Kawasaki

ENGINES

KAWASAKI
ONE CYLINDER MODELS CONDENSED SERVICE DATA
ENGINE MODEL Bore(mm) Inches ., Stroke(mm) Inches No. of Cylinders Displacement-(cc) Cubic Inches Horsepower (a RPM Cooling Type Carburetor Model Number Used Ignition:
Type

KT-ISOA 74 2.913 68 2.677 1 292 17.8 20(ft 5500 HR 1

KT-150B 74 2.913 68 2.677

KT-150C 79 3.110 68 2.677

Point G a p ^ ( m m ) : : : : : : : : : : : : . . . . Inch . Timing Advance? Timing BTDC (mm) Inch Measured At Spark Plug: Bosch Champion NGK Electrode Gap (mm) Inch Fuel/Oil Ratio

0.3-0.4 0.012-0.016 Yes 0.65 0.0256 Retard M280T31 K9 .... 0.5-0.6 0 020-0.024 20:1

292 333 17.8 20.3 22(?/6000 24(2)6000 Centrifugal Fan HD HR 1 1 Flywheel Magneto 0.3-0.4 2A 1 ^ 0.012-0.016 0.012-0.016 Yes Yes 0.65 0.65 0.0256 0.0256 Retard Retard M280T31 K9 B9ES .... 0.5-0.6 0.5-0.6 0.020-0.024 0.020-0.024 20:1 20:1

T4B292 74 2.913 68 2.677 1 292 17.8 WRD2 1 0.3-0.4 0.012-0.016 Yes 0.14 0.005 Retard

B9ES 0.5 0.020 20:1

MAINTENANCE SPARK PLUG. The recommended plug for normal service is given in CONDENSED SERVICE DATA Table. A different heat range or type of plug may be needed for particular applications. Refer to ENGINE SERVICE FUNDAMENTALS Section when selecting a spark plug for other than normal usage. CARBURETOR. A Tillotson diaphragm carburetor is used on all models. Refer to Tillotson section to overhaul and service carburetors. An external impulse line is used to operate fuel pump. Be sure that vacuum and pressure leaks are eliminated. IGNITION SYSTEM. Timing specifications for individual engines are given in CONDENSED SERVICE DATA Tables. Breaker point gap may be adjusted after removing recoil starter, starter pulley and inspection cover. To renew breaker points, the flywheel must be removed. Timing can be checked using a light or buzzer connected to black wire coming from engine with other connector of timing light or buzzer being grounded to engine. Remove recoil starter and note timing holes in flywheel plate as shown in Fig. 1. Use right^ hole to check ignition timing. Stationary timing mark is found on a raised portion of crankcase at base of cylinder. Right hole indicates lO''

BTDC when aligned with crankcase timing mark. Left hole indicates TDC when aligned with crankcase timing mark. Flywheel must be removed to adjust timing. Loosen screws (1 & 2 Fig. 2) and move base plate to adjust timing. LUBRICATION. The engine is lubricated by mixing oil with fuel. A good quality two-cycle oil designed for aircooled engines is recommended. Recommended fuel-oil ratio for all engines is 20:1. Mix fuel and oil thoroughly in a separate container before pouring mixture into fuel tank. For cold weather blending, pre-mix the oil with a small amount of gasoline and shake thoroughly until the mixture is liquid, then
STATiONARY CRANKCASE MARK

blend with remainder of fuel. Do not use kerosene or fuel oil for pre-mixing. REPAIRS TIGHTENING TORQUES. Recommended tightening torques are as follows: Cylinder head 16 ft.-lbs. Crankcase bolts 13 ft.-lbs. Flywheel nut 56 ft.-lbs. Recoil starter mounting bolts 13 ft.-lbs. Spark plug 25 ft.-lbs. DISASSEMBLY AND REASSEMBLY. Refer to Fig. 4 for exploded

Fig. 1-View showing timing hoies in fiywheei plate. Hole (F) indicates 10 BTDC and hoie (T) indicates TDC when aiigned with crankcase Fig. 2-To adjust ignition timing, loosen screws (1 and 2) and move base plate. mark.

