KAWASAKI FC540 - FC260V ENGINE MANUAL
Table of Contents – Page 1 of 5
FOREWORD AND SAFTEY
GENERAL INFORMATION
MECHANICAL SYSTEM
ELECTRICAL SYSTEM
GENERAL SPECIFICATIONS
WIRING DIAGRAM
FC290 ELECTRIC STARTER MODEL
FC420 & FC540 ELECTRIC STARTER MODEL
PERIODIC MAINTENANCE
TROUBLE SHOOTING
ENGINE - HARD STARTING
ENGINE - MALFUNCTIONS AT LOW SPEED
ENGINE - ERRATICAL RUN
ENGINE - LOW POWER
TORQUE SPECIFICATIONS
CONTROL SYSTEM
GOVERNOR LEVER SETTING
THROTTLE CABLE INSTALLATION
FAST IDLE SPEED ADJUSTMENT
CHOKE ADJUSTMENT
SLOW IDLE SPEED ADJUSTMENT
AIR CLEANER
"K" KLEEN SYSTEM
MAINTENANCE
CARBURETOR
COMPONENTS
REMOVAL
FLOAT CHAMBER REMOVAL
CLEANING
FLOAT ADJUSTMENT
ASSEMBLY AND INSTALLATION
CARBURETOR IDENTIFICATION
COOLING SYSTEM
BLADE GAP ADJUSTMENT
KAWASAKI FC540 - FC260V ENGINE MANUAL
Table of Contents – Page 2 of 5
RECOIL STARTER
DISASSEMBLY
DISASSEMBLY
CHECK
REASSEMBLY
ELECTRIC STARTER & CHARGING
TROUBLE SHOOTING
SOLENOID AND CIRCUIT CHECK
STARTER MOTOR CHECK
COMPONENTS-FC290 (BENDIX TYPE)
COMPONENTS-FC420 (SHIFT TYPE)
COMPONENTS-FC540 (SHIFT TYPE)
BRUSH SERVICE LIMIT
BRUSH LENGTH MIN
BRUSH SPRING CHECK
BRUSH HOLDER CHECK
ARMATURE CHECK
ARMATURE SERVICE LIMIT
STD GROOVE DEPTH
COMMUTATOR RUN-OUT MAX
YOKE CHECK
PINION CLUTCH CHECK
STARTER MOTOR REASSEMBLY
REGULATOR CHECK
UNREGULATED STATOR OUTPUT (13-15A TYPE)
UNREGULATED STATOR OUTPUT MIN
STATOR OUTPUT (3A TYPE)
STATOR OUTPUT MIN
IGNITION SYSTEM
TYPE OF IGNITION SYSTEM
SPARK CHECK
CONTROL UNIT CHECK
CONTROL UNIT RESISTANCE (OHM)
IGNITION COIL CHECK
IGNITION COIL RESISTANCE
FLYWHEEL REMOVAL
FLYWHEEL INSTALLATION
IGNITION COIL AIR-GAP ADJUSTMENT
FUEL PUMP
REMOVAL AND DISASSEMBLY
COMPONENTS
CHECK
KAWASAKI FC540 - FC260V ENGINE MANUAL
Table of Contents – Page 3 of 5
FUEL PUMP - Continued
INSTALLATION
CYLINDER HEAD
COMPRESSION CHECK
REMOVAL
MAINTENANCE
INSTALLATION
VALVE
VALVE CLEARANCE ADJUSTMENT
AUTOMATIC COMPRESSION RELEASE (ACR) CHECK
VALVE AND RELATED PARTS REMOVAL
CHECK AND MAINTENANCE
SERVICE LIMIT
VALVE STEM DIA. MIN
VALVE SPRING SERVICE LIMIT
FREE LENGTH MIN (INTAKE & EXHAUST)
LAPPING
VALVE SEAT RECONDITIONING
STD VALVE SEAT WIDTH (INTAKE & EXHAUST)
VALVE GUIDE SERVICE LIMIT
VALVE GUIDE REPLACEMENT
REMOVAL
INSTALLATION
FINISH
ROCKER ARM SERVICE LIMIT
ROCKER SHAFT SERVICE LIMIT
PUSH ROD SERVICE LIMIT
CRANKCASE COVER
REMOVAL
SERVICE LIMIT
PTO BEARING INSIDE DIA. MAX
CAMSHAFT BEARING INSIDE DIA. MAX
BUSHING REPLACEMENT - FC290
OIL SEAL REPLACEMENT
INSTALLATION
CAMSHAFT
REMOVAL
VISUAL CHECK
SERVICE LIMIT
BEARING JOURNAL DIA. MIN
