Kawasaki FH641V 4-Stroke Air-Cooled V-Twin Gasoline Engine Service Repair Manual

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Allinformationcontainedinthispublicationisbasedon thelatestproductinformationavailableatthetime ofpublication.Illustrationsandphotographsinthispublicationareintendedforreferenceuseonlyandmay notdepictactualmodelcomponentparts.

4-StrokeAir-CooledV-TwinGasolineEngine

LISTOFABBREVIATIONS

A ampere(s) lb pound(s)

ABDC afterbottomdeadcenter m meter(s)

AC alternatingcurrent min minute(s)

ATDC aftertopdeadcenter N newton(s)

BBDC beforebottomdeadcenter Pa pascal(s)

BDC bottomdeadcenter PS horsepower

BTDC beforetopdeadcenter psi pound(s)persquareinch

°C degree(s)Celsius r revolution

DC directcurrent rpm revolution(s)perminute

F farad(s) TDC topdeadcenter

°F degree(s)Fahrenheit TIR totalindicatorreading ft foot,feet V volt(s)

g gram(s) W watt(s)

h hour(s) Ω ohm(s)

L liter(s)

EMISSIONCONTROLINFORMATION

Toprotecttheenvironmentinwhichwealllive,Kawasakihasincorporatedcrankcaseemission (1)andexhaustemission(2)controlsystems(EM)incompliancewithapplicableregulationsof theUnitedStatesEnvironmentalProtectionAgencyandCaliforniaAirResourcesBoard.

Asealed-typecrankcaseemissioncontrolsystemisusedtoeliminateblow-bygases.The blow-bygasesareledtothebreatherchamberthroughthecrankcase.Then,itisledtotheair cleaner.

Oilisseparatedfromthegaseswhilepassingthroughtheinsideofthebreatherchamberfrom thecrankcase,andthenreturnedbacktothebottomofcrankcase.

Theexhaustemissioncontrolsystemappliedtothisengineconsistsofacarburetorandan ignitionsystemhavingoptimumignitiontimingcharacteristics.

Thecarburetorhasbeencalibratedtoprovideleanair/fuelmixturecharacteristicsandoptimumfueleconomywithasuitableaircleanerandexhaustsystem.

TAMPERINGWITHEMISSIONCONTROLSYSTEMPROHIBITED

FederallawandCaliforniaStatelawprohibitsthefollowingactsorthecausingthereof:(1)the removalorrenderinginoperativebyanypersonotherthanforpurposesofmaintenance,repair, orreplacement,ofanydeviceorelementofdesignincorporatedintoanynewengineforthe purposeofemissioncontrolpriortoitssaleordeliverytotheultimatepurchaserorwhileitisin use,or(2)theuseoftheengineaftersuchdeviceorelementofdesignhasbeenremovedor renderedinoperativebyanyperson.

Amongthoseactspresumedtoconstitutetamperingaretheactslistedbelow: Donottamperwiththeoriginalemissionrelatedpart:

• Carburetorandinternalparts

• Sparkplugs

• Magnetoorelectronicignitionsystem

• Fuelfilterelement

• Aircleanerelements

• Crankcase

• Cylinderheads

• Breatherchamberandinternalparts

• Inletpipeandtube

1. CrankcaseEmissionControlSystem

2. ExhaustEmissionControlSystem

Foreword

Thismanualisdesignedprimarilyforuseby trainedmechanicsinaproperlyequippedshop. However,itcontainsenoughdetailandbasicinformationtomakeitusefultotheownerwhodesirestoperformhisownbasicmaintenanceand repairwork.Abasicknowledgeofmechanics, theproperuseoftools,andworkshopproceduresmustbeunderstoodinordertocarryout maintenanceandrepairsatisfactorily.Whenevertheownerhasinsufficientexperienceor doubtsastohisabilitytodothework,alladjustments,maintenance,andrepairshouldbe carriedoutonlybyqualifiedmechanics.

Inordertoperformtheworkefficientlyand toavoidcostlymistakes,readthetext,thoroughlyfamiliarizeyourselfwiththeprocedures beforestartingwork,andthendotheworkcarefullyinacleanarea.Wheneverspecialtoolsor equipmentarespecified,donotusemakeshift toolsorequipment.Precisionmeasurements canonlybemadeiftheproperinstrumentsare used,andtheuseofsubstitutetoolsmayadverselyaffectsafeoperation.

Togetthelongestlifeoutofyourengine:

• FollowthePeriodicMaintenanceChartinthe ServiceManual.

• Bealertforproblemsandnon-scheduled maintenance.

• UsepropertoolsandgenuineKawasakiengineparts.Genuinepartsprovidedasspare partsarelistedinthePartsCatalog.

• Followtheproceduresinthismanualcarefully.Don’ttakeshortcuts.

• Remembertokeepcompleterecordsofmaintenanceandrepairwithdatesandanynew partsinstalled.