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ENGINES
view of engine. To disassemble engine, remove carburetor, muffler, drive sheave and recoil starter. Remove cooling shroud to remove cylinder head and cylinder. To disassemble crankcase, remove starter cup and flywheel. Mark position of magneto base assembly and remove. Remove timing advance mechanism. Remove cylinder head, cylinder and piston. Remove crankcase bolts and separate crankcase halves. Note that two of the crankcase bolts are longer than the other four bolts and their location should be marked in reassembly. Refer to -12 CRANKSHAFT section to service crankshaft assembly. To reassemble, reverse disassembly procedure. It may be necessary to heat bearing area of crankcase halves when installing crankshaft assembly. Do not damage oil seals when applying heat. Be sure to install correct length crankcase bolts in crankcase. Tighten crankcase bolts to a torque of 13 ft.-lbs. by tightening in a crisscross pattern. PISTON, RINGS & CYLINDER. Piston pin is fully floating in piston and connecting rod. Piston rings are pinned in place as shown in Fig. 5. Top ring is identified by * * 1 NPR" stamped on upper surface of ring and must be installed with notch in ring end on upper surface as shown in Fig, 5. Bottom ring is stamped "2 NPR". Piston ring end gap should be 0.0060.014 in. (0.15-0.35 mm). Piston pin and connecting rod small end bearing are available only as a matqjied pair and must be renewed as a set. It may be necessary to heat piston to install piston pin. Piston crown is marked with an arrow to indicate piston location in cylinder. Arrow must point towards output end of crankshaft. Piston skirt to cylinder wall clearance should be 0.0035-0.005 in. Cylinder is constructed of aluminum alloy with a cast iron sleeve on models KT-150A and KT-150B. Sleeve may be honed slightly to remove imperfections. Model KT150C is equipped with a chrome lined cylinder. Check for cracking, flaking or other imperfections in chrome lining. Small deposits of aluminum from piston on chrome bore may be removed with very careful sanding. When reinstalling cylinder head, be sure cooling fins are parallel with crankshaft. CRANKSHAFT & CONNECTING ROD ASSEMBLY. The crankshaft and connecting rod are available only as an assembled unit and should not be disassembled. Crankshaft main bearings are a press fit on crankshaft. Support crankshaft between counterweights as shown in Fig. 7 when

Kawasaki
pressing bearings on shaft. Crankshaft runout should not exceed 0.0012 in. (0.03mm). Radial play of connecting rod big end should not exceed 0.0009 in. (0.023mm). Crankshaft end play should be 0.002-0.013 in. (0,050.335mm). Shims (10Fig. 4) are available from manufacturer. RECOIL STARTER. Refer to ex ploded view of starter in Fig. 8. To disassemble starter, remove starter from engine and remove waterproofing plate (1). Pull rope out until it is possible to position rope in notch of rope

Fig. S-Bxploded view of flywheel magneto assemb/y. 1. Plate 2. Flywheel 8. Condenser 3. Ring gear 9. Lighting coil 4. Spring wasber 10. Ignition coil 5. Lock plate 11. Baseplate 6. Wiper felt 12. Cam 7. Breaker points 13. Advance mechanism

Fig. S-lnstall piston so that arrow on piston crown points towards output end of crankshaft.

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Fig. 7-Be sure to place a support between counterweights of crankshaft when pressing bearings.

Fig. 4~Exptoded view of single cylinder models. 1. Crankcase balf 4. 5. 6. 7. 8. 9. 10. 11. 12.
2. Gasket 3. Pulse fitting

Drain plug Oil seal Bearing Crankshaft assy, Needle bearing Key Shim Bearing Oil seal

13. 14 15. 16. 17. 18. 19. 20. 21. 22. 23. 24

Crankcase half Cover Upper cooling shroud Side cooling shroud Piston rings Snap ring Piston pin Piston Carburetor insulator Cylinder head Cylinder Gasket

Fig. 8-Exploded view of recoii starter. 1. 2. 3. 4. 5. 6. 7 Waterproofing plate Starter cup Nut Retainer Return spring Spring Pawls Washer Rope pulley Recoil spring Rope Cover Handle Retainer

Fig. 5-Plston rings are pinned as shown (arrow). Note that upper ring is installed so that notches in ring ends are up.

