outside of the piston 12.5 mm Measure [B] up from diameter [A]of the piston at a right (0.9 in.) the bottom angle to the direction of the piston pin hole. If the measured outside diameter is less than the service limit, replace the piston with a new one.
Piston Diameter Model FH451V, FH500V, FH531V FH541V, FH580V FH601V, FH641V, FH661V, FH680V, FH721V Service Limit 67.79 mm (2.669 in.) 73.79 mm (2.905 in.) 74.99 mm (2.952 in.)
Cylinder Inside Diameter
Clean and measure the cylinder inside diameter.and side Use a cylinder gauge to measure front-to-back
-to-side at the points as shown in the figure. If any of the cylinder inside diameter measured value is greater than the service limit, the cylinder must be bored to the next oversize and then honed (see Cylinder Boring and Honing).
5-22 ENGINE TOP END

Cylinder, Piston
Cylinder Inside Diameter Model Item Standard 67.98 68.00 mm (2.676 2.677 in.) 68.48 68.50 mm (2.696 2.697 in.) 73.98 74.00 mm (2.912 2.913 in.) 74.48 74.50 mm (2.932 2.933 in.) 75.18 75.20 mm (2.960 2.961 in.) 75.68 75.70 mm (2.979 2.980 in.) Service Limit 68.10 mm (2.681 in.) 68.60 mm (2.701 in.) 74.10 mm (2.917 in.) 74.60 mm (2.937 in.) 75.28 mm (2.964 in.) 75.78 mm (2.983 in.)
Standard FH451V, Cylinder FH500V, FH531V 0.5 mm Oversize Cylinder Standard FH541V, Cylinder FH580V 0.5 mm Oversize Cylinder FH601V, FH641V, FH661V, FH680V, FH721V Standard Cylinder 0.5 mm Oversize Cylinder
Cylinder Inside Diameter Out Round Standard: 0.01 mm (0.004 in.) Service Limit: 0.056 mm (0.0022 in.)
Cylinder Boring and Honing

Always resize to exactly 0.5 mm (0.02 in.) over the standard bore size. If this is done accurately, the stock oversize rings and piston will fit perfectly and proper clearance will be maintained. Resize the cylinder bore by a reliable repair shop or by using a drill press and a honing tool. Use the stone recommended by the hone manufactures to produce correct cylinder wall finish. Machine-bore first, the inside diameters are shown in the table.
Boring Inside Diameter Inside Diameter FH451V Oversize FH500V FH531V FH541V FH580V FH601V FH641V FH661V FH680V FH721V 0.50 mm 68.46 68.48 mm (2.695 2.696 in.) 74.46 74.48 mm (2.931 2.932 in.) 75.65 75.68 mm (2.978 2.979 in.)
Honing Inside Diameter Inside Diameter FH451V Oversize FH500V FH531V FH541V FH580V FH601V FH641V FH661V FH680V FH721V 68.48 68.50 0.50 mm mm (2.696 2.697 in.) 74.48 74.50 mm (2.932 2.933 in.) 75.68 75.70 mm (2.979 2.980 in.)
ENGINE TOP END 5-23

Cylinder, Piston
Change to a honing stone for finishing, the final inside diameter should be as shown in the table. Be sure to use correct finishing stone and the stone should not be worn. Clean the cylinder at the top and bottom of the cylinder to remove burns and pieces of the base and head gasket. Anchor the cylinder (block) on the drill press table before honing. Align the center of the cylinder bore to the press center. Set the press to operate from 200 to 250 rpm. Connect the drive shaft to the hone and set the stop on the drill press so the hone can only extend 20 to 25 mm (3/4 to 1.0 in.) above the top or below the bottom of the cylinder liner. Rotate the adjusting nut (knob) on the hone until the stones contact snugly against the narrowest point of the cylinder wall. Do not Force. Turn the honing stone by hand. If you cannot turn it, the stone is too tight. Loosen the hone until you can turn it by hand. Be sure that the cylinder and the hone are centered and aligned with the drive shaft and the drill spindle. Pour honing oil inside of the cylinder during the honing operation. Start the drill press. Move the hone up and down in the cylinder approximately 20 cycles per minute. Check the diameter of the cylinder bore regularly during honing, using an inside micrometer.
CAUTION
Stop the drill press before measuring and remove the hone from the cylinder.
The
NOTE
finished cylinder bore surface should not be smooth, but have a 40 to 60 degree crosshatch pattern.
until it mm Hone the cylinder in) largeistoabout 0.007 to 0.009when (0.0003 to 0.0004 allow for shrinkage the cylinder cools.
Do not use gasoline, kerosene, or commercial solvent

to clean the cylinder bore. These fluids only wash all the oil from the cylinder wall. They do not remove the metal particles produced during honing.
NOTE
Clean the cylinder thoroughly. Using soap, warm water and clean cloth, clean the cylinder wall. A clean white
cloth should not show soil from the cylinder wall. Dry the cylinder and coat with engine oil.
CAUTION
The cylinder must be thoroughly cleaned after honing to eliminate all grit.
5-24 ENGINE TOP END

Muffler/Exhaust Pipe Installation
Muffler/Exhaust Pipe Removal
Early Models; Loosen the clamp nut [A]. Remove the bolt [B] on the muffler bracket and take off the muffler.
Late Models; Loosen the clamp nut [A]. Remove the bolts [B] on the muffler bracket and take off the muffler [C].
the pipe flange nuts [A], and remove the Unscrewpipe exhaustthe pipe cover [C]. Use a penetrative exhaust [B] with
oil if necessary to loosen the nuts easily. Remove the gaskets. Unscrew the hook nut [D], separate the exhaust pipe and the pipe cover. Do not use unnecessary force on the exhaust pipes when removing the muffler assembly, or they could become damaged or distorted.
exhaust pipe flanges to the exhaust gasket Clean theand install a new gaskets each time port muffler surfaces the
installation. Install the gasket. To prevent mis-threading, tighten the flange nuts by finger first. Next, tighten the hook nut. Tighten the nuts to the specified torque.
Torque - Exhaust Pipe Flange Nuts: 15 Nm (1.5 kgfm, 11 ftlb)
the muffler. Installinstallation, thoroughly warm up the engine, wait unAfter til the engine cools down and retighten the bolts and nuts.
ENGINE TOP END 5-25

Inspection
Inspect the exhaust pipe or muffler for dents, cracks, rust and holes.
If the exhaust pipe or muffler is damaged, replace the exhaust pipe or the muffler with a new one for the best performance and minimum noise. Check the muffler for distortion and/or loose internal components. Loose internal components may result in the exhaust flow restriction and the engine output decrease. Check for breaks in the seams and check weld at the junction of the exhaust pipes and the muffler. Tap the muffler with a plastic hammer to decarbonize.
LUBRICATION SYSTEM 6-1
Lubrication System
Table of Contents
Exploded View........................................................................................................................ Engine Oil Flow Chart............................................................................................................. Engine Oil Flow Chart............................................................................................................. Specifications ......................................................................................................................... Engine Oil, Oil Filter, and Oil Cooler....................................................................................... Oil Level Inspection........................................................................................................... Oil Change ........................................................................................................................ Oil Filter Removal ............................................................................................................. Oil Filter Installation .......................................................................................................... Oil Filter Replacement ...................................................................................................... Oil Cooler Removal (FH721V) .......................................................................................... Oil Cooler Installation (FH721V) ....................................................................................... Oil Cooler Cleaning........................................................................................................... Pressurized Lubrication System ............................................................................................. Oil Pressure Measurement ............................................................................................... Oil Pressure Switch Inspection ......................................................................................... Oil Pump, Relief Valve............................................................................................................ Oil Pump, Relief Valve Removal ....................................................................................... Oil Pump, Relief Valve Installation .................................................................................... Oil Pump, Relief Valve Inspection..................................................................................... Oil Screen............................................................................................................................... Oil Screen Removal .......................................................................................................... Oil Screen Installation ....................................................................................................... Cleaning and Inspection ................................................................................................... 6-2 6-4 6-5 6-6 6-7 6-7 6-7 6-7 6-7 6-7 6-8 6-8 6-8 6-9 6-9 6-10 6-11 6-11 6-11 6-12 6-15 6-15 6-15 6-16
6-2 LUBRICATION SYSTEM

