KAWASAKI FH601V (01) PDF Document

To protect the environment, your KAWASAKI FH601V engine has incorporated crankcase emission and exhaust emission 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

• Magneto or electronic ignition system

• Fuel filter element

• Air cleaner elements

• Crankcase

• Cylinder heads

• Breather chamber and internal parts

• Intake pipe and tube

When working on your KAWASAKI FH601V, it is important to understand the safety symbols used in the service manual.

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.

NOTE: This note symbol indicates points of particular interest for more efficient and convenient operation.

Before starting any service on your KAWASAKI FH601V engine, please note the following precautions:

(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 the engine.

(2) Battery Ground: Remove the ground (–) lead from the battery before performing any disassembly operations. This prevents accidental starting, sparks, and damage to electrical parts.

(3) Tightening Sequence: 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 to avoid distortion and leakage.

(4) Torque: Use a good quality, reliable torque wrench to tighten fasteners to the specified values. Too little or too much torque can lead to serious damage.

(5) Force: Use common sense. If a part is difficult to remove or install, stop and find the cause. Use a wooden or plastic-faced mallet for tapping when necessary.

(6) Edges: Watch for sharp edges, especially during major engine disassembly. Protect your hands with gloves or a thick cloth.

(7) High-Flash Point Solvent: Use a high-flash point solvent to reduce fire danger. Always follow manufacturer directions.

(8) Gasket, O-Ring: Do not reuse gaskets or O-rings once they have been in service.

(9) Liquid Gasket, Non-Permanent Locking Agent: Apply sparingly. Excessive amounts may block engine oil passages.

(10) Press: A part installed using a press or driver should be coated with oil on its circumference for smooth installation.

(11) Ball Bearing: When installing a ball bearing, push the race that is affected by friction to prevent stress on the balls and races.

(12) Oil Seal and Grease Seal: Replace any removed oil or grease seals with new ones, as removal generally damages them.

(13) Seal Guide: Use a seal guide for certain seals to avoid damaging the seal lips during installation.

(14) Circlip, Retaining Ring: Replace any removed circlips and retaining rings with new ones, as removal weakens and deforms them.

(15) Cotter Pin: Replace any removed cotter pins with new ones.

(16) Lubrication: During assembly, apply oil or grease to any rubbing surface that has lost its lubricative film. Clean off old grease and dirty oil.

(17) Electrical Wires: Connect electrical wires to wires of the same color. A two-color wire is identified by the primary color first, then the secondary color.

(18) Replacement Parts: Always use new parts for replacement as instructed. Removed parts may be damaged or lose their original function.

(19) Inspection: Visually inspect disassembled parts for conditions like abrasion, cracks, dents, warping, or wear. Replace if there is any doubt about their condition.

(1) Idle speeds may vary depending on each equipment. Refer to the equipment specification.

Regular maintenance is required to ensure satisfactory operation of your KAWASAKI FH601V engine. The following table shows the recommended service intervals.

(1): Service more frequently under dusty conditions.

★: These items must be performed with the proper tools. See your authorized Kawasaki Engine Dealer for service, unless you have the proper equipment and mechanical proficiency.

Low Idle Speed Adjustment

1. Disconnect all possible external loads from the engine.

2. Start the engine and warm it up thoroughly. Keep your hands clear of moving parts.

3. Adjust the low idle speed screw [C] with a Phillips Screwdriver [D] until the engine idles at the specified carburetor idle rpm.

Idle Speed (Carburetor idle rpm): 1450 rpm

4. Release the throttle lever and adjust the low idle speed set screw on the control plate to obtain the specified governed low idle speed.

Low Idle Speed (Governed idle rpm): 1550 rpm

High Idle Speed Adjustment

NOTE: High idle speed adjustment should be made after the idle speed adjustment is performed. Do not adjust high idle speed with the air cleaner removed.

1. Start and warm up the engine thoroughly. Keep your hands clear of moving parts.

2. Move the throttle lever at the dash to the high idle position and match the lever hole position with the panel hole by inserting a 6 mm dia. pin or bolt [A].

3. Loosen two M6 control panel mounting bolts [B] enough to move the control panel assembly.

4. Carefully move the control panel assembly right side [C] up or down to obtain the specified high idle speed.

High Idle Speed: 3600 rpm

5. Tighten the M6 Mounting bolts.

Torque – Control Panel Mounting Bolts: 5.9 N·m (0.60 kg·m, 52 in·lb)

6. Remove the 6 mm dia. pin or bolt.

7. Check the idle speed, and readjust the idle speed if necessary.

At high altitude, the standard carburetor air-fuel mixture will be excessively rich, leading to decreased performance and increased fuel consumption. To improve high altitude performance, install a smaller diameter main jet in the carburetor and correct the idle speed.

Main jet high altitude kits are available. The main jet numbers are stamped on the ends of the main jets.

