Kawasaki FE400 manual

FE120 FE170 FE250 FE290 FE350 FE400 4–str oke air-cooled gasoline engine Ser vice Man ual All rights reserved. No par ts of this publication ma y be reproduced, stored in a retr ie val system, or transmitted in any form or by an y means, electronic mechanical photocopying, recording or otherwise, without the prior written per mission of Quality A[...]

LIST OF ABBREVIA TIONS A ampere(s) lb pound(s) ABDC after bottom dead center m meter(s) AC alternating current min minute(s) A TDC after top dead center N newton(s) BBDC before bottom dead center Pa pascal(s) BDC bottom dead center PS horsepower BTDC before top dead center psi pound(s) per square inch C degree(s) Celsius r rev olution DC direct cur[...]

EMISSION CONTROL INFORMA TION T o protect the environment in which we live , Kawasaki has incor por ated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and the Calif or nia Air Resources Board. 1. Crankcase Emission Control System A seale[...]

Fore w or d This manual is designed pr imarily for use by trained mechanics in a properly equipped shop. Howe ver , it contains enough detail and basic inf or mation to mak e it useful to the owner who desires to perf or m his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures mus[...]

GENERAL INFORMA TION 1-1 General Inf ormation T able of Contents 1 Before Servicing ................................................................................................................................................................. 1-2 General Specifications ............................................................................[...]

1-2 GENERAL INFORMA TION Before Servicing Before starting to service the engine, carefully read the applicable section to eliminate unnecessary work. Photogr aphs, diagrams , notes, cautions, warnings, and detailed descriptions have been included where ver necessary . Nev er theless, ev en a detailed account has limitations, a cer tain amount of ba[...]

GENERAL INFORMA TION 1-3 Before Servicing (15) Cotter Pin Replace any cotter pins that were removed with new ones, as removal def or ms and breaks them. (16) Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surf aces hav e an adequate lubricative film. During assembly , oil or grease (wh[...]

1-4 GENERAL INFORMA TION General Specifications Item FE120 FE170 T ype D T ype G T ype D T ype G Dimensions: L W Hm m 291 349 344 300 354 370 in 11.46 13.43 19.54 11.81 13.94 14.57 Dry Weight kg 14.5 16.8 Engine: T ype of engine Air cooled, 4-stroke, OHV , Single cylinder , Gasoline engine Number of Cylinder 1 Bore Stroke mm 60 44 66 50 in 2.36 1.[...]

GENERAL INFORMA TION 1-5 General Specifications Item FE250 FE290 FE350 FE400 T ype D T ype G T ype D T ype G T ype D T ype G T ype D Type G Dimensions: L W Hm m 344.5 395 432 363 408 441 378 422 454 378 422 459 in 13.56 15.55 17.01 14.29 16.06 17.36 14.88 16.61 17.87 14.88 16.61 18.07 Dry Weight With recoil star ter kg 26.8 30.4 34.4 34.5 With ere[...]

1-6 GENERAL INFORMA TION P eriodic Maintenance Char t T o ensure satisfactory operation over an e xtended period of time, any engine requires nor mal maintenance regular intervals. The P er iodic Maintenance Char t below shows periodic inspection and maintenance items and suitable inter v als. The bullet mark (•) designates that the corresponding[...]

GENERAL INFORMA TION 1-7 Special T ools Compression Gauge: 57001–221 Hand T ester: 57001–1394 Kawasaki Bond (Silicone Sealand): 56019–120 Piston RIng Pliers: 57001–115 Piston Ring Compression Grip: 57001–1095 Piston Ring Compression Belt, 50– 67: 57001–1096 Piston Ring Compression Belt, 67– 79: 57001–1097 Piston Ring Compression B[...]

1-8 GENERAL INFORMA TION Exploded View FE120[...]

GENERAL INFORMA TION 1-9 Exploded View FE170[...]

1-10 GENERAL INFORMA TION Exploded View FE250[...]

GENERAL INFORMA TION 1-11 Exploded View FE290[...]

1-12 GENERAL INFORMA TION Exploded View FE350[...]

