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GENERAL INFORMATION
MECHANICAL SYSTEM
ELECTRICAL SYSTEM
GENERAL SPECIFICATIONS
WIRING DIAGRAM
ELECTRIC STARTER MODEL
PERIODIC MAINTENANCE
TROUBLE SHOOTING
ENGINE - HARD STARTING
ENGINE - MALFUNCTIONS AT LOW SPEED
ENGINE - ERRATICAL RUN
ENGINE - EXCESSIVE OIL CONSUMPTION
ENGINE - LOW POWER
ENGINE - EXCESSIVE FUEL CONSUMPTION
ENGINE - MALFUNCTIONS OF STOPPING
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
ENGINE COVER REMOVAL
ENGINE COVER DISASSEMBLY
ENGINE COVER ASSEMBLY AND INSTALLATION
RECOIL STARTER
DISASSEMBLY
CHECK
REASSEMBLY
KAWASAKI FC150V ENGINE MANUAL
Table of Contents – Page 2 of 3
IGNITION SYSTEM
TYPE OF IGNITION SYSTEM
SPARK CHECK
CONTROL UNIT CHECK
IGNITION COIL CHECK
FLYWHEEL REMOVAL
FLYWHEEL INSTALLATION
IGNITION COIL AIR-GAP ADJUSTMENT
INTERMEDIATE CONNECTOR INSTALLATION
THROTTLE-LEVER-LINKED ENGINE SWITCH
BAND-BRAKE-LINKED ENGINE SWITCH
CYLINDER HEAD
COMPRESSION CHECK
REMOVAL
MAINTENANCE
INSTALLATION
VALVE
VALVE CLEARANCE ADJUSTMENT
AUTOMATIC COMPRESSION RELEASE (ACR) CHECK
VALVE AND RELATED PARTS REMOVAL
ROCKER ARM STUD INSTALLATION
CHECK AND MAINTENANCE
SERVICE LIMIT
VALVE SPRING SERVICE LIMIT
LAPPING
VALVE SEAT RECONDITIONING
VALVE GUIDE SERVICE LIMIT
ROCKER ARM SERVICE LIMIT
PUSH ROD SERVICE LIMIT
CRANKCASE COVER
REMOVAL
SERVICE LIMIT
OIL SEAL REPLACEMENT
INSTALLATION
KAWASAKI FC150V ENGINE MANUAL
Table of Contents – Page 3 of 3
CAMSHAFT
REMOVAL
VISUAL CHECK
SERVICE LIMIT
INSTALLATION
CRANKSHAFT
VISUAL CHECK
SERVICE LIMIT
INSTALLATION
CRANK PIN RE-GRINDING
GOVERNOR
GOVERNOR GEAR CHECK AND REMOVAL
GOVERNOR GEAR INSTALLATION
GOVERNOR SHAFT INSTALLATION
LUBRICATING SYSTEM
ENGINE OIL
OIL SLINGER CHECK
BREATHER SYSTEM
BREATHER REED VALVE CHECK
CYLINDER/CRANKCASE
CYLINDER SERVICE LIMIT
CYLINDER BORE RE-SIZING
BALL BEARING CHECK
BALL BEARING REPLACEMENT
OIL SEAL REPLACEMENT
CAMSHAFT BEARING SERVICE LIMIT
BAND BRAKE
BAND BRAKE MECHANISM
BRAKE SHOE REPLACEMENT
BRAKE CABLE ADJUSTMENT
4=strokeair-cooled gasoline engine
WORKSHOP MANUAL
FOREWORD
This manual is designed for use by trained mecha- The term "Replace" and some abbreviations areused
nics in a properly equipped shop. as follows:
In order to perform the work efficiently and to
avoid costly mistakes, read the text thoroughly, Replace = Usually means replace with a new part
familiarize yourself with the procedures before MIN = Minimum
starting work, and then do the work carefullyin a MAX = Maximum
clean area. Whenever special tools or equipments are Assy = Assembly
specified. do not use makeshift tools or equipment. STD = Standard
Precision measurements can only be madeif the prop- PTO = Powertakeoff
er instruments are used, and the use of substitute Approx. = Approximately (Approximate)
tools may adversely affect safeoperation. Carb. = Carburetor
Con-rod = Connecting rod
Whenever you see these W A R N I N G AND C A U Cyl. = Cylinder
T I 0 N symbols, heed their instructions! Dia. = Diameter
Always follow safe operation and maintenance
prac-
t ices. A l l rights reserved. NO part of this publication
may be reproduced, stored in a retrieval system,
SAFETY
GOVERNOR 60
GOVERNOR GEAR CHECK AND REMOVAL 60
GOVERNOR GEAR INSTALLATION 60
GOVERNOR SHAFT INSTALLATION 60
1 1
G E N E R A L I N F O R M A T I ON
EOSPCOIW7
3 3
GENERAL INFORMAT I ON
KAWASAKI Multimeter-
Name of KAWASAKI Multimeter (P/N 395100-9803A) is recom-
Lead Color ye 1 1 ow/red mended for the electrical system check because a
meter of other type may indicate different value.
