Instruction/ maintenance manual of the product FE120 Kawasaki
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FE120 FE170 FE250 FE290 FE350 FE400 4–str oke air-cooled gasoline engine Ser vice Man ual All rights reserved. No par ts of this publication ma y be reproduced, stored in a retr ie val system, or tr.
LIST OF ABBREVIA TIONS A ampere(s) lb pound(s) ABDC after bottom dead center m meter(s) AC alternating current min minute(s) A TDC after top dead center N newton(s) BBDC before bottom dead center Pa p.
EMISSION CONTROL INFORMA TION T o protect the environment in which we live , Kawasaki has incor por ated crankcase emission (1) and exhaust emission (2) control systems in compliance with applicable regulations of the United States Environmental Protection Agency and the Calif or nia Air Resources Board.
Fore w or d This manual is designed pr imarily for use by trained mechanics in a properly equipped shop. Howe ver , it contains enough detail and basic inf or mation to mak e it useful to the owner who desires to perf or m his own basic maintenance and repair work.
GENERAL INFORMA TION 1-1 General Inf ormation T able of Contents 1 Before Servicing ................................................................................................................................................................. 1-2 General Specifications .
1-2 GENERAL INFORMA TION Before Servicing Before starting to service the engine, carefully read the applicable section to eliminate unnecessary work. Photogr aphs, diagrams , notes, cautions, warnings, and detailed descriptions have been included where ver necessary .
GENERAL INFORMA TION 1-3 Before Servicing (15) Cotter Pin Replace any cotter pins that were removed with new ones, as removal def or ms and breaks them. (16) Lubrication Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surf aces hav e an adequate lubricative film.
1-4 GENERAL INFORMA TION General Specifications Item FE120 FE170 T ype D T ype G T ype D T ype G Dimensions: L W Hm m 291 349 344 300 354 370 in 11.46 13.43 19.54 11.81 13.94 14.57 Dry Weight kg 14.5 16.8 Engine: T ype of engine Air cooled, 4-stroke, OHV , Single cylinder , Gasoline engine Number of Cylinder 1 Bore Stroke mm 60 44 66 50 in 2.
GENERAL INFORMA TION 1-5 General Specifications Item FE250 FE290 FE350 FE400 T ype D T ype G T ype D T ype G T ype D T ype G T ype D Type G Dimensions: L W Hm m 344.5 395 432 363 408 441 378 422 454 378 422 459 in 13.56 15.55 17.01 14.29 16.06 17.36 14.
1-6 GENERAL INFORMA TION P eriodic Maintenance Char t T o ensure satisfactory operation over an e xtended period of time, any engine requires nor mal maintenance regular intervals. The P er iodic Maintenance Char t below shows periodic inspection and maintenance items and suitable inter v als.
GENERAL INFORMA TION 1-7 Special T ools Compression Gauge: 57001–221 Hand T ester: 57001–1394 Kawasaki Bond (Silicone Sealand): 56019–120 Piston RIng Pliers: 57001–115 Piston Ring Compression .
1-8 GENERAL INFORMA TION Exploded View FE120.
GENERAL INFORMA TION 1-9 Exploded View FE170.
1-10 GENERAL INFORMA TION Exploded View FE250.
GENERAL INFORMA TION 1-11 Exploded View FE290.
1-12 GENERAL INFORMA TION Exploded View FE350.
SER VICE D A T A 2-1 Service Data T able of Contents 2 Service Specifications ........................................................................................................................................................ 2-2 Adjustment Specifications .
2-2 SER VICE D A T A Service Specifications Service Limit (mm) FE120 FE170 FE250 Item T ype D T ype G T ype D T ype G T ype D T ype G Compression (minimum) with Recoil Star ter 290 kP a (3 kg/cm 2 , 42 psi) with Electric Star ter 390 kP a (4 kg/cm 2 , 57 psi) Cylinder Bore (maximum) 60.
SER VICE D A T A 2-3 Service Specifications Service Limit (mm) FE120 FE170 FE250 Item T ype D T ype G T ype D T ype G T ype D T ype G Connecting Rod Connecting Rod Big End Bore (maximum) 26.052 29.052 34.067 (1.0257 in) (1.1438 in) (1.3412 in) Connecting Rod Small End Bore (maximum) 14.