FC290
KAWASAKI FC540 - FC260V ENGINE MANUAL
Table of Contents – Page 4 of 5
CAMSHAFT - Continued
FC420
FC540
LOBE HEIGHT MIN (INTAKE AND EXHAUST)
INSTALLATION
AXIAL PLAY ADJUSTMENT
FC290
FC540
PISTON & CON-ROD
REMOVAL
PISTON AND PISTON RING VISUAL CHECK
PISTON CLEANING
PISTON SERVICE LIMIT
RING GROOVE CLEARANCE MAX FC290
RING GROOVE CLEARANCE MAX FC420 * FC540
PISTON PIN HOLE DIA. MAX
PISTON PIN SERVICE LIMIT
PISTON PIN DIA. MIN
PISTON RING SERVICE LIMIT
PISTON RING THICKNESS MIN (TOP AND SECOND)
PISTON RING END GAP MAX (TOP AND SECOND)
PISTON RING INSTALLATION
CON-ROD VISUAL CHECK
CON-ROD SERVICE LIMIT
SMALL END INSIDE DIA. MAX
BIG END INSIDE DIA. MAX
PISTON AND CON-ROD ASSEMBLY
PISTON/CON-ROD ASSEMBLY INSTALLATION
CRANKSHAFT
REMOVAL
VISUAL CHECK
SERVICE LIMIT
JOURNAL OUTSIDE DIA. MIN FC290
JOURNAL OUTSIDE DIA. MIN FC420
JOURNAL OUTSIDE DIA. MIN FC540
CRANKPIN OUTSIDE DIA. MIN
BALANCER LINK ROD JOURNAL OUTSIDE DIA. MIN
AXIAL PLAY ADJUSTMENT
FC290
FC420
INSTALLATION
CRANK PIN REGRINDING
FC290
KAWASAKI FC540 - FC260V ENGINE MANUAL
Table of Contents – Page 5 of 5
CRANKSHAFT - Continued
FC420
FC540
BALANCER
BALANCE WEIGHT SERVICE LIMIT
BALANCE WEIGHT BUSHING INSTALLATION - FC420 & FC540
BALANCER SUPPORT SHAFT SERVICE LIMIT
BALANCER LINK ROD SERVICE LIMIT
BIG END INSIDE DIA. MAX
LINK ROD BUSHING ASSEMBLY
GOVERNOR
GOVERNOR GEAR CHECK AND REMOVAL
GOVERNOR GEAR INSTALLATION
GOVERNOR SHAFT INSTALLATION
LUBRICATING SYSTEM
ENGINE OIL
OIL SLINGER CHECK - FC290
OIL WARNING SYSTEM - FC420 & FC540
FULL FLOW OIL FILTER - FC420 & FC540
OIL PASSAGE CHECK - FC420 & FC540
OIL PUMP COMPONENTS - FC420 & FC540
OIL PUMP CHECK - FC420 & FC540
BREATHER SYSTEM
BREATHER REED VALVE CHECK
REED VALVE GAP MAX
CYLINDER/CRANKCASE
CYLINDER SERVICE LIMIT
CYL. BORE INSIDE DIA. MAX
CYL. BORE OUT OF ROUND MAX
CYLINDER BORE RE-SIZING
FC290
FC420 * FC540
FC290
FC420 * FC540
BALL BEARING CHECK
BALL BEARING REPLACEMENT
OIL SEAL REPLACEMENT
CAMSHAFT BEARING SERVICE LIMIT
CAMSHAFT BEARING INSIDE DIA. MAX
FC290V
FC420V
FC540V
OHV
WORKSHOP
MANUAL
4-stroke air-cooled
gasoline
engine
FOREWORD
This
manual
is
designed for use by trained mecha-
nics in a properly equipped shop.
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
equipments are
specified, do not use makeshift tools
or
equipment.
Precision measurements can only be made if the prop-
er instruments are used, and the use of substitute
tools may adversely affect safe operation.
Whenever you see these
W A
R
N I N
G
AND
C
A
U-
T
I
O
N
symbols. heed their instructions!