HowtoUseThisManual

Inpreparingthismanual,wedividedtheproductintoitsmajorsystems.Thesesystemsbecamethemanual’schapters.Allinformation foraparticularsystemfromadjustmentthrough disassemblyandinspectionislocatedinasinglechapter.

TheQuickReferenceGuideshowsyouall oftheproduct’ssystemandassistsinlocating theirchapters.Eachchapterinturnhasitsown comprehensiveTableofContents.

ThePeriodicMaintenanceChartislocated intheGeneralInformationchapter.Thechart givesatimescheduleforrequiredmaintenance

operations.

Ifyouwantsparkpluginformation,forexample,gotothePeriodicMaintenanceChartfirst. Thecharttellsyouhowfrequentlytocleanand gaptheplug.Next,usetheQuickReference GuidetolocatetheElectricalSystemchapter. Then,usetheTableofContentsonthefirst pageofthechaptertofindtheSparkPlugsection.

WheneveryouseetheseWARNINGand CAUTIONsymbols,heedtheirinstructions! Alwaysfollowsafeoperatingandmaintenance practices.

WARNING

Thiswarningsymbolidentifiesspecial instructionsorprocedureswhich,ifnot correctlyfollowed,couldresultinpersonalinjury,orlossoflife.

CAUTION

Thiscautionsymbolidentifiesspecial instructionsorprocedureswhich,ifnot strictlyobserved,couldresultindamagetoordestructionofequipment.

Thismanualcontainsfourmoresymbols(in additiontoWARNINGandCAUTION)whichwill helpyoudistinguishdifferenttypesofinformation.

NOTE

○Thisnotesymbolindicatespointsofparticularinterestformoreefficientandconvenientoperation.

• Indicatesaproceduralsteporworktobe done.

○Indicatesaproceduralsub-steporhowtodo theworkoftheproceduralstepitfollows.It alsoprecedesthetextofaWARNING,CAUTION,orNOTE.

Indicatesaconditionalsteporwhatactionto takebasedontheresultsofthetestorinspectionintheproceduralsteporsub-stepitfollows.

Inmostchaptersanexplodedviewillustration ofthesystemcomponentsfollowstheTableof Contents.Intheseillustrationsyouwillfindthe instructionsindicatingwhichpartsrequirespecifiedtighteningtorque,oil,greaseoralocking agentduringassembly.

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1-2GENERALINFORMATION

BeforeServicing

Beforestartingtoservicetheengine,carefullyreadtheapplicablesectiontoeliminateunnecessary work.Photographs,diagrams,notes,cautions,warnings,anddetaileddescriptionshavebeenincludedwherevernecessary.Nevertheless,evena detailedaccounthaslimitations,acertainamount ofbasicknowledgeisrequiredforsuccessfulwork.

Especiallynotethefollowing:

(1)Dirt

Beforeremovalanddisassembly,cleantheengine.Anydirtenteringtheengine,carburetor,or otherparts,willworkasanabrasiveandshortenthelifeofengine.Forthesamereason,before installinganewpart,cleanoffanydustormetalfilings.

(2)BatteryGround

Removetheground(–)leadfromthebatterybeforeperforminganydisassemblyoperationson theequipment.Thisprevents:

(a)thepossibilityofaccidentallyturningtheengineoverwhilepartiallydisassembled.

(b)sparksatelectricalconnectionswhichwilloccurwhentheyaredisconnected.

(c)damagetoelectricalparts.

(3)TighteningSequence

Generally,wheninstallingapartwithseveralbolts,nuts,orscrews,startthemallintheirholes andtightenthemtoasnugfit.Thentightenthemevenly,inastaggeredsequence.Thisisto avoiddistortionofthepartand/orcausinggasoroilleakage.Converselywhenlooseningthe bolts,nuts,orscrews,firstloosenallofthembyaboutaquarterofaturnandthenremovethem. WherethereisatighteningsequenceindicationinthisServiceManual,thebolts,nuts,orscrews mustbetightenedintheorderandmethodindicated.

(4)Torque

WhentorquevaluesaregiveninthisServiceManual,usethem.Eithertoolittleortoomuch torquemayleadtoseriousdamage.Useagoodquality,reliabletorquewrench.

(5)Force

Commonsenseshoulddictatehowmuchforceisnecessaryinassemblyanddisassembly.If apartseemsespeciallydifficulttoremoveorinstall,stopandexaminewhatmaybecausingthe problem.Whenevertappingisnecessary,taplightlyusingawoodenorplastic-facedmallet.Use animpactdriverforscrews(particularlyfortheremovalofscrewsheldbyalockingagent)inorder toavoiddamagingtheheads.

(6)Edges

Watchforsharpedges,especiallyduringmajorenginedisassemblyandassembly.Protectyour handswithglovesorapieceofthickclothwhenliftingtheengineorturningitover.

(7)High-FlashPointSolvent

Ahigh-flashpointsolventisrecommendedtoreducefiredanger.AcommercialsolventcommonlyavailableinNorthAmericaisStandardsolvent(genericname).Alwaysfollowmanufacturer andcontainerdirectionsregardingtheuseofanysolvent.