4 4
G E N E R A L S P E C I F I C A T I ONS
~ _ _ = . -
FC15OV
Number 1
Mechanical Flyweight
Type
Capacity
O i l Pan 0.55 L (1.16 US Pt)
1. 3 g . 37 us qt.
Mechanical Flyweight
Band Brake on Flywheel
A: Engine
B: Spark plug
C: Ignition coil
D: Charging coil
E: Control unit
P: Connector (3P)
G: Stop switch
E.
H: Key switch
I: Battery
J: Discharge chute interlock switch
K: Control lever
1: Starter
Lead Color
1: Red
2: Black
3: Yellow
E06PC09W2
6 6
PER I O D I C MA I N T E N A N C E
To ensure satisfactory operation over extended period
of time, engine requires normal maintenance
at regular
intervals.
Chart below shows periodic maintenance. Suitable intervalis shown as (0).
I NTERVAL
MAINTENANCE
Daily Every Every Every Every
25 hr 50 100 hr 300
Check
and
add
engine
oi 1.
Check for looseor lost nuts and screws
Check for fuel and oilleakage.
Check battery electrolytelevel.
Check and clean air intake screen.
Clean engine switchand control panel on engine.
** Clean air cleaner foam element.
Tighten nutsand screws. (first)
Clean
fuel
filter.
*
engineChange oil.
Check band brake system on engine.
Check and adjust band brake
cable.
** Clean air cleaner paper element.
Clean and regap plug.
spark
Clean combustionchamber.
Check and adjust valve clearance.
Clean and lap valve seating surface.
**
** Replace air cleaner paper element.
Clean cylinder and cylinder head fins of dust and
I
Remove spark plug and Are sparks produced spark plug. Replace
check spark by crank- plug
spark
when is e l t y
ing engine whilehav- YES
ing the plug grounded
against engineblock.
Install spare plug to
plug hole to avoid plug cap terminal Correct
fuel spittingfrom the
ha le. lead and engine
I
block in state where
plug cap is removed?
Demagnetizedfly-Rep ace
Rep lace
I.--- ’
Is compression Crank engine several *No fuel in the tank.
sufficient? times and thenre- *Clogged fuel
filter.
Clean
move spark plug and .Plugged
air hole in Clean
observe electrodes. tank cap.
Are they wet? YES *Plugged fuel line. Clean
~_-
Worn piston/piston Replace
ings.
*Stuck piston rings. Clean or replace
Worn cyl. bore. Bore or replace
Insufficient cyl. Retighten
Check
carburetor. I- *Check for plugged
fuel passage.
head tightening.
*Faulty contact of
valve seat.
Lap
EOOPCOIW4
8 8
TROUBLE SHOOT,I N G
I
Remove spark plug and Faulty plug insulation.
check spark by crank- Fouled electrodes.
ing engine whilehav- *Faulty hightensioncord.Rep 1ace
ing the plug grounded STRONG
Incorrect
ignition
Correct
coil
air
against engine block.
Install spare plug to
plug hole to avoid
fuel spitting from the
hole.
To avoid electric
shock, do not hold
plug itself.
Make sure to hold plug
cap.
I
Directly and gradually *Plugging in carburetor Clean
open throttle valveby interior.
hand. Does revolution NO
drop or does engine
stall at a certain
position?
Is clearance
valve
Compression
leakage
through
Is alignment of timing
EOBPCOZW4
9 9
TROUBLE SHOOT I N G
.Entry of dust or
fuel pipe or fuel filter.
.Air or vapourlock in fuelRemove
1 ine.
*Plugged airvent
fuel
ofClean
tank cap.
*Plugged air/fuel passes in Clean
carburetor.
.Too littleopening ofcarb. Correct
pilot air-screw.
Adjust load
~Carb. notproperly
adjusted.
Adjust
*Dirty or cloggedairintakeClean
screens, shroud and engine
fins.