Exploded View

Exploded View
[FH451V, FH500V, FH531V] T1: 3.9 Nm (0.40 kgfm, 35 inlb) T2: 6.9 Nm (0.70 kgfm, 61 inlb) (Plastic) T3: 9.8 Nm (1.0 kgfm, 87 inlb) T4: 20 Nm (2.0 kgfm, 14.5 ftlb) (Metal) T5: 39 Nm (4.0 kgfm, 29 ftlb) (Metal) T6: 17 Nm (1.7 kgfm, 12.0 ftlb) (Plastic) T7: See the text T8: 5.9 Nm (0.60 kgfm, 52 inlb) [FH541V, FH580V] T1: 3.9 Nm (0.40 kgfm, 35 inlb) T2: 6.9 Nm (0.70 kgfm, 61 inlb) (Plastic) T3: 9.8 Nm (1.0 kgfm, 87 inlb) T4: 20 Nm (2.0 kgfm, 14.5 ftlb) (Metal) T5: 39 Nm (4.0 kgfm, 29 ftlb) (Metal) T6: 17 Nm (1.7 kgfm, 12.0 ftlb) (Plastic) T7: See the text T8: 5.9 Nm (0.60 kgfm, 52 inlb) [FH601V, FH641V, FH661V, FH680V, FH721V] T1: 3.9 Nm (0.40 kgfm, 35 inlb) T2: 6.9 Nm (0.70 kgfm, 61 inlb) (Plastic) T3: 9.8 Nm (1.0 kgfm, 87 inlb) T4: 20 Nm (2.0 kgfm, 14.5 ftlb) (Metal) T5: 39 Nm (4.0 kgfm, 29 ftlb) (Metal) T6: 17 Nm (1.7 kgfm, 12.0 ftlb) (Plastic) T7: See the text T8: 5.9 Nm (0.60 kgfm, 52 inlb) T9: 44 Nm (4.5 kgfm, 33 ftlb) A: FH721V B: Before FH500V-A50316, FH531V-A07510 Model C: FH451V, FH500V, FH531V, FH451V, FH580V Model D: FH601V, FH641V, FH661V, FH680V, FH721V Model O: Apply engine oil. SS: Apply silicone sealant.

Engine Oil Flow Chart
FH451V, FH500V, FH531V, FH601V, FH641V, FH661V, FH680V, FH721V

Engine Oil Flow Chart
FH541V FH580V FH601V, FH641V, FH661V, FH680V, FH721V (On and after 2003/5 product model)

Specifications
Item Engine Oil: Grade Viscosity Capacity: When the oil filter is not removed When the oil filter is removed Level Oil Pressure Standard SF, SG, SH, SJ or SL class SAE40, SAE30, SAE10W-30/SAE10W-40, or SAE5W-20 1.5 L (1.6 US qt) 1.7 L (1.8 US qt) except FH721V 1.8 L (1.9 Us-qt) FH721V Operating range (grid area) on dipstick 241 to 310 kPa (35 to 45 psi): Engine oil temperature 120C 414 to 690 kPa (60 to 100 psi): Engine oil temperature 50C to 60C 98 kPa (14.2 psi) PT 1/8 pipe thread 78.5 117.5 kPa (11.4 17.1 psi) Service Limit 0.2 mm (0.008 in.) 40.470 mm (1.5933 in.) 9.830 mm (0.3870 in.) 40.801 mm (1.6063 in.) 10.230 mm (0.4028 in.) 10.923 mm (0.4300 in.) 11.072 mm (0.4359 in.) 19.50 mm (0.77 in.)
Oil Pressure Switch: Detect pressure Screw Oil Filter By-pass Valve Opening Pressure Item Oil Pump: Inner and outer rotor clearance Outer rotor outside diameter Outer rotor thickness Pump housing inside diameter Pump housing depth Pump shaft outside diameter Pump shaft bearing inside diameter Relief valve spring free length
Special Tool - Oil Filter Wrench: 57001-1249 Sealant - Kawasaki Bond (Silicone Sealant): 56019-120

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. Before starting the engine for the first time, add oil: The engine is shipped dry. Preoil the engine to force all air from the internal oil passages and the oil filter.
Fill fresh engine oil to the specified level (see Oil Level Inspection). minutes. Run the engine at slow speed for 2level. Stop the engine and check the oil
Oil Level Inspection
Refer to the Oil Level Inspection in the Periodic Maintenance chapter.

Oil Change
Refer to the Oil Change in the Periodic Maintenance chapter.

Oil Filter Removal
strap Using a [B]. wrench or oil filter wrench [A], remove the oil filter
Special Tool - Oil Filter Wrench: 57001-1249
When unscrewing the oil filter, place a suitable container
beneath the oil drip tray to receive oil from the oil filter and oil passages in the engine. Turn the filter counterclockwise to remove it.
Oil Filter Installation
layer Apply a thinfilter. of the engine oil to the seal [A]. Install new Turn the filter until the seal contacts the mounting surface
[B] of the engine. Then turn the filter by hand (S) 3/4 turn more. Run the engine at low idle speed 2 minutes. Check for leaks around the engine. Stop the engine. Check the oil level (see Oil Level Inspection).
Oil Filter Replacement
Refer to the Oil Filter Replacement in the Periodic Maintenance chapter.

Engine Oil, Oil Filter, and Oil Cooler
Oil Cooler Removal (FH721V)
Filter Remove the oil filter (see Oil[A] andRemoval). oil cooler Unscrew the mounting joint remove the [B]. Check the O-ring [C] in the groove of the oil cooler for damage. Replace the O-ring with a new one if necessary.
Oil Cooler Installation (FH721V)
Install the oil cooler with the mounting joint and tighten it. Install the oil filter (see Oil Filter Installation).
Oil Cooler Cleaning
Torque - Oil Cooler Mounting Joint: 44 Nm (4.5 kgfm, 33 ftlb)
Refer to the Oil Cooler Cleaning in the Periodic Maintenance chapter.

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 engines oil passages to lubricate internal components, and returns to the crankcase. A pressure relief valve is used between the oil pump and oil filter to relieve excessive oil pressure by returning excessive oil to the crankcase (see Oil Flow Chart).
Oil Pressure Measurement
Remove the oil pressure switch or oil passage plug from the crankcase. Install an appropriately sized oil pressure gauge adapter [A] and oil pressure gauge [B]. Run the engine and warm up thorouqhly. the oil pres Run the engine at high idle speed and read sure gauge. engine. Stop the the oil pressure gauge and the adapter. Remove Apply silicone sealant to the threads of the pressure switch and tighten it, or tighten the oil passage plug.
Sealant - Kawasaki Bond (Silicone Sealant): 56019-120 Torque - Oil Pressure Switch: 9.8 Nm (1.0 kgfm, 87 inlb) Oil Passage Plug: 3.9 Nm (0.40 kgfm, 35 inlb)
If the measured oil pressure is below the specification, inspect the oil pump and the relief valve. If the oil pump and the relief valve are not at fault, inspect the rest of the lubrication system.
Oil Pressure 414 to 690 kPa (60 to 100 psi) Measurement Condition Engine Oil: 10 W-30 Engine Oil Temperature: 50 60C Oil Pressure Switch PT 1/8 (Taper Pipe Threads)

Pressurized Lubrication System
Oil Pressure Switch Inspection
When the oil pressure falls below 98 kPa (14.2 psi), the oil pressure switch activates the oil warning lamp to alert the operator or lubricating problem. To check the oil warning system, insert the switch key into the engine switch at the OFF position, then turn the switch key to the RUN position. The warning light must be illuminated. When the engine is running be sure the warning light is OFF. If the warning light comes on, stop the engine immediately and check the oil level. When starting the engine, note the warning light on dash carefully. If the warning light is on when the engine starts in spite of adequate oil level, check the lead from the pressure switch to the warning light for short circuit and/or check the pressure switch and replace damaged part with a new one. If the light is not on at the moment of the engine switch operation, check all leads of the warning light circuit or bulb and replace damaged parts with new ones.

Oil Pump, Relief Valve
Oil Pump, Relief Valve Removal
Remove the crankcase cover (see Camshaft/Crankshaft chapter). Unscrew the mounting bolts and remove the oil pump parts assembly (pump gear, pump cover plate, pump
shaft, pins and rotors). Take off the relief valve spring and the ball. Disassemble the pump parts assembly. Pin [A] Pump Gear [B] Mounting Bolts [C] Outer Rotor [D] Inner Rotor [E] Pump Shaft [F] Relief Valve Ball [G] Spring [H] Pump Cover Plate [I] 6 mm dia. Hole [J]
Oil Pump, Relief Valve Installation
Fill the rotor housing with the engine oil for initial lubrication. valve ball and spring in position, then Install the reliefparts assembly in the crankcase cover. install the pump
When installing the pump parts assembly, align the 6 mm dia. hole [A] on the cover plate with center of the relief valve.
NOTE
Install the mounting bolts and tighten them.
Torque - Oil Pump Cover Plate Mounting Bolts: 5.9 Nm (0.60 kgfm, 52 inlb)
FH500-A50316, Beforeand the relief valveFH531-A07510inmodel, the oil pump are as shown the figure.