(8)Gasket,O-Ring

DonotreuseagasketorO-ringonceithasbeeninservice.Thematingsurfacesaroundthe gasketshouldbefreeofforeignmaterialandperfectlysmoothtoavoidoilorcompressionleaks.

(9)LiquidGasket,Non-PermanentLockingAgent

Followmanufacturer’sdirectionsforcleaningandpreparingsurfaceswherethesecompounds willbeused.Applysparingly.Excessiveamountsmayblockengineoilpassagesandcause seriousdamage.Anexampleofanon-permanentlockingagentcommonlyavailableinNorth AmericaisLoctiteLock’nSeal(Blue).

(10)Press

Apartinstalledusingapressordriver,suchasajournal,shouldfirstbecoatedwithoilonits outerorinnercircumferencesothatitwillgointoplacesmoothly.

(11)BallBearing

Wheninstallingaballbearing,thebearingracewhichisaffectedbyfrictionshouldbepushed byasuitabledriver.Thispreventsseverestressontheballsandraces,andpreventsracesand ballsfrombeingdented.Pressaballbearinguntilitstopsatthestopintheholeorontheshaft.

(12)OilSealandGreaseSeal

Replaceanyoilorgreasesealsthatwereremovedwithnewones,asremovalgenerallydamagesseals.

BeforeServicing

Whenpressinginasealwhichhasmanufacturer’smarks,pressitinwiththemarksfacingout. Sealsshouldbepressedintoplaceusingasuitabledriver,whichcontactsevenlywiththesideof seal,untilthefaceofthesealisevenwiththeendofthehole.

(13)SealGuide

Asealguideisrequiredforcertainoilorgreasesealsduringinstallationtoavoiddamageto theseallips.Beforeashaftpassesthroughaseal,applyalittleoil,preferablyhightemperature greaseonthelipstoreducerubbertometalfriction.

(14)Circlip,RetainingRing

Replaceanycirclipsandretainingringsthatwereremovedwithnewones,asremovalweakens anddeformsthem.Wheninstallingcirclipsandretainingrings,takecaretocompressorexpand themonlyenoughtoinstallthemandnomore.

(15)CotterPin

Replaceanycotterpinsthatwereremovedwithnewones,asremovaldeformsandbreaks them.

(16)Lubrication

Enginewearisgenerallyatitsmaximumwhiletheengineiswarmingupandbeforeallthe rubbingsurfaceshaveanadequatelubricativefilm.Duringassembly,oilorgrease(whichever ismoresuitable)shouldbeappliedtoanyrubbingsurfacewhichhaslostitslubricativefilm.Old greaseanddirtyoilshouldbecleanedoff.Deterioratedgreasehaslostitslubricativequalityand maycontainabrasiveforeignparticles.

Don’tusejustanyoilorgrease.Someoilsandgreasesinparticularshouldbeusedonlyin certainapplicationsandmaybeharmfulifusedinanapplicationforwhichtheyarenotintended. Thismanualmakesreferencetomolybdenumdisulfidegrease(MoS2)intheassemblyofcertain engineparts.Alwayscheckmanufacturerrecommendationsbeforeusingsuchspeciallubricants.

(17)ElectricalWires

Alltheelectricalwiresareeithersingle-colorortwo-colorand,withonlyafewexceptions,must beconnectedtowiresofthesamecolor.Onanyofthetwo-colorwiresthereisagreateramount ofonecolorandalesseramountofasecondcolor,soatwo-colorwireisidentifiedbyfirstthe primarycolorandthenthesecondarycolor.Forexample,ayellowwirewiththinredstripesis referredtoasa“yellow/red”wire;itwouldbea“red/yellow”wireifthecolorswerereversedto makeredthemaincolor.

(18)ReplacementParts

Whenthereisareplacementinstruction,replacethesepartswithnewoneseverytimetheyare removed.Therereplacementpartswillbedamagedorlosetheiroriginalfunctiononceremoved.

(19)Inspection

Whenpartshavebeendisassembled,visuallyinspectthesepartsforthefollowingconditions orotherdamage.Ifthereisanydoubtastotheconditionofthem,replacethemwithnewones.

(20)Specifications

Colorchange Deterioration Seizure

Specificationtermsaredefinedasfollows:

“Standards”showdimensionsorperformanceswhichbrand-newpartsorsystemshave.

“ServiceLimits”indicatetheusablelimits.If themeasurementshowsexcessivewearordeterioratedperformance,replacethedamagedparts.

1-4GENERALINFORMATION

ModelIdentification

ElectricStarterModel-FH500V

RecoilStarterModel-FH500V

CylinderNumberDesignation:

No.1Cylinderistheleft-handcylinderviewedfromtheaircleaner.

No.2Cylinderistheright-handcylinderviewedfromtheaircleaner.

ModelIdentification

ElectricStarterModel-FH580V

ElectricStarterModel-FH680V