Main Jet Replacement:

1. Place the engine on a level surface and close the fuel shut-off valve.

2. Drain the fuel in the carburetor by unscrewing the drain screw.

3. Remove the carburetor.

4. Unscrew the main jet plugs [C] and take off the main jet plugs and gaskets.

5. Make sure the “L” or “R” mark on the float chamber corresponds to the main jet position.

6. Using a proper blade screwdriver, carefully replace the main jet [D] with a new one for the expected altitude.

7. Tighten the main jet to the specification.

8. Install the gasket and the main jet plug.

Torque – Main Jet Plug: 19 N·m (1.9 kg·m, 14 ft·lb)

Element Removal

1. Remove the Air Cleaner Case Nut and Air Cleaner Case.

2. Remove the Wing Nut [A], Foam Element [B], and Paper Element [C].

Element Cleaning and Inspection

NOTE: In dusty areas, the elements should be cleaned more frequently than recommended. Do not use gasoline or a low flash-point solvent to clean the element due to the danger of fire.

1. Remove the foam and paper elements.

2. Clean the foam element [A] in a bath of detergent and water. Let the element air-dry thoroughly before installing it.

3. Clean the paper element [A] by tapping it gently on a flat surface to remove dust. If the element is very dirty, replace it with a new one.

CAUTION: Do not use compressed air to clean the paper element. Do not oil the paper or foam element.

Element Installation

1. Install the element correctly on the air cleaner body.

2. Be sure the paper element is in-place in the air cleaner body.

3. Be sure the foam element is in-place on the paper element body.

1. Be sure the battery is fully charged.

2. Thoroughly warm up the engine.

3. Stop the engine.

4. Disconnect the spark plug caps and remove the spark plugs.

5. Ground the spark plugs to the engine. WARNING: To avoid fire, do not ground the spark plugs in proximity to the plug holes. Keep them as far away as possible.

6. Attach a compression gauge assembly firmly into one plug hole.

7. For Electric Starter Models: With the throttle fully open, use the starter motor to turn the engine over until the compression gauge stops rising. The compression is the highest reading obtainable.

Cylinder Compression (MIN): 390 kPa (57 psi)

8. Repeat the measurement for the other cylinder.

If compression is too high, check for:

• Carbon build-up on the piston crown and cylinder head.

• Incorrect cylinder head gasket thickness.

• Worn valve guides or piston oil rings causing rapid carbon accumulation.

If cylinder compression is lower than the minimum, check for:

• Gas leakage around the cylinder head (replace gasket, check for head warp).

• Poor valve seating.

• Incorrect valve clearance.

• Piston/cylinder wear or seizure.

• Damaged piston rings or ring grooves.

NOTE: Valve clearance must be checked when the engine is cold (at room temperature).

Valve Clearance Inspection

1. Remove the rocker cover.

2. Place the piston at top dead center (TDC) of the compression stroke by turning the crankshaft clockwise (facing the flywheel).

• No.1 Cylinder: The left projection on the flywheel is faced with the right leg on the #1 ignition coil.

• No.2 Cylinder: The left projection on the flywheel is faced with the right leg on the #2 ignition coil.

3. Using a thickness gauge, measure the valve clearance between the rocker arm and the valve stem end. If the clearance is incorrect, adjust it.

Valve Clearance (when cold): Intake, Exhaust 0.075 – 0.125 mm (0.003 – 0.005 in.)

Valve Clearance Adjustment

1. Turn the crankshaft so the piston is at TDC of the compression stroke (as described above).

2. Loosen the lock screws and valve clearance adjusting nuts.

3. Insert a thickness gauge of the correct thickness between the rocker arm and valve stem. Tighten the adjusting nut until the thickness gauge begins to bind. Use a sweeping motion with the gauge while making this adjustment.

4. Holding the adjusting nut with a spanner, tighten the lock screw to the specified torque. Do not overtighten.

Torque – Valve Clearance Lock screws: 6.9 N·m (0.70 kg·m, 61 in·lb)

5. Remeasure the clearance. Readjust if necessary.

Oil Level Inspection

1. Place the engine on a level surface.

2. Remove the oil filler cap [A] and wipe its dipstick [B] with a clean cloth.

3. Insert the dipstick into the tube [C] without screwing it in, then check the oil level.

4. The oil level should be in the operating range [D] (grid area) on the dipstick.

5. If the oil level is in the “ADD” range [E], add enough specified engine oil to bring the level to the operating range. Do not add oil above the “FULL” range [F].

Oil Change

1. Change the oil after the first 8 hours of operation. Thereafter, change the oil every 100 hours.

2. Start and warm up the engine so the oil will drain easily. Stop the engine.

3. Place the engine on a level surface with a suitable container underneath.

4. Remove the drain plug and drain the oil. WARNING: Be careful of hot oil, as it may be hot enough to burn you severely.

5. Check the O-ring at the drain plug for damage. Replace if necessary.

6. Install the drain plug with the O-ring and tighten it.

Torque – Oil Drain Plug (Plastic): 6.9 N·m (0.7 kg·m, 61 in·lb)

Torque – Oil Drain Plug (Metal): 20 N·m (2.0 kg·m, 14.5 ft·lb)

7. Remove the oil filler cap and pour in the specified type and amount of oil.

Engine Oil Grade: SF, SG, SH or SJ Class

Viscosity: SAE40, SAE30, SAE10W-30/SAE10W-40, or SAE5W-20

Capacity (when filter is removed): 1.7 L (1.8 US qt) – except FH721V. 1.8 L (1.9 US qt) – FH721V.

