Kawasaki FC420V Workshop Manual

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

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.

TABLE

OF

CONTENTS

GENERAL SPEC

I

F

I

CAT

I

ONS

4

PER

I

OD

I

C MA

I

NTENANCE

7

TORQUE SPEC

I

F

I

CAT

I

ONS

12

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

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

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

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

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

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

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

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

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

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

Are they wet?

Plugged

fuel

line.

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

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

Is

valve clearance *Compression leakage through Adjust

normal? valve.

Is

alignment of timing

Largely deviated valve tim-

gear marks correct?

ng.

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

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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Kawasaki FC420V Workshop Manual

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Kawasaki FC420V Workshop Manual

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