Always follow safe operation and maintenance prac-
t ices.
A
W A
R
N
I
N
G
:
This safety alert symbol iden-
tifies important safety messages in this man-
ual and on the equipment. When you see this symbol,
read the message that follows very carefully to
avoid fire, personal. injury,
or
loss of life.
The term "Replace" and some abbreviations are used
as follows:
Replace
=
Usually means replace with a new part
MIN
=
Minimum
MAX
=
Maximum
Assy
=
Assembly
STD
=
Standard
PTO
=
Power take off
Approx.
=
Approximately (Approximate)
Carb.
=
Carburetor
Con-rod
=
Connecting rod
Cyl.
=
Cylinder
Dia.
=
Diameter
All
rights reserved. No part of this publication
may be reproduced, stored in a retrieval system,
or
transmitted in any form or by any means, elec-
tronic mechanical photocopying, recording
or
other-
wise, without the prior written permission of Engine
Division/Kawasaki Heavy Industries, Ltd. No liabili-
ty can be accepted for any inaccuracies
or
omissions
in this publication. although every possible care
C
AUT
I
O
N
:This identifies special instructions
has been taken to make it as complete and accurate
or
procedures to avoid equipment damage
or
destruc-
as possible.
All
procedures and specifications sub-
t ion.
ject to change without prior notice
or
obligation.
Illustrations in this publication are intended for
N
O
T
E
:
Indicates message
or
points of particular
reference use only and may not depict actual model
interest for more efficient and convenient operation.
component parts.
SAFETY
A
W A
R
N
I N
G
:
Gasoline
is
extremely flam-
mable and can be explosive under certain con- sembly operations on the equipment with the
ditions. Stop the engine.
Do
not smoke. Make sure electric starter, disconnect the negative
(-)
the area
is
well ventilated and free from any source
lead
from
the battery to avoid the possibility of
of flame
or
sparks: this includes any appliance with accidentally cranking the engine while partially
a pilot light.
d
i
sassembl ed.
A
W A
R
N
I
N
G
:
Before performing any disas-
A
W A
R
N I
N
G
:
When servicing the engine'
or
equipment, always stop the engine and remove
the spark
plug
wire from the spark plug to avoid
accidental starting.
A
WA
R
N
I N
G
:
Always minimize shock hazards
when working on the electrical equipment. Work
in a clean, dry environment with dry hands. For max-
imum shock hazard protection, connect the equipment
A
WA
R
N
I N
G
:
Always minimize shock hazards
when working on the electrical equipment. Work
in a clean, dry environment with dry hands. For max-
imum shock hazard protection, connect the equipment
ground terminal to an earth ground
\
A
W A
R
N I N
G
:
Protect your hands with gloves
or
a piece of thick cloth from edges and heat
in servicing the product.
1
1
GENERAL
I
NFORMAT
I
ON
Be familiar with OPERATOR’S
MANUAL
before service.
Lubrication
Supply engine
oil
as specified even for a short
test running to avoid any score in the engine,
which may destroy the engine in the field use.
Use clean engine oil in the case specified as just
“coat oil” in this manual.
Don’t use just any oil
or
grease. Some oils and
greases in particular should be used only in certain
applications and may be harmful if used in an ap-
plication for which they are not intended.
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.
Fuel
Unleaded gasoline
is
preferably recommended because
of the less deposit in the combustion chamber.
Alcohol mixed gasoline
is
not recommended due to
bad influences of alcohol on the engine components
in the fuel and combustion systems.
High Flash-point Solvent
A
high flash-point solvent
is
recommended to reduce
fire danger.
A
commercial solvent commonly available
in North America is Stoddard solvent (generic name).
Always follow manufacturer’s and container’s direc-
tions regarding the use of any solvent.
Dirt
Before removal and disassembly, clean the product.
Any dirt entering the product, carburetor,
or
other
parts will work as an abrasive and shorten the life
of the product.
For
the same reason, before install-
ing a new part, clean off any dust
or
metal fillings.
Liquid
Gasket and Non-permanent Locking Agent
Follow manufacturer’s directions for cleaning and
preparing surfaces where these compounds wi
1)
be
used.
Apply
sparingly. Excessive amounts may block
engine oi
1
passages and cause serious damage. An
example of a non-permanent locking agent commonly
available in North America
is
Loctite Lock’n Seal
(Blue).