Oil Pump, Relief Valve Inspection
Remove the oil pump (see Oil Pump, Relief Valve Removal). Visually inspect the pump gear, the outer and inner rotor, and the cover plate.
If there is any damage or uneven wear, replace them with new ones. Check the clearance [A] between the inner and outer rotor with a feeler gauge. Measure the clearance between the highest point of the inner rotor and the highest point of the outer rotor. If the measured valve exceeds the service limit, replace the rotors as a set with new ones.
Inner and Outer Rotor Clearance Service Limit: 0.2 mm (0.008 in.)
FH500-A50136, FH531-A07510 model, as shown Beforefigure. in the
Measure theatoutside diameter [A] of the outer rotor with a micrometer several points.
If the rotor diameter is less than the service limit, replace both the inner and outer rotor with new ones.
Outer Rotor Outside Diameter Service Limit: 40.470 mm (1.5933 in.)
the thickness [B] Measure at several points. of the outer rotor with a micrometer If the rotor thickness is less than the service limit, replace both the inner and outer rotor with new ones.
Outer Rotor Thickness Service Limit: 9.830 mm (0.3870 in.)
the inside of the Measuremicrometerdiameter [A]points. pump housing with a inside at several If the inside diameter is more than the service limit, replace the crankcase cover with a new one.
Pump Housing Inside Diameter Service Limit: 40.801 mm (1.6063 in.)
of the Measure theatdepth [B] points.pump housing with a depth micrometer several If any of measurement is more than the service limit, replace the crankcase cover with a new one.
Pump Housing Depth Service Limit: 10.230 mm (0.4028 in.)

FH531-A07510 Before FH500-A50136, the figure. model, the pump housing is as shown in
diameter Measure the outside [A] points. of the pump shaft with a micrometer at several 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 (0.4300 in.)
of Measure the inside diameter [A] an the pump shaft bearing in the crankcase cover with inside micrometer at several points. If the inside diameter is more than the service limit, replace the crankcase cover with a new one.
Pump Shaft Bearing Inside Diameter Service Limit: 11.072 mm (0.4359 in.)
Before FH500-A50136, FH531-A07510 model, the pump shaft bearing is as shown in the figure.
Visually inspect the relief valve spring, the steel ball and the valve seat in the crankcase cover.
If any rough spot is found during above inspection, wash the valve clean with a high-flash point solvent and blow out any foreign particles on the valve with compressed air.
WARNING
Clean the parts in a well ventilated area, and take care that there is no spark or flame anywhere near the working areas. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvents.

If cleaning does not solve the problem, replace the relief valve parts with new ones. If necessary, put the ball in position and lightly tap the ball with a suitable tool to form a perfect seat. Measure the 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 with a new one.
Relief Valve Spring Free Length Service Limit: 19.50 mm (0.77 in.)

Oil Screen
Oil Screen Removal
Remove the crankcase cover (see Camshaft/Crankcase chapter). Unscrew the mounting bolts [A] and remove the oil pump parts assembly.
Remove the oil screen [B].
FH500-A50136, Before is as shown in theFH531-A07510 model, screen figure.
the oil
Oil Screen Installation
Clean the oil screen thoroughly whenever it is removed for any reason. the oil screen position and install the oil pump Insertassembly (see[A] inPump, Relief Valve Installation). parts Oil
FH500-A50136, Before is as shown in theFH531-A07510 model, screen figure.
the oil

Oil Screen
Cleaning and Inspection
the with Clean any oil screenon it. high-flash point solvent and remove particles
WARNING
Clean the screen in a well ventilated area, and take care that there is no spark or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvents.
While cleaning the screen, check for any metal particles that might indicate internal engine damage.
NOTE
Check the screen carefully for any damage: broken wire.
holes and
If the screen is damaged, replace it with a new one.
CAMSHAFT/CRANKSHAFT 7-1
Camshaft/Crankshaft
Table of Contents
Exploded View........................................................................................................................ Specifications ......................................................................................................................... Crankcase .............................................................................................................................. Crankcase Cover Removal ............................................................................................... Crankcase Cover Installation ............................................................................................ Inspection.......................................................................................................................... Cleaning............................................................................................................................ Breather.................................................................................................................................. Breather Element Removal - FH451V, 500V, 531V, 541V, 580V ...................................... Breather Element Installation - FH451V, 500V, 531V, 541V, 580V ................................... Breather Valve Inspection - FH601V, 641V, 661V, 680V, 721V ....................................... Camshaft, Tappet ................................................................................................................... Camshaft, Tappet Removal............................................................................................... Camshaft, Tappet Installation............................................................................................ Camshaft Disassembly ..................................................................................................... Camshaft Assembly .......................................................................................................... Camshaft Inspection ......................................................................................................... Camshaft Bearing/Journal Wear....................................................................................... Crankshaft, Connecting Rod .................................................................................................. Connecting Rod Removal ................................................................................................. Connecting Rod Installation .............................................................................................. Crankshaft Removal ......................................................................................................... Crankshaft Installation ...................................................................................................... Cleaning/Inspection ......................................................................................................... Connecting Rod Bend/Twist.............................................................................................. Connecting Rod Big End/Crankpin Width Wear ............................................................... Connecting Rod Big End Bearing/Crankpin Wear ............................................................ Crankshaft Runout ............................................................................................................ Crankshaft Main Journal/Wear ......................................................................................... Crankpin Resizing............................................................................................................. 7-2 7-4 7-5 7-5 7-5 7-6 7-7 7-8 7-11 7-11 7-11 7-12 7-12 7-12 7-13 7-13 7-13 7-13 7-15 7-15 7-15 7-15 7-15 7-15 7-16 7-16 7-17 7-17 7-18 7-18
7-2 CAMSHAFT/CRANKSHAFT
Exploded View
Exploded View
[FH451V, FH500V, FH531V] T1: 5.9 Nm (0.60 kgfm, 52 inlb) T2: 25 Nm (2.6 kgfm, 19.0 ftlb) T3: See Engine Top End chapter. [FH541V, FH580V] T1: 5.9 Nm (0.60 kgfm, 52 inlb) T2: 25 Nm (2.6 kgfm, 19.0 ftlb) T3: See Engine Top End chapter. [FH601V, FH641V, FH661V, FH680V, FH721V] T1: 5.9 Nm (0.60 kgfm, 52 inlb) T2: 25 Nm (2.6 kgfm, 19.0 ftlb) T3: See Engine Top End chapter. G: Apply grease. O: Apply engine oil. S: Follow the specific tightening sequence. SS: Apply silicone sealant. A: FH451V, FH500V, FH531V, FH541V, FH580V Model B: FH601V, FH641V, FH661V, FH680V, FH721V Model C: Applicable Model only 1. Screw 2. Plate 3. Breather Valve
Specifications
Service Limit Item Camshaft, Tappet Cam Lobe Height: Inlet Exhaust Camshaft Journal Diameter PTO Side Flywheel Side Camshaft Bearing Inside Diameter Crankcase Crankcase Cover Crankshaft, Connecting Rod Connecting Rod Bend Connecting Rod Twist Connecting Rod Big End Width Crankpin Width Connecting Rod Big End Inside Diameter Crankpin Outside Diameter Crankshaft Runout Crankshaft Journal Diameter PTO Side Flywheel Side Crankcase PTO Shaft Bearing Inside Diameter Crankcase Cover Crankshaft Journal Bearing Inside Diameter Crankcase 34.90 mm (1.374 in.) 34.93 mm (1.375 in.) 35.15 mm (1.384 in.) 35.15 mm (1.384 in.) 39.896 (1.571 39.896 (1.571 mm in.) mm in.) 16.136 mm (0.6352 in.) 16.136 mm (0.6352 in.) 0.15/100 mm (0.006/3.94 in.) 0.15/100 mm (0.006/3.94 in.) 18.80 mm (0.74 in.) 39.50 mm (1.56 in.) 35.055 mm (1.3801 in.) 34.94 mm 0.05 mm (0.002 in.) TIR 15.985 mm (0.6293 in.) 15.985 mm (0.6293 in.) FH451V, 500V, 531V, FH541V, 580V FH601V, 641V, 661V, 680V, 721V
29.131 mm (1.1469 in.) 29.131 mm (1.1469 in.)
29.621 (1.166 29.621 (1.166
mm in.) mm in.)
38.055 mm (1.498 in.) 37.94 mm (1.494 in.)
19.90 mm (0.783 in.) 43.1 mm (1.697 in.)
40.15 mm (1.581 in.) 40.15 mm (1.581 in.)
Sealant - Kawasaki Bond (Silicone Sealant): 56019-120
Crankcase
Crankcase Cover Removal
Set the engine on a clean surface while parts are being removed. Drain the oil (see Lubrication System chapter). Remove: Pipe and Muffler (see Engine Top End chapter) Exhaust
Control Panel (see Fuel System chapter) Governor Arm (see Fuel System chapter) Unscrew the mounting bolts [A] and remove the crankcase cover [B] from the crankcase. There are two knock pins on the crankcase mating surface. Using a wooden or plastic mallet, gently tap crankcase to loosen the crankcase cover.
Crankcase Cover Installation
gasket Remove the oldcover. from the mating surfaces of the crankcase and Using compressed air, blow out the oil passage in the crankcase cover. solvent, clean off With aofhigh-flash point and the cover, andthe mating surfaces the crankcase wipe them dry.
WARNING
Clean the crankcase and cover in a well ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Do not use gasoline or a low-flash point solvent to clean parts. A fire or explosion could result. replace any oil seal with Be sure tooil seal so that the marks a new one. [A] face out. Install the
Pack some amount of high temperature grease [B] into