SER VICE D A T A 2-1 Service Data T able of Contents 2 Service Specifications ........................................................................................................................................................ 2-2 Adjustment Specifications .......................................................................................[...]

2-2 SER VICE D A T A Service Specifications Service Limit (mm) FE120 FE170 FE250 Item T ype D T ype G T ype D T ype G T ype D T ype G Compression (minimum) with Recoil Star ter 290 kP a (3 kg/cm 2 , 42 psi) with Electric Star ter 390 kP a (4 kg/cm 2 , 57 psi) Cylinder Bore (maximum) 60.067 66.067 76.070 (2.3648 in) (2.3648 in) (2.9949 in) Roundnes[...]

SER VICE D A T A 2-3 Service Specifications Service Limit (mm) FE120 FE170 FE250 Item T ype D T ype G T ype D T ype G T ype D T ype G Connecting Rod Connecting Rod Big End Bore (maximum) 26.052 29.052 34.067 (1.0257 in) (1.1438 in) (1.3412 in) Connecting Rod Small End Bore (maximum) 14.042 16.047 18.051 (0.5528 in) (0.6318 in) (0.7107 in) Connecti[...]

2-4 SER VICE D A T A Service Specifications Service Limit (mm) FE290 FE350 FE400 Item T ype D T ype G T ype D T ype G T ype D T ype G Compression (minimum) with Recoil Star ter 290 kP a (3 kg/cm 2 , 42 psi) with Electric Star ter 390 kP a (4 kg/cm 2 , 57 psi) Cylinder Bore (maximum) 78.067 83.067 87.067 (3.0735 in) (3.2703 in) (3.4278 in) Roundnes[...]

SER VICE D A T A 2-5 Service Specifications Service Limit (mm) FE290 FE350 FE400 Item T ype D T ype G T ype D T ype G T ype D T ype G Axial Play (maxim um) ––– 0.35 0.35 0.35 0.06 0.35 (0.013 in) (0.013 in) (0.013 in) (0.024) (0.013 in) (standard: (standard: (standard: (standard: (standard: 0.07 ~ 0.21) 0.06 ~ 0.24) 0.07 ~ 0.21) 0.06~ 0.24) [...]

2-6 SER VICE D A T A Service Specifications Service Limit (mm) FE120 FE170 FE250 Item T ype D T ype G T ype D T ype G T ype D Type G Piston Ring Piston Ring Thickness (minimum) T op , Second 1.42 (0.056 in) 1.44 (0.057 in) Piston Ring End Gap (maximum) T op , Second 1.0 (0.039 in) Oil Ring Visual Inspection Cylinder Head V alve Seating Surf ace Wi[...]

SER VICE D A T A 2-7 Service Specifications Service Limit (mm) FE290 FE350 FE400 Item T ype D T ype G T ype D T ype G T ype D T ype G Piston Ring Piston Ring Thickness (minimum) T op , Second 1.44 (0.057 in) Piston Ring End Gap (maximum) T op , Second 1.2 (0.047 in) Oil Ring Visual Inspection Cylinder Head V alve Seating Surf ace Width Standard 0.[...]

2-8 SER VICE D A T A Adjustment Specifications Adjustment Specifications FE350 Item FE120 FE170 FE250 FE290 FE400 Idle Speed Setting (crankshaft) 1600 rpm 1300 rpm No-Load Maximum Speed Setting (crankshaft) 4000 rpm V alve Clear ance: Intake, Exhaust Adjustment (clearance on cold engine) 0.12 mm (0.0047 in) unnecessary Spark Plug Electrode Gap 0.[...]

SER VICE D A T A 2-9 Tightening T orque Specifications Tightening T orque Specifications Unit: N m (kg m, ft lb) Tightening T orque FE350 Tightening Location FE120 FE170 FE250 FE290 FE400 Cylinder Head Bolts 25 (2.5, 18) Connecting Rod Bolts 12 20 23 (Apply Oil to Threadss before Tightening) (1.2, 8.9 in lb) (2.0, 15) (2.3, 17) Flywheel Retaning [...]