Oil Seal, Grease Seal
Replace any oil
or
grease seals that were removed,
because the removal generally damages seals.
A
seal guide
is
required for certain oil
or
grease
seals during installation to avoid damage to the
seal
1
ips.
Gasket,
0-r
ing
When in doubt as to the condition of a gasket
or
O-ring, replace it. The mating surfaces around the
gasket should be free from foreign matter and smooth
to avoid leakage.
Circl ip. Retaining Ring
Replace any circlips and retaining rings that were
removed, because the removal weakens and deforms
them. When installing circlips and retaining rings,
take care to compress
or
expand them only enough to
install them.
2
2
GENERAL
I
NFORMAT
I
ON
Force
Common sense should dictate how much force is neces-
sary
in
assembly and disassembly.
If
a part seems
especially difficult to remove or install, stop and
check what may be causing the problem. Whenever tap-
ping
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.
Press
A
part. such as a seal, installed
using
a press or
driver should first be coated with oil on its outer
or inner surface
so
that
it
will
go into place
smoothly.
Ball
Bearing Installation
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.
Torque
The torque values given
in
this manual should
always be adhered to. Either too little or too much
torque may lead to serious damage. Use
a
good qual
i-
ty.
reliable torque wrench.
Tightening Sequence
Follow the tightening sequence shown
in
this
manual.
When installing a part with several bolts, nuts or
screws, they should all be started
in
their holes
and tightened to a
snug
fit.
Then tighten them
evenly, according to the tightening sequence, to
the specified torque.
This
is to
avoid
distortion
of the part and/or leakage. Conversely, when loosen-
ing
the bolts, nuts. or screws, loosen all of
them
about a quarter of a turn and then remove them.
3
3
GENERAL
I
NFORMATI ON
NO
Shock
The electrical parts should never be sharply struck,
with a hammer, or dropped on a hard surface. Such
a shock to the parts may damage them.
Electrical Leads
All
the electrical leads are either single-color
or
two-color and, with only a few exceptions, must be
connected to leads of the same color. On any of the
two-color leads, there
is
greater amount of prime
color and lesser amount of second color,
so
the two-
color lead
is
identified first by the prime color
and then the second color. For example, a yellow
lead with thin red stripes
is
referred to as a
"yellow/red" lead;
it
would be a "red/yellow" lead
if the colors were reversed to make red the prime
color.
TWO-COLOR
LEAD
Lead
(cross-section)
Name of
Lead Color
red
red
yel low/red
Defective Component
Never replace a defective electrical component with-
out determining what caused the failure. If the
failure was brought on by some other item
or
items,
they too must be repaired
or
replaced,
or
the new
replacement will fail again.
Connectors
Make sure all connectors
in
the circuit are clean
and tight, and examine leads for signs of burning,
fraying, etc. Poor leads and bad connections will
affect electrical system operat ion.
Coil
Resistance
Measure coil and winding resistance when the part
is
cold (at room temperature).
Battery
Do not disconnect the battery leads
or
any other
electrical connections when the ignition switch
is
on,
or
while the engine
is
running, unless
specifically noted.
Do
not reverse the battery lead connections. This
will
burn out the diodes
or
other parts in the
electrical systems.
Always check battery condition before blaming other
parts
of
an electrical system.
A
fully charged
battery
is
a must for performing accurate electrical
system check.
Starter
Never keep the starter engaged if the starter motor
will not turn over,
or
the current may burn out the
starter motor windings.
KAWASAKI Multimeter
KAWASAKI Mult imeter-(P/N
395100-9803A)
is
recom-
mended for the electrical system check because a
meter of other type may indicate different value.
4
4
GENERAL SPEC
I
F
I
CAT
I
ONS
ITEM
Engine Type
Number of Cylinder
Piston Displacement
Bore
x
Stroke
Direction of Rotation
Fast Idle Speed
low Idle Speed
ACR
Lubricating Method
Oil
Pan Capacity
Carburetor
Choke Control
Air
Cleaner
Ignition
Charging Coil
*
Spark Plug
RFI
Suppressor
*
Electric Starter
Cooling
Air
Inlet
Fuel Pump
*
Governor
Balancing
Recommended Battery
FC29OV
1
Forced Air-cooled, Vertical Shaft, OHV, 4-Stroke Gasoline Engine
FC54OV
FC420V
286
cc
(17.5
cub-in.)