the space between the seal lip [C] and the dust lip [D]. Press in the new oil seal using a press or suitable tools until it is flush or below the flange surface [E]. Do not damage the seal lips. [F]: PTO Side 1 2 mm (0.04 0.08 in.) Flywheel Side 0 1 mm (0 0.04 in.)
When replacing the oil seal [A] of the governor shaft, note the following.
Install the oil seal into the crankcase cover [B] after insert-
ing the governor shaft in the crankcase cover, and so that the marks [C] face out. The depth [D] is 0 1 mm (0 0.04 in.). When installing the governor shaft and plate in the crankcase cover, see Fuel System chapter.
Crankcase
to see that the Checkon the crankcase.crankcase dowel pins [A] are in place Install the gasket on the crankcase.
the cover and tighten the Install boltscrankcase the tightening sequencecrankcase cover following shown in the figure.
Torque - Crankcase Cover Bolts: 25 Nm (2.6 kgfm, 19.0 ftlb)
Do not turn one screw down completely before the others,

as it may cause the crankcase cover to warp.
641V, 661V, 680V, 721V For FH601V,as shown in the figure. model, tightening sequence is
Torque - Crankcase Cover Bolts: 25 Nm (2.6 kgfm, 19.0 ftlb)
Inspection
diameter [A] of bearing Measure the insidecover at severalthe PTO shaft bearing on the crankcase points. This is not replaceable. Replace the crankcase cover if with a new one the inside diameter is greater than the service limit.
PTO Shaft Bearing Inside Diameter Model FH451V, 500V, 531V FH541V, 580V FH601V, 641V, 661V, 680V, 721V Service Limit 35.15 mm (1.384 in.) 35.15 mm (1.384 in.) 40.15 mm (1.581 in.)
Crankcase
the inside diameter [A] of the crankshaft journal Measureon the crankcase at several points. This bearing bearing is not replaceable. Replace the crankcase with a new one if the inside diameter is greater than the service limit.
Crankshaft Journal Bearing Inside Diameter Model FH451V, 500V, 531V FH541V, 580V FH601V, 641V, 661V, 680V, 721V Service Limit 35.15 mm (1.384 in.) 35.15 mm (1.384 in.) 40.15 mm (1.581 in.)
Cleaning
Remove: and Tappets (see Camshaft, Tappet Removal) Camshaft

Crankshaft (see Crankshaft Removal) Clean up the crankcase and cover with a high-flash point solvent, and blow out any foreign particles that may be in the pockets inside of the crankcase with compressed air.
WARNING
Clean the crankcase and cover in a well ventilated area, and take care that there is no spark or flame anywhere near the working area. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvents.
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 emission control system is used to eliminate blow-by gases. The blow-by gases are led to the breather chamber through the crankcase and the camshaft. Then, it is drawn into the clean side of the air cleaner through the cylinder head and the hose and mixed with the clean air flow, and subsequently coming into the combustion chamber through the carburetor and the inlet manifold. The oil is primarily separated from the gases while passing through the inside of the rocker chamber from the crankcase, and secondly separated from the gases in the breather chamber, then returned back to the crankcase cover.
[Standard Type]
Breather
[Heavy Duty Air Cleaner Type for FH541V, FH580V]
Breather
[Heavy Duty Air Cleaner Type for FH601V, FH641V,FH680V, FH721V]
Breather
Breather Element Removal - FH451V, 500V, 531V, 541V, 580V
Remove the bolts [A] and the breather chamber cover [B].
Remove the element [A]. [B] is in place under the eleto Check[A]. see that the plate ment
Breather Element Installation - FH451V, 500V, 531V, 541V, 580V
Apply the sealant crankcase.
to the mating surface [A] of the
new gasket Install athe bolts. and the breather chamber cover, and tighten
Torque - Breather Chamber Cover Bolts: 5.9 Nm (0.60 kgfm, 52 inlb)
Sealant - Kawasaki Bond (Silicone Sealant) : 56019-120
Breather Valve Inspection - FH601V, 641V, 661V, 680V, 721V
the mounting screw Unscrewthe breather valve (C).(A), and remove the plate (B) and the breather Inspect replace it withvalve (C) for ifbreakage, crack or distortion, a new one necessary. Inspect the plate (B) for damage or rough contact surface, replace it with a new one if necessary. Inspect the valve seating surface. The surface should be no nicks or burrs. drain hole on the breather chamber is Be sure that the with slugs before installing the breather not accumulated
valve. Align the center of the valve seat with the center of the breather valve and the plate, then tighten the mounting screw.
The mounting screw is a self-tapping one.
NOTE
Be aware that misthreading or overtightening screw will strip the female threads and break the hole.
Camshaft, Tappet
Camshaft, Tappet Removal
Set the engine on a clean surface while parts are removed. Drain the oil (see Lubrication System chapter). Remove:(see Engine Top End chapter) Muffler
Throttle Control Panel (see Fuel System chapter) Carburetor (see Fuel System chapter) Inlet Manifold (see Fuel System chapter) Crankcase Cover (see Crankcase Cover Removal) Rocker Covers [A] piston stroke. Position the [A] the at the TDC of the compression[B] and Push down spring side of the rocker arm move it to clear the push rod [C]. the push rods and mark them so they can Remove in their original positions during assembly. be installed
upside down Turn the crankcasecam lobes. so that the tappets will fall away from the Pull the camshaft [A] out of the crankcase.
the tappets [A] Removepositions duringand mark them to reinstall in their original assembly.
Camshaft, Tappet Installation
Apply engine oil to the followings. Tappet Journal

Camshaft Journal Cam Lobe Surface Camshaft Gear Align the punch marks [A] on the crankshaft gear and camshaft gear. Install the shim [B] on the camshaft.
Camshaft, Tappet
Camshaft Disassembly
Remove the governor assembly (see Fuel System chapter). Remove:[A] Spring
weight [B].
Do not remove the ACR (automatic compression release)
Camshaft Assembly
the governor Installassembling theassembly (see Fuel System chapter). After camshaft, check the The governor plate [A] must move freely. following items.
While shaking the camshaft, check if the ACR weight [B]

swings smoothly.
Camshaft Inspection
fatigue Checkorthe camshaft gear [A] for pitting,contact. cracks, burrs any evidence of improper tooth
Replace the shaft with a new one if necessary. Check the top of the cam lobes [B] for wear, burrs or uneven contact. Replace the shaft with a new one if necessary.
Camshaft Bearing/Journal Wear
Measure the height of each cam lobe. limit for either If the cam height is less than the service
lobe, replace the camshaft with a new one.
Cam Lobe Height Model FH451V, 500V, 531V FH541V, 580V Service Limit IN. 29.131 mm (1.1469 in.) EX. 29.131 mm (1.1469 in.) IN. 29.131 mm (1.1469 in.) EX. 29.131 mm (1.1469 in.) FH601V, 641V, 661V, 680V, IN. 29.621 mm (1.166 in.) 721V EX. 29.621 mm (1.166 in.)
Camshaft, Tappet
Measure both camshaft journals at several points around the journal circumference.
If the journal diameter is less than the service limit, replace the camshaft with a new one.
PTO Side Camshaft Journal Diameter Service Limit: 15.985 mm (0.6293 in.) Flywheel Side Camshaft Journal Diameter Service Limit: 15.985 mm (0.6293 in.)
[A] of Measure the insideatdiameter points.the camshaft bearing on the crankcase several This bearing is not replaceable. If the inside diameter is greater than the service limit, replace the crankcase with a new one.
Camshaft Bearing Inside Diameter (Crankcase) Service Limit: 16.136 mm (0.6352 in.)
the camshaft bearing Measure the inside diameter [A] ofpoints. This bearing is on the crankcase cover at several not replaceable. If the inside diameter is greater than the service limit, replace the crankcase cover with a new one.
Camshaft Bearing Inside Diameter (Crankcase Cover) Service Limit: 16.136 mm (0.6352 in.)
Crankshaft, Connecting Rod
Connecting Rod Removal
Remove: Engine Top End Chapter) Piston (see