2-10 SER VICE D A T A Wiring Diagram Ignition Coil/Ignition Separate T ype[...]

SER VICE D A T A 2-11 Wiring Diagram Ignition Coil/Igniter Integrated T ype[...]

2-12 SER VICE D A T A T roub leshooting If the engine malfunctions, first check whether th engine has been operated correctly . Then, systematically carr y out the troubleshooting procedure starting with simple items. This troubleshooting chart lists typical malfunctions. Do not unnecessarily disassemble any par ts bef ore the cause of the problem[...]

SER VICE D A T A 2-13 T roub leshooting[...]

2-14 SER VICE D A T A T roub leshooting[...]

SER VICE D A T A 2-15 T roub leshooting[...]

2-16 SER VICE D A T A T roub leshooting[...]

SER VICE D A T A 2-17 T roub leshooting Star ter Motor T roub leshooting and Actions • Remov e the spark plug cap and ground the high-tension lead terminal. • P erform an inspection by turning the key s witch to the ST ART position. CA UTION Do not touch the par ts or accessories other than the star ter motor when troubleshooting the starter mo[...]

2-18 SER VICE D A T A Disassembly Sequence (FE120, 170) Bolt to be removed f or tool Disassembly Precaution Name Quantity Drain Plug W arm up engine and drain oil. 14 across flats Fuel T ap , Fuel T ank Drain fuel before disassemb ly . 17 across flats (tap) 1 M6 bolt (tank) 4 Spark Plug 21 across flats Shroud M6 bolt 6 Muffler Assembly Remov e [...]

SER VICE D A T A 2-19 Disassembly Sequence (FE250, 290, 350, 400) Bolt to be removed f or tool Disassembly Area Precaution Name Quantity Drain Plug W ar m up engine and dr ain oil. 14 across Fuel T ap , Fuel T ank Drain fuel before disassemb ly . M6 bolt (tap) 1 M6 bolt (tank) 6 Spark Plug 21 across Muffler Assembly Remove the e xhaust pipe cover [...]

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DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-1 Disassembl y , Reassembly , Inspection, and Maintenance T able of Contents 3 Carburetor....................................................................3-2 Construction and Function ................................... 3-2 Disassembly , Cleaning, and Reassembly Precau- tions ...........[...]

3-2 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Carburetor Construction and Function The function of a carburetor is to mix fuel and air b y applying the principle of an atomizer , thus creating an appropr iate air-fuel mixture in accordance with load fluctuations. The major functions of a carburetor consist of the follo wing four sys[...]

DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-3 Carburetor An optimal fuel lev el is prescribed at the time the carburetor is designed. Along with the fluctuations in the fuel level, the float mov es up and down in order to open and close the float valv e. The flow of fuel into the float chamber is enabled or stopped in this manne[...]

3-4 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Carburetor • Check how the float v alve spring is fitted. Make sure that the first coil of the float v alve spring is completely wrapped in both spring groo ves that are pro vided at the two ear-shaped protrusions on the float valv e body . NO TE Do not unnecessarily disassemble th[...]

DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-5 Carburetor Minimum No-Load Speed Adjustment • After completing the pilot screw adjustment, the minimum no-load adjustment must be adjusted. • K eep the throttle lev er on the carburetor pushed gently to the fully closed position, and turn the idle adjustment scre w so that the engine [...]

3-6 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Carburetor Carburetor with Fuel Cutoff V alve T o prev ent after-burns that occur in the f or m of combustion in the muffler when the engine is stopped, the float chamber of this carburetor is provided with a solenoid-actuated fuel cutoff valv e. When the engine switch is tur ned to the[...]

DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-7 Governor Mec hanism Gov ernor Operating Mechanism Connected to the throttle le ver on the carb uretor via a link rod, the gov ernor operates automatically in accordance with load fluctuations in order to maintain a constant engine speed. The gov ernor relies on centr ifugal f orce f or i[...]

3-8 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Governor Mec hanism Gov ernor Gear Assembly Installation CA UTION Do not remove the governor gear assembly unless the parts are to be replaced. The par ts cannot be reused once they are removed. • Use two screwdriv ers of an appropriate size to remov e the gov er nor gear assembly . Pro[...]

DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-9 Governor Mec hanism A: Gov er nor Arm B: Throttle V alve C: Gov er nor Shaft D: Clamp Nut E: Pin[...]

3-10 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Air Cleaner The quality of the inspection or maintenance of the air cleaner significantly aff ects the durability and the perf or mance of the engine. If the engine is used in a dusty area, the air cleaner element should be cleaned more frequently than the regular inspection inter v als[...]

DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-11 Cooling System All the cooling fans of the FE ser ies engines are the separate type that can be separated from the flywheel. FE290 type: NO TE On the engine produced before May 1996, the flywheel and the cooling fan are integrated and cannot be disassembled. • A separate type cooling[...]

3-12 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Fuel T ank and Filter • Place an appropriate container under the fuel filter to catch the fuel. Remov e the filter pot, turn the fuel tap ON, and completely drain the fuel from the fuel tank and the fuel line. If the drained fuel contains dust or w ater , the fuel line from the fuel [...]

DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-13 Ignition System Description of Function The ignition mechanism is the transistorized type and consists of the follo wing par ts: Ignition Coil Igniter Flywheel (with per manent magnet) These components do not contain mechanical contact par ts and do not require regular inspection. Electr[...]

3-14 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Ignition System Automatic Ignition Adv ance Device This device enables the engine to achiev e appropriate ignition timing in all speed ranges. The ignition timing must be retarded slightly when the engine is started and at the lo w- to medium-speed range. On the other hand, the ignition [...]

DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-15 Ignition System Ignition Coil Inspection Spark Characteristics Measurement • Connect the ignition coil to a coil tester to measure its spark characteristics. Follow the measurement instructions provided by the tester manufacturer f or the proper measurement procedure. (For testing pur [...]

3-16 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Ignition System Igniter Inspection Measure the internal resistance of the igniter . Individual Igniter Inspection • T o test the individual igniter shown in the diag ram on the right, set the measurement range of the hand tester to R 100 and measure the resistance. Individual Igniter R[...]

DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-17 Ignition System Controller (with W arning Light) Measurement • Set the measurement range of the hand tester to R 1k and measure the resistance at the areas giv en in the table below . Controller (without ground) Resistance (k ) T ester (–) Negative T ester P ositive (+) T er minal T [...]

3-18 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Ignition System Ignition Coil Reassembly (Air Gap Adjustment) • Rotate the flywheel so that the magnet on the flywheel is on the opposite side of the area in which the ignition coil is to be installed. • Use two bolts to hand-tighten the ignition coil to the area in which the coil [...]

DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-19 Charging System The state of charge of the batter y must be determined by measuring the terminal v oltage of the individual batter y . Individual Battery’s T erminal V oltage Standard: 12 V If the ter minal v oltage is below the standard, the battery must be recharged. Charging System [...]

3-20 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Charging System Regulator Inspection • Disconnect the connector from the regulator . • Set the measurement range of the hand tester to R 1k and measure the resistance at the areas given in the table below . • Although this test is not sufficient to deter mine the integ rity of the[...]

DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-21 Starter System Star ter Motor Construction An FE series engine comes with a Bendix type or shift-lev er type star ter motor . The electrical circuit of a star ter motor consists of a key s witch (engine switch), solenoid (or solenoid s witch on the Bendix type), batter y , and star ter m[...]

3-22 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Starter System 1. Snap Ring 2. Collar 3. Spring 4. Clutch Assembly 5. Nut 6. Spring Washer 7. Bolt 8. Rear Cov er 9. W asher 10. Brush Holder 11. Brush Spr ing 12. Brush 13. Y oke Assembly 14. Armature 15. W asher 16. F ront Cov er Solenoid (Star ter Motor) Wiring Inspection Although the[...]

DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-23 Starter System • Connect lead [B] to ter minal [C]. Set the measurement range of the tester to R 1 , and connect it to the tw o terminals on the solenoid. T urn the key switch to the ST ART position to read the tester . If the solenoid clicks once , the tester reads 0 , and the pinion [...]