Carbon deposit in combust ion Clean
chamber.
*Wrong spark plug. Rep 1ace
I
NO- *Too muchortoolittleoilCorrect
in crankcase.
Excessively
contaminated
Change
I lubricating oil.
Is unusual Clogged
air cleaner. Clean
ted out of Carbondeposit io exhaustClean
hole andmuffler.
Carb.not properlyadjusted.Adjust
Correct
EOBFCO4W3
Is compression
sufficient? *Carb. not properly adjusted. Adjust
cleaner.
Clogged
air
Clean
High ing
id1 R. P.M. Adjust
Incompleteopening of choke Open
valve.
___-
11 11
TROUBLE SHOOT I NG
(BANB
D R A KM
E ODEL)
I
Engine does not stop *Faulty band brake. Rep 1ace
within 3 seconds .Faulty switch lead. Rep 1ace
when being braked. Faulty switchterminal. Repair or replace
Dirty
switch terminal. Clean
Faulty
switch lead. Replace
*Faulty switch terminal. Repair or replace
Dirty
switch terminal. Clean
E08PC07W2
12 12
TORQUE S P E C I F I C A T I O N S
I
FC150
12 N-m (105 lbf-in __.___..___
*** DoBBCnotBlade
=
over-tighten it. Crankcase cover may bedamaged.
Brake Clutch
E09FCOZW4
13 13
CONTROL S Y S T E M
E I6FCO6W2
E 16FCO?W2
14 14
CONTROL S Y S T E M
1. Align hole (B) of speed control lever (C) with hole (D)
of control plate (E) and insert 6 mm (0.24 in.) dia. pin
or 6 mm bolt through two holes.
2. Turn choke setting screw (K) counterclockwise until it
is clear of choke control lever (1) and then turn choke
setting screw clockwiseuntil it just contacts choke
control lever.
3. Remove 6 mm pin and set throttle lever on dash in "CHOKE"
posit ion.
Make sure carb. choke valve is closed completely.
E16PCOSWZ
15 15
CONTROL S Y S T E M
E I6FC I O W 2
16 16
A I R CLEANER
E22FC03W2
E22FCO4W2
17 17
CARBURETOR
10
E24FC08WS
18 18
CARBURETOR
7. Unhook throttle rod (E) and rod spring (F) from throttle
lever (GI.
8. Unhook choke rod (H) and choke rod spring ( I ) from choke
lever (J).
E24FCOSW3
19 19
CARBURETOR
E24FCIOWI
E 2 4 F C I 1W3
20
I I
EZIFCIZWI
CAUT I ONS:
1. Do not over-tighten small carb. components. Finger:
tighten pilot screw.
2. Do not bend throttle and choke shaftswhen assembling.
3. Apply screw locking agent toscrews of throttle valve
or choke valve. Do not allow agent to flowinto shaft
bearing surfaces.
4. Make sure movement of throttle and choke valves is
smooth.
315510 5510C
6100C
150012541 12541
EZIPAOTWI
23 23
C O O L I NG S Y S T E M
1. Shut fuel valve (A) and disconnect fuel line (B) from
carburetor inlet.
2. Open fuel valve and drain fuel into suitable container,
3. Remove recoil starter.
E26FCOZW4
24 24
COOLING SYSTEM
: : :
: : : : :
.::,
t ,
E2SFC03W3
25
COOLING SYSTEM
:‘:’
:::::
.::::
,jjjj
: :
EZSFCO4W2
26 26
RECO IL STARTER
i
27 27
RECO I L 'STARTER
W A R N I N G :When removingreel (C), be careful
that recoil spring under reel thedoes
not fly loose
and causes injury. The s p r i n gisunder great pressure.
E27FAO2W2
28 28
RECO IL STARTER
1. Disconnect spark plug cap, and ground the cap W A R N I N G : Engine maybe cranked in this
terminal.
test. rotating
Do
any
touch
parts
not of engine
and equipment during -_-
test.
2. Turn key switch to "ON" position and check
condition. C A U T I 0 N : If starter does not stopkey byswitch
"OFF", disconnect negative lead from battery as
soon as possible.
Repair or replace
Correct
Repair or replace
31 31
E L E C T R I CS T A R T E R & C H A R G Nl G
E28FC22W2
E28FC23W2
32 32
E L E C T R I CS T A R T E R & C H A R G Nl G
E28FC15WI
E28FC24WI
E28FC25WI
33
I G N I T I ON S Y S T E M
1. Ignitioncoil
2. Control unit
3. Flywheel (with permanent magnet)
E30FCOIW2
E30FCOBW2
34 34
I GN IT I O N S Y S T E M
C A U T I 0 N : Do not useMegger.