Connecting Rod Installation
Install: (see Engine Top End chapter) Piston

Crankshaft Removal
Set the engine on a clean surface while parts are removed. Drain the oil (see Lubrication System chapter). Remove: (see Electrical System chapter) Flywheel
Camshaft (see Camshaft, Tappet Removal) Connecting Rod and Piston Assembly (see Engine Top End chapter) Pull the crankshaft [A] out of the crankcase. Using a wooden or plastic mallet, gently tap the crankcase to loosen the crankshaft.
Crankshaft Installation
up the crankshaft and crankcase Cleanat the bearing contact surfaces. thoroughly, especially amount of high Pack somethe crankcase. temperature grease into the oil seal on to and bearing. Apply engine oilthe the journal flywheel end into the main Carefully insert crankshaft bearing and the oil seal in the crankcase.
Cleaning/Inspection
removing, clean After with a high-flashthe crankshaft and the connecting rods point solvent and dry them with
compressed air. Inspect the teeth of the crankshaft gear for pitting, fatigue cracks, burrs and any evidence of improper tooth contact. Replace the gear with a new one if necessary. Inspect the crankshaft and connecting rods especially at the bearing surfaces for wear, scratches, any evidence of improper contact or other damages. Replace them with new ones if necessary.
Connecting Rod Bend/Twist
Measure the connecting rod bend. of the connecting Select an arbor of the same diameter
rod big end, and insert the arbor through the connecting rod big end. Select an arbor of the same diameter of the piston pin and at least 100 mm (3.94 in.) long, and insert the arbor through the connecting rod small end. On a surface plate, set the big end arbor on V blocks. With the connecting rod held vertically, use a height gauge to measure the height difference of the small end arbor on the surface plate. Using a dial gauge, measure the height at two different positions and the distance of the two positions is 100 mm (3.94 in.). Then determine the connecting rod bent from the measured height differences. If connecting rod bend exceeds the service limit, replace the connecting rod with a new one.
Connecting Rod Bend Service Limit: 0.15/100 mm (0.006/3.94 in.)
the connecting rod Measure big end arbor still ontwist.V blocks, hold the conthe With the
nection rod horizontally and measure the amount that the small end arbor difference. Using a dial gauge, measure the height at tow different positions and the distance of the two positions is 100 mm (3.94 in.). Then determine the connecting rod twist from the measured height differences. If connection rod twist exceeds the service limit, replace the connecting rod with a new one.
Connecting Rod Twist Service Limit: 0.15/100 mm (0.006/3.94 in.)
Connecting Rod Big End/Crankpin Width Wear
Measure theaconnecting rod big end width [A] with a micrometer or dial caliper.
If the measurement is less than the service limit, replace the connecting rod with a new one.
Connecting Rod Big End Width Model FH451V, 500V, 531V FH541V, 580V FH601V, 641V, 661V, 680V, 721V Service Limit 18.80 mm (0.74 in.) 18.80 mm (0.74 in.) 19.90 mm (0.783 in.)
with Measure the crankpiniswidth [A] than a dial caliper. reIf the crankpin width greater the service limit, place the crankshaft with a new one.
Crankpin Width Model FH451V, 500V, 531V FH541V, 580V FH601V, 641V, 661V, 680V, 721V Service Limit 39.50 mm (1.56 in.) 39.50 mm (1.56 in.) 43.1 mm (1.697 in.)
Connecting Rod Big End Bearing/Crankpin Wear
oil cap bolts. Apply a thin layer of andon the threads of thethe specified Install the cap bolts tighten the bolts to torque (see Piston Installation in Engine Top End chap-
ter). Measure the big end inside diameter [A] at several points with a telescoping gauge or inside micrometer. If the inside diameter is greater than the service limit, replace the connecting rod with a new one.
Model Service Limit 35.055 mm (1.380 in.) 38.055 mm (1.498 in.) 38.055 mm (1.498 in.)
Connecting Rod Big End Inside Diameter FH451V, 500V, 531V FH541V, 580V FH601V, 641V, 661V, 680V, 721V
outside [A]. Measure the crankpinmeasure diameterpoints around the several Use a micrometer to
crankpin circumference. If the crankpin diameter is less than the service limit, replace the crankshaft with a new one.
Model Service Limit 34.94 mm (1.3756 in.) 37.94 mm (1.494 in.) 37.94 mm (1.494 in.)
Crankpin Outside Diameter FH451V, 500V, 531V FH541V, 580V FH601V, 641V, 661V, 680V, 721V
Crankshaft Runout
blocks gauge.
the crankshaft Measurecrankshaft in a runout. alignment jig or on V Set the flywheel
Set a dial gauge against both bearing journals. Turn the crankshaft slowly to measure the runout.
The difference between the highest and the lowest dial gauge readings (TIR) is the amount of runout. If the measurement exceeds the service limit, replace the crankshaft with a new one.
Crankshaft Runout Service Limit: 0.05 mm (0.002 in.) TIR
Crankshaft Main Journal/Wear
Measure both main journals at several points around the journal circumference.
If the journal diameter is less than the service limit, replace the crankshaft with a new one.
PTO Side Crankshaft Journal Diameter [A] Model FH451V, 500V, 531V FH541V, 580V FH601V, 641V, 661V, 680V, 721V Service Limit 34.90 mm (1.374 in.) 34.90 mm (1.374 in.) 39.896 mm (1.571 in.)
Flywheel Side Crankshaft Journal Diameter [B] Model FH451V, 500V, 531V FH541V, 580V FH601V, 641V, 661V, 680V, 721V Service Limit 34.93 mm (1.375 in.) 34.93 mm (1.375 in.) 39.896 mm (1.571 in.)
Crankpin Resizing
The crankpin can be resized to accept 34.5 mm (1.3583 in.) dia. under sized connecting rod. If the crankpin is too scored to lap, re-grind the crankpin. See a reliable repair shop for re-grinding. Before sending the crankshaft to a reliable repair shop, inspect the crankpin for cracks. If any crack, no matter how small, are found, the crankshaft cannot be used anymore. The final finishing dimensions are shown in the below table.
Finishing Dimensional Specifications [FH451V, FH500V, FH531V] [A] [B] [C] [D] 34.457 34.470 mm (1.356 1.357 in.) R 2.0 2.4 mm (R 0.0787 0.0945 in.) 39.50 mm MAX (1.555 in. MAX) 33.950 34.050 mm (1.337 1.340 in.)
Finishing Dimensional Specifications [FH541V, FH580V] [A] [B] [C] [D] 37.457 37.470 mm (1.4747 1.4752 in.) R 2.0 2.4 mm (R 0.0787 0.0945 in.) 39.50 mm MAX (1.555 in. MAX) 33.950 34.050 mm (1.337 1.340 in.)
Finishing Dimensional Specifications [FH601V, FH641V, FH661V, FH680V, FH721V] [A] [B] [C] [D] 37.457 37.470 mm (1.4747 1.4752 in.) R 2.0 2.4 mm (R 0.0787 0.0945 in.) 43.0 mm MAX (1.693 in. MAX) 37.95 38.05 mm (1.4941 1.4980 in.)
surface should and parallel The crankpin within 0.006 mmbe concentric full indicator to each other (0.0002 in.)
reading. Finish the crankpin surface with a super finishing stone.
STARTER SYSTEM 8-1
Starter System
Table of Contents
Exploded View........................................................................................................................ Specifications ......................................................................................................................... Starter System........................................................................................................................ Starter Motor Removal...................................................................................................... Starter Motor Installation................................................................................................... Starter Motor Disassembly................................................................................................ Starter Motor Assembly ................................................................................................... Starter Motor Brush Inspection ......................................................................................... Brush Spring Inspection.................................................................................................... Armature Inspection.......................................................................................................... Yoke Assembly Inspection ................................................................................................ Pinion Clutch Inspection ................................................................................................... Recoil Starter Removal ..................................................................................................... Recoil Starter Installation .................................................................................................. Recoil Starter Disassembly............................................................................................... Recoil Starter Assembly.................................................................................................... 8-2 8-4 8-5 8-5 8-5 8-5 8-6 8-6 8-6 8-6 8-8 8-8 8-8 8-8 8-9 8-10
8-2 STARTER SYSTEM