3-24 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Starter System Commutator Diameter Measurement Measure the diameter of the commutator at sever al areas. If the diameter is smaller than the service limit, replace the ar mature. Commutator Diameter Service Limit (minimum) Sift Le ver T ype: P/N 21163-2089, 2095 27 mm (1.06 in) Bendix T [...]

DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-25 Recoil Starter CA UTION The recoil spring is stored in the reel under high tension. Hold it firmly when handling so that the spring does not jump out. Disassembly • Pull the rope out approximately 350 mm, and tentatively tie a knot at that position. • Pull out the knot of the rope t[...]

3-26 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Cylinder Head Compression Inspection • After warming up the engine, stop the engine. Remove the spark plug and connect a compression gauge to the spark plug hole. NO TE Connect the spark plug cap to the remov ed spark plug and ground the spar k plug against the engine body . Make sure [...]

DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-27 Cylinder Head Cleaning and Inspection • Inspect the cylinder head for the presence of any cracks or missing fins. Replace the cylinder head if any of those conditions e xist. • Clean the carbon deposits off the combustion chamber and the exhaust port, and wash the cylinder head in a[...]

3-28 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE V alve System Hydraulic Lash Adjuster (HLA) The FE350 and 400 are equipped with a Hydraulic Lash Adjuster (HLA) to automatically adjust the v alve tr ain to zero clearance through hydr aulic means. Purpose of the HLA The HLA hydr aulically adjusts the valv e train to zero clear ance by a[...]

DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-29 V alve System HLA Construction and Operation • When the cam pushes the HLA upward, the oil in the high-pressure chamber [H] tries to flow back to the oil pool [I] of the plunger [G] by passing through the passage [M], b ut because the check ball [E] closes the passage [M], the oil can[...]

3-30 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE V alve System HLA Removal CA UTION Always keep the HLA upright, with the end of the HLA on which the snap ring is visible facing up (socket "A" faces up). If it is placed on its side or upside down, the oil that is sealed in the high-pressure chamber [B] could leak out, disab l[...]

DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-31 V alve System HLA Reassembly • Make sure that the piston is at the top-dead-center of the compression stroke. CA UTION Make sure to apply engine oil to all the sliding areas of the HLA, pushrod, rocker arm, rocker shaft, and valve before reassembly . • Inser t the HLA (with its end o[...]

3-32 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE V alve System • Using a wrench, secure the rocker arm pivot, and tighten the lock nut to the specified torque. (Refer to the section on Tightening T orque Specifications.) On the FE290, use a pair of pliers to hold the adjustment bolt, and tighten the lock n ut to the specified torq[...]

DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-33 V alve System For FE250, 290, 350, 400: Disassembly • Use a v alve spring compressor to compress the valv e spr ing and remov e the collet. • Remov e the valv e spring compressor . • Remov e the retainer , valv e spring, and valv e. • If the stem seal that is provided on the inta[...]

3-34 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE V alve System Use a wire br ush to remov e the deposits from the valv e stem. If the valv e stem does not mov e smoothly in the v alve guide or the stem shows abnormal wear , replace the v alve with a new one. • Using a micrometer , measure the v alve stem diameter in sev eral places. [...]

DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-35 V alve System V alv e Seat Inspection and Lapping A prerequisite for inspecting the valv e seat contact is that the valv e guide and the v alve stem are normal. • Apply a thin layer of fine lapping compound on the contact surface of the valv e. • Using a lapper [A], lap the valv e a[...]

3-36 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE V alve System V alve Seat Contact Standard Width and Service Limit (minimum) – for both Intake and Exhaust Standart Service Limit FE120, 170: 0.7 mm (0.028 in) 1.7 mm (0.067 in) FE250, 290, 350, 400: 0.8 mm (0.031 in) 1.9 mm (0.075 in) • Using a 45 (30 only f or the intake on FE350 a[...]

DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-37 Piston and Connecting Rod Disassembly • Drain the engine oil into an appropr iate container . • Remov e the retaining bolts from the crankcase cov er . Using a wooden or a plastic mallet, gently tap on the crankcase cover at the area where the cov er is f astened to the crankcase , a[...]