423
cc
(25.8
cub-in.
)
535
cc
(32.6
cub-in.
)
78
x
60
mm
89
x
68
mm
(3.50
x
3.39
in.)
(3.50
x
2.68
in.
)
(3.07
x
2.36
in.
)
89
x
86
mm
Counterclockwise facing the PTO Shaft
3275
3425
rpm cf. Note
5
1450
1650
rpm
Mechanical Flyweight Type
Splash
Pressurized
1.1
L
(2.3
us
Pt)
1.6
L
(3.4
US
Pt)
1.3
L
(2.7
us
Pt)
Float Type Fixed Main Jet
Automatic (with Throttle Control)
Semi-cyclone Type
with
Dual Element
Transistorized Flywheel Magneto
12
V
-
3
A
with Rectifier
12
V
-
13
A
with Regulator
12
V
-
15
A
with Regulator
Champion
RN11YC
or
NGK
BPR5ES
Per Canada and
USA
Requirement
12
V
-
0.6
kW Bendix
12
V
-
0.6
kW
Shift
12
V
-
0.8
kW
Shift
Type
Rotating Screen with Periphery Blade Protector
Diaphragm Type Pulse Pump
Mechanical Flyweight
Reciprocating Balance Weight
12
V
-
ZOO
CCA
-
510
CCA
12
V
-
280
CCA
Note
:
1.
Specifications are subject to change without notice.
2.
ACR
=
Automatic Compression Release.
3.
Parts with
*
are option.
4.
Recommended Batteries listed
in
upper column are for regular use and
in
lower column
for
low temper-
5.
Fast idle speed may vary depending on each equipment on which engine
is
used. Refer to the equipment
ature application.
specification.
5
WIRING
DIAGRAM
5
1.
Charging coil outputs are shown above each dia-
2.
Portion surrounded by hatching shows KAWASAKI
3.
Key switch connections are shown below.
gram.
procurement parts.
A:
Engine
B:
Spark
plug
C:
Ignition coil
D:
Charging coil
E:
Control
unit
F:
Rectifier
G:
Connector
(3P)
H:
Key switch
I:
Fuse
(10
A)
J:
Fuse
(20
A)
K: Battery
L:
Solenoid switch
M:
Starter
N:
Regulator
0:
Charge light
(12
V,
3.4
W)
12V-3A
12V-13A
n
6
6
WIRING
DIAGRAM
1.
Charging coil outputs are shown above each dia-
2.
Portion surrounded
by
hatching shows KAWASAKI
3.
Key switch connections are shown below.
gram.
procurement parts.
START
A:
Engine
B:
Spark
plug
C: Ignition coil
D:
Charging coil
E:
Control unit
F:
Rectifier
G:
Connector
(3P)
H:
Key switch
I:
Fuse
(10
A)
J:
Fuse
(20
A)
K:
Battery
1:
Oil pressure switch
M:
Starter
N:
Regulator
0:
Charge light
(12
V,
3.4
W)
P:
Oil pressure light
(12
V,
3.4
W)
12V-3A
12V-13A (FC420)
12V-15A (FC540)
7
7
PER
I
OD
I
C MA
I
NTENANCE
To
ensure satisfactory operation over extended period of time, engine requires normal maintenance at regular
intervals.
Chart below shows periodic maintenance. Suitable interval is shown as
(0).
I
INTERVAL
MAINTENANCE
Tighten nuts and screws.
Clean air cleaner paper element.
Clean fuel valve.
Change engine oil (without oil filter).
Change engine oil (with oil filter).
Clean and regap spark plug.
Change oil
filter.
Replace air cleaner paper element.
Clean dust and dirt from cylinder and
cyl inder head f ins.
Clean combust ion chamber.
Check and adjust valve clearance.
Clean and lap valve seating surface.
Perform these maintenances after first
5
hours (FC290V)
or
10
hours of use, then at
recommended intervals.
Service more frequently under dusty conditions.
8
8
TROUBLE.
SHOOT
I
NG
Remove spark plug and
check spark by crank-
ing engine while hav-
ing the plug grounded
against engine block.
Install spare plug to
plug hole to avoid
fuel spitting from the
hole.