2-4 SER VICE D A T A Service Specifications Service Limit (mm) FE290 FE350 FE400 Item T ype D T ype G T ype D T ype G T ype D T ype G Compression (minimum) with Recoil Star ter 290 kP a (3 kg/cm 2 , 42 psi) with Electric Star ter 390 kP a (4 kg/cm 2 , 57 psi) Cylinder Bore (maximum) 78.
SER VICE D A T A 2-5 Service Specifications Service Limit (mm) FE290 FE350 FE400 Item T ype D T ype G T ype D T ype G T ype D T ype G Axial Play (maxim um) ––– 0.35 0.35 0.35 0.06 0.35 (0.013 in) (0.013 in) (0.013 in) (0.024) (0.013 in) (standard: (standard: (standard: (standard: (standard: 0.
2-6 SER VICE D A T A Service Specifications Service Limit (mm) FE120 FE170 FE250 Item T ype D T ype G T ype D T ype G T ype D Type G Piston Ring Piston Ring Thickness (minimum) T op , Second 1.42 (0.056 in) 1.44 (0.057 in) Piston Ring End Gap (maximum) T op , Second 1.
SER VICE D A T A 2-7 Service Specifications Service Limit (mm) FE290 FE350 FE400 Item T ype D T ype G T ype D T ype G T ype D T ype G Piston Ring Piston Ring Thickness (minimum) T op , Second 1.44 (0.057 in) Piston Ring End Gap (maximum) T op , Second 1.
2-8 SER VICE D A T A Adjustment Specifications Adjustment Specifications FE350 Item FE120 FE170 FE250 FE290 FE400 Idle Speed Setting (crankshaft) 1600 rpm 1300 rpm No-Load Maximum Speed Setting (crankshaft) 4000 rpm V alve Clear ance: Intake, Exhaust Adjustment (clearance on cold engine) 0.
SER VICE D A T A 2-9 Tightening T orque Specifications Tightening T orque Specifications Unit: N m (kg m, ft lb) Tightening T orque FE350 Tightening Location FE120 FE170 FE250 FE290 FE400 Cylinder Head Bolts 25 (2.5, 18) Connecting Rod Bolts 12 20 23 (Apply Oil to Threadss before Tightening) (1.
2-10 SER VICE D A T A Wiring Diagram Ignition Coil/Ignition Separate T ype.
SER VICE D A T A 2-11 Wiring Diagram Ignition Coil/Igniter Integrated T ype.
2-12 SER VICE D A T A T roub leshooting If the engine malfunctions, first check whether th engine has been operated correctly . Then, systematically carr y out the troubleshooting procedure starting with simple items. This troubleshooting chart lists typical malfunctions.
SER VICE D A T A 2-13 T roub leshooting.
2-14 SER VICE D A T A T roub leshooting.
SER VICE D A T A 2-15 T roub leshooting.
2-16 SER VICE D A T A T roub leshooting.
SER VICE D A T A 2-17 T roub leshooting Star ter Motor T roub leshooting and Actions • Remov e the spark plug cap and ground the high-tension lead terminal.
2-18 SER VICE D A T A Disassembly Sequence (FE120, 170) Bolt to be removed f or tool Disassembly Precaution Name Quantity Drain Plug W arm up engine and drain oil.
SER VICE D A T A 2-19 Disassembly Sequence (FE250, 290, 350, 400) Bolt to be removed f or tool Disassembly Area Precaution Name Quantity Drain Plug W ar m up engine and dr ain oil.
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DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-1 Disassembl y , Reassembly , Inspection, and Maintenance T able of Contents 3 Carburetor....................................................................3-2 Construction and Function .....
3-2 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Carburetor Construction and Function The function of a carburetor is to mix fuel and air b y applying the principle of an atomizer , thus creating an appropr iate air-fuel mixture in accordance with load fluctuations.
DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-3 Carburetor An optimal fuel lev el is prescribed at the time the carburetor is designed. Along with the fluctuations in the fuel level, the float mov es up and down in order to open and close the float valv e.