3-38 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Piston and Connecting Rod For FE120, 170, 250, 350, 400 • On type D , face the "R" mark on the top of the piston towards the side of the connecting rod mar ked "MADE IN JAP AN". • On type G, face the "L" mark on the top of the piston towards the side of [...]

DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-39 Piston and Connecting Rod For FE290 • On type D , face the arrow on the top of the piston opposite to the side of the connecting rod mar ked "MADE IN JAP AN". • On type G, f ace the arrow on the top of the piston towards the side of the connecting rod marked "MADE IN J[...]

3-40 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Piston and Connecting Rod • Using an inside micrometer , measure the pin hole bore of the piston in sev eral places. Piston Pin Hole Bore Service Limit (maximum) FE120: 14.033 mm (0.5525 in) FE170: 16.033 mm (0.6312 in) FE250: 18.033 mm (0.7100 in) FE290: 19.033 mm (0.7493 in) FE350, 4[...]

DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-41 Piston and Connecting Rod Connecting Rod Inspection • Inspect the big end of the connecting rod for wear or any traces of seizure scratches or discoloration. Abnormal wear or scratches could be caused by the presence of foreign particles in the engine oil. V er tical scr atches or disc[...]

3-42 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Piston and Connecting Rod A: Dial Gauge B: V Block[...]

DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-43 Cylinder Block and Crankcase Cover Cylinder Inspection • Inspect the cylinder wall f or the presence of any scratches , the cylinder exterior f or any broken fins, and for an y other damage. If the cylinder has non-repairable damage, replace the cylinder block with a new one. • Usin[...]

3-44 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Cylinder Bloc k and Crankcase Cover • V erify that a crankshaft or the camshaft that requires an axial play adjustment shim is provided with an adjustment shim. (Refer to the section on Axial Play Adjustment.) • V erify that the governor weight is closed. Also v erify that the govern[...]

DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-45 Cylinder Block and Crankcase Cover Replace a ball bearing in the f ollowing manner: • Remov e the oil seal. Do not reuse an oil seal once it has been remov ed. • Using a bear ing puller as shown in the diagram on the right, remove the bearing. • Clean the bear ing housing and allow[...]

3-46 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Lubrication System Lubrication Method For FE120, 170, 250 As shown in the diag ram on the right, the rev olution of the crankshaft causes the splash ar m that is pro vided at the big end of the connecting rod to pick up the engine oil from the crankshaft chamber and splash it in a spra y[...]

DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-47 Lubrication System Oil Pump Disassembly and Reassemb ly Disassembly • Remov e the six retaining bolts from the oil pump cover and remov e the oil pump cover , gasket, and plate, in that order . A: Retaining Bolts B: Oil Pump Cover • Remov e the inner rotor and outer rotor , in that o[...]

3-48 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Lubrication System • The reassembly is the re verse order of disassemb ly . • Install the outer rotor and the inner rotor , in that order , making sure to prev ent dust from enter ing the oil pump. CA UTION T o install the inner rotor , make sure that the protrusion [B] of the inner [...]

DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-49 Lubrication System • Using a micrometer , measure the follo wing par ts: Inner Rotor Shaft Diameter (maximum) - for FE290, 350, 400 Service Limit: 12.627 mm (0.4971 in) Outer Rotor Diameter (maximum) - f or FE290, 350, 400 Service Limit: 40.467 mm (1.5932 in) Outer Rotor Width (maximum[...]

3-50 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Lubrication System Oil Level Sensor Switch If the oil lev el becomes lower than the preset value , the sensor switch [A] closes. As a result, the base current [IB1] passes through the Zener diode [Z1] and the resistor [R12] to flo w to [TR1] to maintain the circuit. The base current [IB[...]

DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-51 Lubrication System • When the engine is tilted to a cer tain angle, the tester should read 0 . If the tester does not read 0 , but remains at ∞ , the oil lev el sensor switch is f aulty . A: T er minal B: O-ring C: Clamp D: Oil Lev el Sensor Switch Igniter (with oil level warning lig[...]