8. Run the engine at slow speed for 2 minutes, stop the engine, and re-check the oil level.

Oil Filter Removal

1. Place a suitable container beneath the oil filter to catch any oil.

2. Using a strap wrench or oil filter wrench, remove the oil filter by turning it counterclockwise.

Oil Filter Installation

1. Apply a light film of engine oil to the seal of the new filter.

2. Install the new filter.

3. Turn the filter until the seal contacts the mounting surface of the engine.

4. Then turn the filter BY HAND an additional 3/4 turn.

5. Run the engine at a slow idle speed for 2 minutes and check for leaks around the filter.

6. Stop the engine and check the oil level, adding oil if necessary.

Spark Plug Cleaning and Inspection

1. Carefully pull the plug cap from the spark plug and remove the spark plug.

2. If the plug is oily or has carbon buildup, clean it using a high flash-point solvent and a wire brush or other suitable tool.

3. If the spark plug electrodes are corroded or damaged, or if the insulator is cracked, replace the plug. Use the standard spark plug (NGK BPR4ES) or its equivalent.

Spark Plug Gap Inspection

1. Measure the gap with a wire-type thickness gauge.

2. If the gap is incorrect, carefully bend the side electrode with a suitable tool to obtain the correct gap.

Spark Plug Gap (Standard): 0.75 mm (0.030 in.)

If your KAWASAKI FH601V engine is hard to start, follow these steps:

1. Check for Spark: Remove the spark plug, connect it to the plug cap, and ground it against the engine block while cranking. Do you see a spark?

• YES: Go to step 2.

• NO: Is a spark produced when the spark plug is replaced? • YES: The original spark plug was faulty. Replace it. • NO: Are sparks produced when the ignition coil is replaced? • YES: The ignition coil was faulty. Replace it. • NO: The ignition coil may be incorrect, or the flywheel is faulty. Correct or replace.

2. Check Compression: Is the compression sufficient?

• YES: Go to step 3.

• NO: Check the piston rings, cylinder bore, cylinder head tightening, valve seat contact, valve clearance, and head gasket. Repair or replace as needed.

3. Check Fuel and Air: Make starting attempts a number of times and then remove the spark plug. Is it wet?

• YES: This indicates excessive use of choke, a plugged air cleaner, or too high fuel level in the float bowl. Remove the plug and turn the crankshaft without loading. Adjust fuel level or clean the air cleaner.

• NO: This indicates a fuel delivery problem. Check the following:

• Is there fuel in the tank? Add fuel if needed.

• Is there entry of dust or air into the fuel line? Clean it.

• Is the plugged air hole in the tank cap? Clean it.

• Is the fuel line plugged? Clean it.

4. Check Carburetor: If the issue persists, check the carburetor for:

• Plugged fuel line.

• Plugged air passage.

• Float level.

• Carburetor setting.

If your KAWASAKI FH601V engine is losing power, investigate the following potential causes:

1. Is the engine overheated?

• YES: Check for low oil level, too much oil, excessive load, improperly adjusted carburetor, carbon deposit in the combustion chamber, a clogged cooling system, or a damaged cooling fan. Adjust level, load, or carb setting. Clean components as needed or replace the fan.

• NO: Proceed to the next step.

2. Is the ignition spark normal?

• NO: Check for a wrong spark plug, faulty ignition coil, or incorrect air gap. Replace the plug, coil, or adjust the gap.

• YES: Proceed to the next step.

3. Is the lubrication condition normal?

• NO: Check for too much or too little oil, excessively contaminated oil, a clogged oil filter, faulty relief valve, faulty oil pump, or a clogged oil system. Correct oil level, change oil, or replace faulty components.

• YES: Proceed to the next step.

4. Is there unusual smoke from the muffler?

• YES: This could be a plugged air cleaner or carbon deposit in the exhaust. Clean as necessary.

• NO: Proceed to the next step.

5. Is the compression sufficient?

• NO: This indicates an internal engine issue. Refer to troubleshooting for an engine that is hard to start, which covers compression problems.

If the starter motor on your KAWASAKI FH601V does not rotate, follow these troubleshooting steps after disconnecting the spark plug caps:

1. Listen for a “click” sound from the solenoid when you turn the key to START.

• If you hear a click (solenoid activates):

• Check for a weak battery. Charge or replace.

• Check for a faulty lead or connection to the starter motor. Repair or replace.

• The starter motor itself may be faulty. Repair or replace.

• If you do not hear a click:

• Check for a faulty battery. Charge or replace.

• Check for faulty leads or connections. Repair or replace.

• Check for a melted fuse. Replace.

• Check the engine switch. Replace if faulty.

• Check the solenoid (switch). Replace if faulty.