3-4 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Carburetor • Check how the float v alve spring is fitted. Make sure that the first coil of the float v alve spring is completely wrapped in both spring groo ves that are pro vided at the two ear-shaped protrusions on the float valv e body .
DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-5 Carburetor Minimum No-Load Speed Adjustment • After completing the pilot screw adjustment, the minimum no-load adjustment must be adjusted.
3-6 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Carburetor Carburetor with Fuel Cutoff V alve T o prev ent after-burns that occur in the f or m of combustion in the muffler when the engine is stopped, the float chamber of this carburetor is provided with a solenoid-actuated fuel cutoff valv e.
DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-7 Governor Mec hanism Gov ernor Operating Mechanism Connected to the throttle le ver on the carb uretor via a link rod, the gov ernor operates automatically in accordance with load fluctuations in order to maintain a constant engine speed.
3-8 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Governor Mec hanism Gov ernor Gear Assembly Installation CA UTION Do not remove the governor gear assembly unless the parts are to be replaced. The par ts cannot be reused once they are removed.
DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-9 Governor Mec hanism A: Gov er nor Arm B: Throttle V alve C: Gov er nor Shaft D: Clamp Nut E: Pin.
3-10 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Air Cleaner The quality of the inspection or maintenance of the air cleaner significantly aff ects the durability and the perf or mance of the engine.
DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-11 Cooling System All the cooling fans of the FE ser ies engines are the separate type that can be separated from the flywheel. FE290 type: NO TE On the engine produced before May 1996, the flywheel and the cooling fan are integrated and cannot be disassembled.
3-12 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Fuel T ank and Filter • Place an appropriate container under the fuel filter to catch the fuel. Remov e the filter pot, turn the fuel tap ON, and completely drain the fuel from the fuel tank and the fuel line.
DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-13 Ignition System Description of Function The ignition mechanism is the transistorized type and consists of the follo wing par ts: Ignition Coil Igniter Flywheel (with per manent magnet) These components do not contain mechanical contact par ts and do not require regular inspection.
3-14 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Ignition System Automatic Ignition Adv ance Device This device enables the engine to achiev e appropriate ignition timing in all speed ranges. The ignition timing must be retarded slightly when the engine is started and at the lo w- to medium-speed range.
DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-15 Ignition System Ignition Coil Inspection Spark Characteristics Measurement • Connect the ignition coil to a coil tester to measure its spark characteristics. Follow the measurement instructions provided by the tester manufacturer f or the proper measurement procedure.
3-16 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Ignition System Igniter Inspection Measure the internal resistance of the igniter . Individual Igniter Inspection • T o test the individual igniter shown in the diag ram on the right, set the measurement range of the hand tester to R 100 and measure the resistance.
DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-17 Ignition System Controller (with W arning Light) Measurement • Set the measurement range of the hand tester to R 1k and measure the resistance at the areas giv en in the table below .
3-18 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Ignition System Ignition Coil Reassembly (Air Gap Adjustment) • Rotate the flywheel so that the magnet on the flywheel is on the opposite side of the area in which the ignition coil is to be installed.
DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-19 Charging System The state of charge of the batter y must be determined by measuring the terminal v oltage of the individual batter y . Individual Battery’s T erminal V oltage Standard: 12 V If the ter minal v oltage is below the standard, the battery must be recharged.
3-20 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Charging System Regulator Inspection • Disconnect the connector from the regulator . • Set the measurement range of the hand tester to R 1k and measure the resistance at the areas given in the table below .
DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-21 Starter System Star ter Motor Construction An FE series engine comes with a Bendix type or shift-lev er type star ter motor .
3-22 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Starter System 1. Snap Ring 2. Collar 3. Spring 4. Clutch Assembly 5. Nut 6. Spring Washer 7. Bolt 8. Rear Cov er 9. W asher 10. Brush Holder 11. Brush Spr ing 12. Brush 13. Y oke Assembly 14.
DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-23 Starter System • Connect lead [B] to ter minal [C]. Set the measurement range of the tester to R 1 , and connect it to the tw o terminals on the solenoid. T urn the key switch to the ST ART position to read the tester .