Exploded View
STARTER SYSTEM 8-3

Exploded View
[FH451V, FH500V, FH531V] T1: 3.9 Nm (0.40 kgfm, 35 inlb) T2: 5.9 Nm (0.60 kgfm, 52 inlb) T3: 7.8 Nm (0.80 kgfm, 69 inlb) T4: 17 Nm (1.7 kgfm, 12 ftlb) [FH541V, FH580V] T1: 3.9 Nm (0.40 kgfm, 35 inlb) T2: 5.9 Nm (0.60 kgfm, 52 inlb) T3: 7.8 Nm (0.80 kgfm, 69 inlb) T4: 17 Nm (1.7 kgfm, 12 ftlb) [FH601V, FH641V, FH661V, FH680V, FH721V] T1: 3.9 Nm (0.40 kgfm, 35 inlb) T2: 5.9 Nm (0.60 kgfm, 52 inlb) T3: 7.8 Nm (0.80 kgfm, 69 inlb) T4: 17 Nm (1.7 kgfm, 12 ftlb) A: Recoil Starter Model B: Electric Starter Model G: Apply grease. O: Apply engine oil.
8-4 STARTER SYSTEM

Specifications
Item Electric Starter System Starter Motor: Carbon Brush Length (with spring boss) Commutator Groove Depth (approx.) Commutator Diameter Commutator Runout Standard FH451V, 500V, FH601V, 641V, Service Limit 531V, 541V, 580V 661V, 680V, 721V
12.7 mm (0.500 in.) 2.0 mm (0.078 in.) 31.7 mm (1.250 in.)
6.4 mm (0.250 in.) 0.9 mm (0.035 in.) 31.1 mm (1.225 in.) 0.4 mm (0.016 in.)
STARTER SYSTEM 8-5

Starter System
Starter Motor Removal
the mounting Remove the engine. bolts [A] and pull the starter motor [B] from
Starter Motor Installation

bolts.
and engine mounting Clean the starter motorcontact and tighten theflanges to ensure good electrical mounting
Torque - Starter Motor Mounting Bolts: 15 Nm (1.5 kgfm, 11.0 ftlb)
Starter Motor Disassembly
Remove: Bolts and Nuts [A] Through

Brush Plate [B] York [C] Cap [D]
While pushing the collar [A], remove the snap ring [B].
Remove:[A] Spring
Pinion Assembly [B] Washer [C] Bracket [D] Armature [E]
8-6 STARTER SYSTEM

Starter System
Starter Motor Assembly
starter reverse Assemble the amountmotor in the[A] to the of disassembly. Apply a small of grease armature Do not reuse the snap ring [B]. Replace it with a newshaft. one. Check the cap and replace it with a new one if damaged.
Fit the projection [A] on the bracket into the notch [B] in the yoke. the Pressclips. springs and holding the brush leads with suitable the washer [C] Putthe projection [D]among the brushes.into the notch [E] Fit on the brush plate in the yoke.
Starter Motor Brush Inspection
them with new ones.
Brush Length Service Limit 6.4 mm (0.25 in.)
of each Measure the overall lengththan the brush [A]. replace If the brushes are shorter service limit,
Brush Spring Inspection
Inspect the brush springs for pitting, cracks, rusting and burrs.
Replace the spring with a new one if necessary. Inspect the springs for weakened conditions and distortion. Replace the springs with new ones if necessary. If the brush springs can press the brushes firmly into place, they may be considered serviceable. If they cannot, replace them with new ones.
Armature Inspection
of the commutator Inspect the surfacedirty, polish it with a[A]. of very fine If it is scratched or piece emery cloth [B], and clean out the grooves.
STARTER SYSTEM 8-7

Starter System
Measure the depth of the grooves between the commutator segments.

If the grooves are shallower than the specified limit, replace the armature with a new one. If the grooves are only dirty, clean them carefully.
Commutator Groove Depth Limit 0.9 mm (0.035 in.)
Bad [A] Segment [B] Good [C] 0.9 mm (0.035 in.) limit [D] Mica [E]
Measure the diameter [A] of the commutator [B] at several points.

If the diameter is less than the service limit, replace the armature with a new one.
Commutator Outside Diameter Service Limit: 31.1 mm (1.225 in.)
armature in each end of Support the shown in thean alignment jig atdial indicator the shaft as figure. Position a
perpendicular to the commutator. Rotate the armature slowly and read the commutator runout. If runout is greater than the service limit, turn down the commutator or replace the armature with a new one.
Commutator Runout Service Limit: 0.4 mm (0.016 in.)
armature winding resistance. Measure the tester to the R 1 range and measure the Set the hand resistance between each segment [A] and all the others. If the resistance it too high or even infinite, the armature winding has an open circuit. Replace the starter motor with a new one.
Armature Winding Resistance Close to 0
Set the hand measure the resistancetester to the R 1 k range and armature between the commutator and the shaft [B]. If the resistance is less than infinite, the armature is shorted. Replace the starter motor with a new one.
Commutator to Shaft Resistance ()
8-8 STARTER SYSTEM

Starter System
Test the armature winding for shorts. Place the armature on a growler [A].
armature.
Hold a thin metal strip (e.g., hack saw blade) on top of the Turn on the growler and rotate the armature one complete
turn. If the metal strip vibrates, the windings are internally shorted to each other, replace the starter motor with a new one.
Yoke Assembly Inspection
Set the hand tester the R 1 k range and measure the resistance betweentothe 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 with a new one.
Positive Brush to Ground Resistance ()
range and measure the Set the hand tester to the R 1 brush (es) [A] and brush resistance between the negative plate [B]. If the meter does not read close to 0 , the brush plate is faulty. Replace the brush plate assembly with a new one.
Negative Brush to Ground Resistance Close to 0
Pinion Clutch Inspection
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 with a new one.
Recoil Starter Removal

Recoil Starter [B]
Remove: Recoil Starter Mounting Nuts [A]
Recoil Starter Installation
Install the recoil starter and tighten the mounting nuts.
Torque - Recoil Starter Mounting Nuts: 5.9 Nm (0.60 kgfm, 52 inlb)
STARTER SYSTEM 8-9

Starter System
Recoil Starter Disassembly
the recoil Recoil Starter Removal). Removehandle [A]starter (see (1 ft), and clamp the rope Pull the out 30 cm [B] with the clip [C] so it can not wind back onto the reel
[D]. Pry the knot [E] out of the handle and untie it. Remove the handle from the rope.
WARNING
Wear gloves to avoid injury for the remaining steps.
While carefully holding the reel [A] and case [B], remove the clip. Unwind the spring tension slowly.
Do not wedge the rope between the reel and case.
NOTE
Remove:[A] Screw
Washer [B] Retainer [C] Center Spring [D] Washer [E] Pawls [F] Return Springs [G]
WARNING
When removing the reel [A], be careful that the recoil spring [B] under the reel does not fly loose and cause injury. The spring is under great pressure.
There should be no spring tension on the reel when

removing it. If tension is felt, push the reel back into place and gently wiggle it until the reel can be easily removed.
NOTE
Slowly lift the reel straight up out of the case [C].

WARNING
If the recoil spring cassette is sticking with the reel, be careful that the cassette does not drop. Be careful that the recoil spring does not fly loose from the cassette and cause injury. The spring is under great pressure.
Slowly lift the recoil spring cassette straight up out of the case or reel.
8-10 STARTER SYSTEM

Starter System
If necessary, remove the recoil spring [A] as follows:
Place the cassette [B] facing down in a suitable container. Tap the cassette [B] to remove the recoil spring.
Recoil Starter Assembly
WARNING
Wear gloves during the recoil spring installation to avoid injury. The recoil spring must be assembled with great pressure. the recoil Lightly greasespring into spring. cassette. Set the recoil the spring the rope clockwise [A] on the reel, and hold the rope Wind[B] with tape. end [C] that the Install the spring cassette fit in on the reel so the reel. tongues [D] on the cassette the openings of
Lightly grease the shaft [A]. the round peg [B] aligned the Put the reel intoinnercase, with with the spring tongue [C]. Turn the reel clockwise until you feel the spring inner tongue catches the round peg.
Install: Springs [A] and Pawls [B] Return

Washer [C] and Center Spring [D] Lightly grease the center spring.
STARTER SYSTEM 8-11