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Kawasaki
pulley. Release rope and allow recoil spring to unwind. Remove retaining nut (3) and components (6 thru 8). Carefully remove rope pulley so that recoil spring remains in cover. If necessary to remove recoil spring, guard against uncontrolled uncoiling of spring which may cause personal injury. To assemble starter, install recoil spring in cover so that spring is wound in counterclockwise direction and outer hook of spring contacts lug of cover. Install rope pulley and rope so that lug of pulley engages with inner hook of recoil spring. Install washer (8), pawls (7), spring (6) and pawl return spring (5). Install retainer cover (4) so that end of return spring (5) protrudes through retainer cover (4) and turn retainer cover one-third turn clockwise to pre-load spring. Install washers and

ENGINES
retaining nut. If rope handle was not removed during disassembly, position rope in notch of rope pulley and turn pulley two turns counter-clockwise to pre-load recoil spring. If handle was removed, turn rope pulley counterclockwise two or three turns and insert end of rope through rope outlet in cover. Tension on rope should be apparent. Tie a temporary knot to hold rope and install rope handle.

KAWASAKI TWO CYLINDER

CONDENSED SERVICE DATA
ENGINE MODEL Bore(mm) Inches ^ Stroke(mm) Inches No. of Cylinders Displacement(cc) Cubic Inches Horsepower (c RPM Cooling Type Carburetor Model Number Used Ignition: Type Point Gap(mm) Inch Timing Advance? Timing BTDC (mm) Inch Measured at Spark Plug: NGK Electrode Gap (mm) Inch Fuel/Oil Ratio T1A340F1
60

T1A340S1
60

T1A400F1
65

T1A400S1
65

*T1A44OF2
68

T1A440S1
68

2.362
60

2.362
60

2.559
60

2.559
60

2.677
60

2.677
60

2.362
2 339

2.362
2 339

2.362
2 398

2.362
2 398

2.362
2 436

2.362
2 436

20.7 35 (w 7500 Free Air

HR 2

20.7 27.5 (a 6500 Axial Fan HD

1

24.3 40 (il 7500 Free Air HD

2

24.3 32 (ii) 6500 Axial Fan HD

1

26.6 45 @ 7500 Free Air

HD 2

26.6 35 @ 6500 Axial Fan HD

1

0.3-0.4 0.012-0.016
Yes

0.3-0.51 0.012-0.016
Yes

0.3-0.4 0.012-0.016
Yes

0.3-0.4 0.012-0.016
Yes

0.3-0.4 0.012-0.016
Yes

0.37 0.015 Retard BlOE 0.5-0.6 0.020-0.024 20:1

0.37 0.015 Retard B9ES 0.5-0.6 0.020-0.024 20:1

0.37 0.015 Retard BlOE 0.5-0.6 0.020-0.024 20:1

0.37 0.015 Retard B9ES 0.5-0.6 0.020-0.024 20:1

0.37 0.015 Retard BlOE 0.5-0.6 0.020-0.024 20:1

0.3-0.4 0.012-0.016 Yes 0.37 0.015 Retard B9ES 0.5-0.6 0.020-0.024 20:1

= > May be equipped with Capacitor Discharge Ignition; all data is for Energy Transfer models.

ENGINE MODEL Bore(mm) Inches Stroke(mm) Inches No. of Cylinders Displacement(cc) Cubic Inches Horsepower RPM Cooling Type Carburetor Model Number Used Ignition: Type Point Gap(mm) Inch Timing Advance? Timing BTDC Measured at Spark Plug: NGK Electrode Gap(mm) . Inch Fuel/Oil Ratio

T1B340S1 60 2.362 60 2.362 2 339 20.7 Axial Fan WDA 1 0.3 0.4 0.012 0.016 Yes 0.14 mm 0.005 In. Retard B9ES 0.5 0.020 20:1

T1B400S1 65
2.559 60 2.362 2

T1B440S1
68 2.667 60 2.362 2 436

398 24.3 Axial Fan WDA

1

26.6 Axial Fan WDA

1

T1C340S2A 60 2.362 60 2.362 2 339 20.7

T1C440S2A 68 2.677 60 2.362 2 436

T1D250F1 51 2.001 60
2.362 2 245

26.6 Axial Fan WFIA

1

14.9 Free Air

VM 1

Axial Fan WFIA

1

rni
0.30.4 0.0120.016
Yes

GDI .... Electronic

25 ....

0.14 mm 0.005 In. Retard B9ES 0.5

0.020 20:1

0.30.4 0.0120.016 Yes 0.14 mm 0.005 In. Retard B9ES 0.5 0.020
20:1

Electronic 25^ 6000 rpm B8ESA 0.75 0.030

20:1

....

ET 0.30.4 0.012-O.Oie Yes

5 ....

6000 rpm B8ESA 0.75 0.030 20:1

Retard BR8ESA 0.5

0.020 20:1

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