3-52 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Lubrication System Breather The function of the breather is to maintain a vacuum in the crankcase to pre vent the engine oil from being discharged outside the engine . The breather valv e regulates the flow of the air that is created by the mov ement of the piston b y allowing the air t[...]

DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-53 Lubrication System Oil Filter Replacement Procedure NO TE Be careful with hot oil to prev ent bur ns . Alwa ys use a genuine Kaw asaki oil filter for replacement. Other brands of oil filters ma y also fit but they ma y be of poor quality . • Drain the engine oil into an appropr iate[...]

3-54 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Crankshaft Disassembly • Remov e the crankcase cov er. • If axial play adjustment shims are provided for the crankshaft and the camshaft, remove the shims and identify them so that the y can be installed correctly during reassembly . • Place the cylinder block on a base so that the[...]

DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-55 Crankshaft Crankshaft Inspection • Inspect the crank pin and the journal for galling, wear , or rust. If the crank pin e xhibits damage as described above , carefully inspect and repair the big end of the connecting rod, or replace the connecting rod or the crankshaft with a new par t.[...]

3-56 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Crankshaft For e xample, on the FE350, if measurement [A] is 15.87 mm and measurement [B] is 17.66 mm, the correct shim thickness is t = 1.53 mm. Crankshaft Axial Play Standard and Service Limit (maximum) (unit: mm) Standard Ser vice Limit FE120 0 ~ 0.24 (0 ~ 0.009 in) 0.5 (0.0197 in) FE[...]

DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-57 Balancer Engine vibration is generated primar ily by the iner tia that is created through the reciprocal mov ement mass such as the piston, piston pin, piston ring, and the small end of the connecting rod. On the FE400, 350, 290, and 250, a reciprocal movement balancer system in which ba[...]

3-58 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Balancer Reciprocal Mov ement Balancer (FE400, 350, 290, 250) Disassembly • Remov e the retaining nuts from the balancer guide and pull out the balancer guide from the crankcase. • Remov e the connecting rod bolt and remov e the connecting rod cap. • T urn the crankshaft to be near[...]

DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-59 Balancer • Using a micrometer , measure the balancer guide hole bore of the balance weight in sev eral places. Balancer Guide Hole Bore Service Limit (maximum) FE250, 290: 26.118 mm (1.0283 in) FE350, 400: 26.097 mm (1.0274 in) If the measured value is greater than the service limit, r[...]

3-60 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Balancer Balancer Shaft Journal Diameter Service Limit (minimum) PT O Side Flywheel Side FE170: 14.943 mm (0.5883 in) 14.933 mm (0.5879 in) If the measured value is smaller than the service limit, replace the balancer shaft. * For details on the bore of the balancer shaft bearing hole, r[...]

DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-61 Camshaft Disassembly • Remov e the crankcase cov er. • If axial play adjustment shims are provided for the crankshaft and the camshaft, remove the shims and identify them so that the y can be installed correctly during reassembly . • Place the cylinder block on a base so that the ?[...]

3-62 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Camshaft • Using a micrometer , measure the camshaft jour nal in se ver al places. Camshaft Journal Diameter Ser vice Limit (minimum) (Unit: mm) PT O Side Flywheel Side T ype D T ype G T ype D , G 14.910 19.930 14.910 FE120 (0.5870 in) (0.7846 in) (0.5870 in) 15.910 24.930 15.910 FE170[...]

DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-63 Camshaft A: Matching Marks Camshaft Axial Play Adjustment If a par t that aff ects the axial play has been replaced, the axial play must be adjusted as descr ibed below . Shim adjustment is not av ailable on the FE120 and 170. • Place a gasket on the crankcase and measure and record th[...]

3-64 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Camshaft[...]

DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-65 Camshaft Apply these measurements on the cr ankshaft shim selection table , and select the next thinner shim. For example , on the FE350D , if measurement [A] is 13.41 mm and measurement [B] is 14.09 mm, the correct shim thickness is t = 0.4 mm. For e xample, on the FE350G, if measuremen[...]