Starter System
Install: [A] Retainer

Washer [B] Screw [C]
Torque - Recoil Starter Retainer Screw: kgfm, 69 inlb) 7.8 Nm (0.80
Turn the reel two turns counterclockwise to preload the recoil spring.
keep it While holding the reel to the holefrom unwinding, feed the end of the rope through in the case. Clip the rope as shown to hold it. Install the handle [A], and secure it with a knot [B]. Remove the clip [C] to release the rope.
ELECTRICAL SYSTEM 9-1
Electrical System
Table of Contents
Exploded View........................................................................................................................ Specifications ......................................................................................................................... Wiring Diagram [FH451V, FH500V, FH531V, FH541V, FH580V] ........................................... Wiring Diagram [FH451V, FH500V, FH531V]......................................................................... Wiring Diagram [FH601V, FH641V, FH661V, FH680V, FH721V] ........................................... Precautions............................................................................................................................. Charging System .................................................................................................................... Flywheel, Stator Coil Removal.......................................................................................... Flywheel, Stator Coil Installation....................................................................................... Charging System Operational Inspection ......................................................................... Stator Coil Resistance ...................................................................................................... Unregulated Stator Output ................................................................................................ Regulator Removal ........................................................................................................... Regulator Installation ........................................................................................................ Regulator Resistance........................................................................................................ Ignition System ....................................................................................................................... Ignition Coil Removal ........................................................................................................ Ignition Coil Installation ..................................................................................................... Ignition Coil Inspection...................................................................................................... Spark Plug Cleaning and Inspection................................................................................. Spark Plug Gap Inspection ............................................................................................... 9-2 9-4 9-5 9-6 9-8 9-9 9-10 9-10 9-11 9-13 9-14 9-14 9-14 9-14 9-15 9-16 9-17 9-17 9-18 9-18 9-18
9-2 ELECTRICAL SYSTEM

Exploded View

Exploded View
[FH451V, FH500V, FH531V] T1: 3.9 Nm (0.40 kgfm, 35 inlb) T2: 5.9 Nm (0.60 kgfm, 52 inlb) T3: 7.8 Nm (0.80 kgfm, 69 inlb) T4: 22 Nm (2.2 kgfm, 16 ftlb) T5: 56 Nm (5.7 kgfm, 41 ftlb) [FH541V, FH580V] T1: 3.9 Nm (0.40 kgfm, 35 inlb) T2: 5.9 Nm (0.60 kgfm, 52 inlb) T3: 7.8 Nm (0.80 kgfm, 69 inlb) T4: 22 Nm (2.2 kgfm, 16 ftlb) T5: 56 Nm (5.7 kgfm, 41 ftlb) [FH601V, FH641V, FH661V, FH680V, FH721V] T1: 3.9 Nm (0.40 kgfm, 35 inlb) T2: 5.9 Nm (0.60 kgfm, 52 inlb) T3: 7.8 Nm (0.80 kgfm, 69 inlb) T4: 22 Nm (2.2 kgfm, 16 ftlb) T5: 56 Nm (5.7 kgfm, 41 ftlb) 1. Flywheel (Recoil Starter Model) 2. Flywheel (Electric Starter Model) 3. Charging Coil 4. Voltage Regulator 5. Stud (Before 2002/4 Product Model) 6. Stud (On and after 2002/5 Product Model)

Specifications
Item Standard FH451V, 500V, 531V, FH601V, 641V, 541V, 580V 661V, 680V, 721V Service Limit
Charging System Regulated Output Voltage 14.1 V DC Alternator Stator Coil Resistance in the text Unregulated Stator Output 28.4 V AC/3 000 rpm Regulator Resistance Ignition System Ignition Coil: Primary Winding Resistance Secondary Winding Resistance Spark Plug Plug Gap in the text
15 V DC 26 V AC/3 000 rpm
in the text 8 to 11 k CHAMPION RCJ8Y 0.75 mm (0.030 in.)
NGK BPR4ES 0.75 mm (0.030 in.)
Special Tool - Hand Tester: 57001-1394

Wiring Diagram [FH451V, FH500V, FH531V, FH541V, FH580V]
Electric Starter Model

Wiring Diagram [FH451V, FH500V, FH531V]
Recoil Starter (with Charging Coil) Model

Wiring Diagram [FH451V, FH500V, FH531V]
Recoil Starter Model

Wiring Diagram [FH601V, FH641V, FH661V, FH680V, FH721V]
Electric Starter Model

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 battery condition before judging other parts of the electrical system. A fully charged battery is necessary for conducting accurate electrical system tests. Do not hit the electric parts with a hammer or do not drop the electric parts. These may result in the electric parts damage or breakage. To prevent damage to electrical parts, do not disconnect the battery cables or any other electrical connections when the engine switch is on, or while the engine is running. Because of the large amount of current, never keep the engine switch turned to the start position when the starter motor will not start, or the current may burn out the starter motor windings. Take care not to short the leads that are directly connected to the battery positive (+) terminal to the chassis ground. Troubles may involve one or all items in some cases. Never replace a defective part without determining what CAUSED the failure. If the failure was occurred by another item or some other items, repair and/or replace the item(s). Or the failure may happen again. Make sure all connectors in the circuit are clean and tight, and examine the leads for signs of burning, fraying, etc. Poor leads and bad connections will affect electrical system operation. Measure the coil and the winding resistance when the parts are cold (at room temperature). Electrical connectors: Connectors [A]
Connectors [B]

Charging System
Flywheel, Stator Coil Removal
Remove: Recoil Starter (see Recoil Starter Removal) Loosen the fan housing bolts [A] and remove the fan housing [B].
Remove:Coils (see Ignition Coil Removal) Ignition

Stud Bolts [A]
the Holdand flywheel with a suitable tool, remove the flywheel bolt the washer.
For Electric Starter model, note the following procedure. Remove:

Nuts [A] and Guard [B] Bolt [C] and Screen [D] Spacer [E]
Loosen
the fan housing bolts [A] and remove the fan housing [B].

Charging System
Remove:
Ignition Coil (see Ignition Coil Removal) Stud Bolts [A]
Hold the flywheel with a suitable tool, remove the flywheel

bolt and the washer.
Using a suitable flywheel puller [A], remove the flywheel [B].

CAUTION
Always use flywheel puller.
Remove: Key [A] Woodruff

Stator Coil Lead Connector [B] Stator Coil Screw [C] Stator Coil [D]
Flywheel, Stator Coil Installation
Install the stator coil and tighten the screws.
cleaning fluid, oil or dirt on Using aportions and dryclean off any clean cloth. the following them with a
Torque - Stator Coil Screws: 3.4 Nm (0.35 kgfm, 30 inlb)
Crankshaft Tapered Portion [A] Flywheel Tapered Portion [B] Fit the Woodruff key [C] securely in the slot in the crankshaft before installing the flywheel.

Charging System
Install the fan [A] so that two positioning bosses [B] fit around flywheel ignition magnet [C]. plate [D] Install the flywheel. so that the notch [E] inserts into the slot in the
[A] Install the screen fan.so that the projections [B] fit into the recess [C] of the
the [A] so Install [B] inpulleypulley. that the tabs of the plate fit into holes the Put the washer [C] as shown in the figure. Tighten the flywheel bolt [D].
Install the fan housing and tighten the bolts.
Torque - Flywheel Bolt: 56 Nm (5.7 kgfm, 41 ftlb)
Install: Starter (see Recoil Starter Installation) Recoil

slot in the flywheel. Put the washer [C]. Tighten the flywheel bolt [D].
Torque - Fan Housing Bolts: 5.9 Nm (0.60 kgfm, 52 inlb)
model, note For Electric Starter[A] so that thethe following procedure. notch [B] inserts into the Install the bracket
Install the fan housing and tighten the bolts.
Torque - Flywheel Bolt: 56 Nm (5.7 kgfm, 41 ftlb) Torque - Fan Housing Bolts: 5.9 Nm (0.60 kgfm, 52 inlb)

Charging System
Install:
Spacer [A] Screen [B] Position three sets [C] of screen notches around the fan blades. Tighten the screen bolts [D]
Torque - Screen Bolts: 5.9 Nm (0.60 kgfm, 52 inlb)
Charging System Operational Inspection
Check the battery condition.
Always check the battery condition before judging other
NOTE
parts of the charging system. The battery must be fully charged for accurate charging system tests.
Warm up the engine to bring the components up to their normal operating temperatures. Measure regulated output voltage at various engine speeds.
Connect a voltmeter across the battery terminals.
The readings should show nearly battery voltage when the engine speed is low, and as the engine speed rises, the readings should also rise. But they must stay within the specified range. If the output voltage is much higher than the specification, the regulator is defective, or the regulator leads are loose or open. If the output voltage dose not rise as the engine speed increase, the regulator is defective or the alternator output is insufficient for the loads.
Regulated Output Voltage Battery Voltage to 15 VDC