I
NG:
To
avoid electric
shock. do not hold
plug itself.
Make sure to hold plug
cap.
I
YES
I
I
Are sparks produced
between high tension
lead and engine
block
in
state where
plug cap
is
removed?
contact
of
plug cap terminal
NO
to lead.
I
I
control
unit.
Replace
Are sparks produced
between high tension
lead and engine
block when control
unit
is
replaced?
ignition coil.
Faulty high tension Replace
Incorrect ignition Correct
Demagnetized fly- Rep ace
cord.
coil air gap.
wheel.
I
*No
fuel
in
the tank.
Add
fuel filter.
Clean
move spark plug and air hole
in
observe electrodes. tank cap.
Clean
Clean
Are they wet?
Plugged
fuel
line.
I
I
I
*Check for plugged
Check
for
plugged
f ue passage.
air passage.
Check float level.
Check carb. set-
t
ing.
Excessive use
of
Open choke
Clogged air cleaner.
Clean
high fuel level
Adjust
choke.
in
float bowl.
Worn piston/piston
Stuck piston rings.
*Worn cyl. bore.
lnsuff icient cyl.
head tightening.
contact of
valve seat.
Plunged-up valve.
*Warped cyl. head.
Broken valve spring.
Stuck valve.
Burned head gasket.
r
i
ngs.
Replace
Clean
or
replace
Bore or replace
Retighten
Lap
Adjust
Repair
or
replace
Replace
Clean or grind
Rep
l
ace
9
9
TROUBLE
SHOOT
I
NG
n
Remove spark plug and
check spark by crank-
ing engine while hav-
ing the plug grounded
against engine block.
Install spare
plug
to
plug
hole to avoid
fuel spitting from the
hole.
I
NG:
To
avoid electric
shock, do not hold
plug
itself.
Make sure to hold
plug
cap.
STRONG
Faulty
plug
insulation. Rep
1
ace
Fouled electrodes. Clean
*Faulty high tension cord. Rep
1
ace
gap.
Correct
Incorrect ignition coil air
Is
unusual smoke emit-
*
Overrich fuel in carburetor Adjust
ted out of muffler? slow system.
t
Directly and gradually
open throttle valve by
hand.
Does
revolution
drop
or
does engine
NO
pos it ion?
stall at a certain
I
Is
air drawn through
carburetor flange?
Loose flange nuts. Tighten
NO
Damaged gaket. Repl ace
I
I
Is
valve clearance *Compression leakage through Adjust
normal? valve.
Is
alignment of timing
Largely deviated valve tim-
gear marks correct?
ng.
10
10
TROUBLE
SHOOT
I
NG
Problem in fuel system
(lack of fuel)
*Entry of dust
or
water into
little opening of carb.
Clean
air/fuel passes in
Clean
*Plugged air vent
of
fuel
Remove
or
vapour lock in fuel
Clean
Correct
fuel pipe
or
fuel filter.
l
i
ne.
tank cap.
carburetor.
pilot air-screw.
NO
*Plugged oil ring groove.
Replace
valve stems and valve
Correct
*High
oil
level.
Clean
leakage along governor
Replace
leakage from oil seal.
Replace
leakage from gasket.
Replace
leakage from drain plug.
Clogged breather valve. Retighten
or
replace
*Drain-back hole in tappet
Clean
chamber plugged.
Clean
Incorrect oil viscosity.
Change
guides.
shaft.
Same as
HARD
STARTING.
11
11
TROUBLE
SHOOT
I
NG
Is
engine overheated?
YES
NO
Excessive engine load. Adjust load
Carb. not properly adjusted. Adjust
or
clogged air intake Clean
screens, shroud and engine
fins.
chamber.
Carbon deposit in combust ion Clean
spark
plug.
Replace
Is
lubricating condi-
t ion normal? in crankcase.
Excessively contaminated
lubricating oil.
ted out of muffler?
I
Clogged air cleaner. Clean
deposit in exhaust Clean
Carb. not properly adjusted. Ad just
Too much oil in crankcase. Correct
hole and muffler.
Is
compression Same as
HARD
STARTING.
sufficient?
s
compression
sufficient?
Adjust
High idling
R.
P.
M.
Clean
Clogged air cleaner.
Adjust
not properly adjusted.
NO
Open Incomplete opening of choke
valve.
Same as
HARD
NG.
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