I .CONTROLUNITRES I STANCE
Case (B)
E30FCOSW2
I G N I T I O NC O I LR E S I S T A N C E
EBOFC I OW2
35 35
IGNITION S Y S T E M
ESOFCIIWI
E30FCIZWI
E30FC I3Wl
A: Nut F: Insulator
B: Control unit terminal G: Controlplate
C: Stopswitchterminal H: Insulator
D: Nut I : Bolt
E: Washer
36 36
I GN I T I O N S Y S T E M
is equipped on con-
Engine switch linked with throttle lever
trol pannel of engine and operated
as follows:
is equipped on crank-
Engine switch linked with band brake
case side and operated as follows:
E30FC16W2
31 37
CYL I N D E R H E A D
E32FCOSWI
E32FC06WI
E32FCOSW2
39 39
VALVE
E33FC I4W3
40 40
VALVE
E33FC15WZ
41 41
VALVE
E33FC16W3
E33FC I7W4
43 43
VALVE
V A L V ES T E MD I A . MIN
2. V blocks
Check bend of valve stem at center part with
(A) and dial indicator (B).
E33FC I8W2
E 3 3 F C I9WI
44 44
VALVE
If valve does not contact all way around with seat, lap
valve into seat.
E33FC2OW2
E33FC2lW2
45 45
VALVE
VALVE GUIDE I N S I D E D I A. M A X
Intake 5.550 mm (0.2185 in.
Exhaust 5.560 mm (0.2189 in.
E33FC22W2
E33FC23WI
E33FC24WI
46 46
C R A N K C A S CE O V E R
E34PCOIWI
E34FCO6W2
47 47
CRANKCASE COVER
0 1 ':L SEAL REPLACEMENT
E34FC04W2
E34FCO7W2
48 48
CAMSHAFT
E35FC06WI
E35PCO'IWZ
49 49
C A M S HAF T
E35FC08W2
E35FCOSWI
50 50
P I STON 4t CON-ROD
E36FCIZW2
51 51
PI STON & CON-ROD
or wire
C A U T I 0 N :Do not use caustic cleaning solution
brush to clean piston.
E 3 6 F C 1 3 WI
E 3 6 F C I4W2
E 3 6 F C I SW I
53 53
PI S T O N & CON-ROD
Second
Top 1.0 mm (0.04 in.
E 3 6 P C I6W2
E 3 6 F C I9W2
E36FCZIW3
57 57
CRANKSHAFT
E37FCOZW2
58 58
CRANKSHAFT
E37FCO7W3
E37FCOSW2
60 60
GOVERNOR
E39FC04W2
E39FCOZWI
E39PCOSYI
61 61
LUBR I C A T I NG S Y S T E M
E4OPCOIWI
E4OFCIOWI
E4OFC11W2
62 62
LUBR I C A T I N G S Y S T E M
1. Check valve and valve seat for any damage such as crack
or wear.
2. Install reed valve (A) and back plate (B) on inspection
tool (C), and check gap between reed valve (A) and tool
surface (C) with feeler gauge.
EIOFC12WI
63 63
CYL I
__-
CYL. B O R IEN S I D D
EIA. MAX
E41FC06W2
S. : Over Size
B.S. : Boring Size
64 64
CYL I N D E R / C R A N K C A S E
2. Hone cylinder to final size as shown on right table
following procedure shown below. F. S.
E4lFC07W6
65 65
C Y L INDER/CRANKCASE
E4IFC03WI
EIIFCO4WI
E4IFCOIWI
67 67
B A N DB R A K E
1. Starting
When brake controllever on equipment is moved to start
position, control cable (D) pulls lever (A) to release
shoe (B) from flywheel (C) and to release engine switch I
tang (F) from lever (A).
2. Stopping
When brake controllever on equipment is moved to stop
position, control cable (D)releases lever (A) to force
shoe (B) to contact flywheel(C) and to make engine
switch tang (F) contact lever (A).
1. Do not remove brake shoe (B) from stud (G) except when
replacing theshoe.
2. If stud (G)is removed to replace shoe (B), apply lock-
ing agent on the thread when reinstalling stud. the
3. Shoe (B) does not requ ire adjustment in installation.
E43FC02WI
E43FCO3WI