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 (Electric Starter Model) 0.01 to 0.1
(Recoil Starter Model with Electric Clutch) Connect an ohmmeter between the stator pin and engine body.
Stator Coil Resistance (Recoil Starter Model with Electric Clutch) 4.4 to 15
If the measured value is not within the specification, replace the stator coil with a new one. If the coil has normal resistance, but the voltage inspection shows the alternator to be defective; the flywheel magnets have probably weakened, and the flywheel must be replaced. Check for continuity between each stator pin and ground. There should be no continuity (infinite ohm). If the stator coil fails any of these tests, replace the coil with a new one.
Unregulated Stator Output
[A]. Disconnect the connectorthe stator pins [B]. Connect AC voltmeter to Start the engine. Run the engine at the 3 000 rpm speed. Voltage reading should be minimum 26 VAC/3 000 rpm. If the AC voltage reading is less than the specification, replace the stator with a new one.
Unregulated Stator Output (MIN) 26 VAC/3 000 rpm
Regulator Removal
Remove: Lead Connector [A] Stator Coil

Regulator Screws [B] Regulator [C]
Regulator Installation
Install the regulator and tighten the screws.
Torque - Regulator Screws: 3.4 Nm (0.35 kgfm, 30 inlb)

Charging System
Regulator Resistance
Set theKAWASAKI Hand Tester selector switch to the R 100 position. Connect the test leads to the points shown on the chart and read the resistance.
There are two (2) types of Regulator on FH engines as
follows:
(Without Charging Monitor Type 3 Blades)
Resistance value may vary with individual meters.

(With Charging Monitor type 5 Blades)
NOTE
If the resistance is not as specified, replace the regulator with a new one.

Ignition System
This engine ignition is controlled by a solid state ignition assembly and requires no periodic maintenance except for the spark plugs. The system consists of the following: Inductive Ignition Assemblies Permanent Magnet Flywheel Spark Plugs Stop Switch
Ignition Theory of Operation Mounted to the periphery of a flywheel are a pair of magnetic poles (south leading in clockwise rotation), generated by a permanent magnet. By rotating the flywheel (magnetic poles) clockwise past the ignition module on a laminated core group, a voltage is generated in the primary winding (L1). This generates a small bias current to flow through the control resistor (R1) to the base of the transistor (Q1). This base drive causes the transistor to conduct (turns on) completing the primary circuit. Current flows from the high side of the primary winding through the transistor (collector to emitter) to ground. The trigger sensor (TS1) senses the optimum time (peak current) to remove the base drive from the transistor (Q1). This abrupt turning off of the transistor causes an interruption in current flow which allows its associated flux collapse, and several hundred volts is induced through the primary winding (L1) inducing a very large voltage in the secondary winding (L2). When the secondary voltage reaches several thousand volts, the spark plug (SP) gap is ionized and ignition occurs. The placement of the trigger sensor internal to the ignition insures the constant timing over speed and temperature and prevents counterclockwise operation. The diode (D1) in the ignition shut off circuit blocks the inadvertent application of the battery voltage, protecting the internal components of the ignition. With the stop switch (SW) in the closed position, the primary voltage is routed to ground, preventing the ignition operation.

Ignition System
Ignition Coil Removal
Remove: (see Flywheel, Stator Coil Removal) Fan Housing

Spark Plug Cap [A] Stop Switch Lead Connector [B] Bolts [C] Ignition Coil [D]
Ignition Coil Installation
on the Install the ignition coil [B] facecrankcase so that the stop switch lead connector the screen, and tighten the bolt (1) first, then tighten the bolts (2). While tightening bolts, adjust the air gap [A] between the three legs of ignition coil and the two pole-plates of magnet to the specified gap value as shown in the figure.
Ignition Coil Air Gap Standard: 0.2 0.4 mm (0.008 0.016 in.) Torque - Ignition Coil Bolts (Stud Bolt): 7.8 Nm (0.80 kgfm, 69 inlb) Ignition Coil Bolts (Flanged Bolt): 5.9 Nm (0.60 kgfm, 52 inlb)
Use the above procedure to insure proper coil air gap.
NOTE

Ignition System
Ignition Coil Inspection
Remove the ignition coils (see Ignition Coil Removal). as Measure the winding resistance k follows: Set the hand tester to the R 1 range.
Measure the ignition coil winding resistance as shown in
the table.
Ignition Coil Winding Resistance Special Tool - Hand Tester: 57001-1394
CAUTION
Use only Tester 57001-1394 with new battery at room temperature for this test. A tester other than the Kawasaki Hand Tester should show different readings. If a megger or a meter with a large capacity battery is used, the ignition coil will be damaged. If the tester does not read as specified, replace the coil with a new one.
Spark Plug Cleaning and Inspection
the Spark Plug Cleaning Refer to Maintenance chapter. and Inspection in the Periodic
Spark Plug Gap Inspection
Refer to the Spark Plug Gap Inspection in the Periodic Maintenance chapter.
TROUBLESHOOTING 10-1
Troubleshooting
Table of Contents
Engine Troubleshooting Guide ............................................................................................... Starter Motor Troubleshooting Guide ..................................................................................... 10-2 10-6
10
10-2 TROUBLESHOOTING
Engine Troubleshooting Guide
If the engine malfunctions, check if the way the engine is used is correct. If the engine malfunctions even if the engine is used correctly, systematically carry out troubleshooting starting with simple points. This chart describes typical troubleshooting procedures. Do not unnecessarily disassemble the carburetor, the magneto or the engine unless it has been found to be the cause of malfunctioning.
Starter Motor Troubleshooting Guide
1. Disconnect the spark plug caps from the spark plugs. 2. Turn engine switch to start position and check condition.
WARNING
Engine may be cranked in this test. Do not touch any rotating parts of engine and equipment during test.
CAUTION
If starter does not stop by engine switch OFF, disconnect negative () cable from battery as soon as possible.
Part No.99924-2078-01
Printed in Japan

Kawasaki Manual 99924 2078 01

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Quick Reference Guide

4-Stroke Air-Cooled V-Twin Gasoline Engine

2006 Kawasaki Heavy Industries, Ltd.

1 Edition (1):Mar. 31, 2006 (K)

EMISSION CONTROL INFORMATION

TAMPERING WITH EMISSION CONTROL SYSTEM PROHIBITED

This note symbol indicates points of par-

ticular interest for more efficient and convenient operation.

How to Use This Manual

Indicates a procedural step or work to be done.

Indicates a procedural sub-step or how to do

GENERAL INFORMATION 1-1

1-2 GENERAL INFORMATION

Especially note the following:

GENERAL INFORMATION 1-3

1-4 GENERAL INFORMATION

Recoil Starter Model-FH500V

Cylinder Number Designation:

GENERAL INFORMATION 1-5

Electric Starter Model-FH680V

1-6 GENERAL INFORMATION

GENERAL INFORMATION 1-7

PERIODIC MAINTENANCE 2-1

2-2 PERIODIC MAINTENANCE

FH451V, FH500V, FH531V, FH541V, FH580V

PERIODIC MAINTENANCE 2-3

2-4 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE 2-5

2-6 PERIODIC MAINTENANCE

Basic Torque for General Fasteners

PERIODIC MAINTENANCE 2-7

2-8 PERIODIC MAINTENANCE

Basic Torque for General Fasteners

PERIODIC MAINTENANCE 2-9

2-10 PERIODIC MAINTENANCE

Valve Seat Cutter, 32 57001-1120

Oil Filter Wrench: 57001-1249

Valve Seat Cutter Holder Bar: 57001-1128

Valve Seat Cutter Holder, 57001-1360

PERIODIC MAINTENANCE 2-11

High Idle Speed Adjustment

High idle speed adjustment should be made after the

Start and warm up the engine thoroughly.

2-12 PERIODIC MAINTENANCE

Tighten the M6 Mounting bolts.

Torque - Control Panel Mounting Bolts: kgfm, 52 inlb)

PERIODIC MAINTENANCE 2-13

Element Cleaning and Inspection

2-14 PERIODIC MAINTENANCE

Operating in dusty condition may require more frequent

Operating in dusty condition may require more frequent

PERIODIC MAINTENANCE 2-15

Housing (Cap and Body) Inspection

Engine Top End

2-16 PERIODIC MAINTENANCE

Valve Clearance Inspection

PERIODIC MAINTENANCE 2-17

Valve Seat Inspection

The valve stem and guide must be in good condition or

2-18 PERIODIC MAINTENANCE