3-24 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Starter System Commutator Diameter Measurement Measure the diameter of the commutator at sever al areas. If the diameter is smaller than the service limit, replace the ar mature. Commutator Diameter Service Limit (minimum) Sift Le ver T ype: P/N 21163-2089, 2095 27 mm (1.
DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-25 Recoil Starter CA UTION The recoil spring is stored in the reel under high tension. Hold it firmly when handling so that the spring does not jump out. Disassembly • Pull the rope out approximately 350 mm, and tentatively tie a knot at that position.
3-26 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Cylinder Head Compression Inspection • After warming up the engine, stop the engine. Remove the spark plug and connect a compression gauge to the spark plug hole. NO TE Connect the spark plug cap to the remov ed spark plug and ground the spar k plug against the engine body .
DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-27 Cylinder Head Cleaning and Inspection • Inspect the cylinder head for the presence of any cracks or missing fins.
3-28 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE V alve System Hydraulic Lash Adjuster (HLA) The FE350 and 400 are equipped with a Hydraulic Lash Adjuster (HLA) to automatically adjust the v alve tr ain to zero clearance through hydr aulic means.
DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-29 V alve System HLA Construction and Operation • When the cam pushes the HLA upward, the oil in the high-pressure chamber [H] tries to fl.
3-30 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE V alve System HLA Removal CA UTION Always keep the HLA upright, with the end of the HLA on which the snap ring is visible facing up (socket "A" faces up).
DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-31 V alve System HLA Reassembly • Make sure that the piston is at the top-dead-center of the compression stroke. CA UTION Make sure to apply engine oil to all the sliding areas of the HLA, pushrod, rocker arm, rocker shaft, and valve before reassembly .
3-32 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE V alve System • Using a wrench, secure the rocker arm pivot, and tighten the lock nut to the specified torque.
DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-33 V alve System For FE250, 290, 350, 400: Disassembly • Use a v alve spring compressor to compress the valv e spr ing and remov e the collet. • Remov e the valv e spring compressor . • Remov e the retainer , valv e spring, and valv e.
3-34 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE V alve System Use a wire br ush to remov e the deposits from the valv e stem. If the valv e stem does not mov e smoothly in the v alve guide or the stem shows abnormal wear , replace the v alve with a new one.
DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-35 V alve System V alv e Seat Inspection and Lapping A prerequisite for inspecting the valv e seat contact is that the valv e guide and the v alve stem are normal. • Apply a thin layer of fine lapping compound on the contact surface of the valv e.
3-36 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE V alve System V alve Seat Contact Standard Width and Service Limit (minimum) – for both Intake and Exhaust Standart Service Limit FE120, 170: 0.7 mm (0.028 in) 1.7 mm (0.067 in) FE250, 290, 350, 400: 0.
DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-37 Piston and Connecting Rod Disassembly • Drain the engine oil into an appropr iate container .
3-38 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Piston and Connecting Rod For FE120, 170, 250, 350, 400 • On type D , face the "R" mark on the top of the piston towards the side of the connecting rod mar ked "MADE IN JAP AN".
DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-39 Piston and Connecting Rod For FE290 • On type D , face the arrow on the top of the piston opposite to the side of the connecting rod mar ked "MADE IN JAP AN".
3-40 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Piston and Connecting Rod • Using an inside micrometer , measure the pin hole bore of the piston in sev eral places. Piston Pin Hole Bore Service Limit (maximum) FE120: 14.033 mm (0.5525 in) FE170: 16.
DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-41 Piston and Connecting Rod Connecting Rod Inspection • Inspect the big end of the connecting rod for wear or any traces of seizure scratches or discoloration. Abnormal wear or scratches could be caused by the presence of foreign particles in the engine oil.
3-42 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Piston and Connecting Rod A: Dial Gauge B: V Block.
DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-43 Cylinder Block and Crankcase Cover Cylinder Inspection • Inspect the cylinder wall f or the presence of any scratches , the cylinder exterior f or any broken fins, and for an y other damage.
3-44 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Cylinder Bloc k and Crankcase Cover • V erify that a crankshaft or the camshaft that requires an axial play adjustment shim is provided with an adjustment shim. (Refer to the section on Axial Play Adjustment.
DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-45 Cylinder Block and Crankcase Cover Replace a ball bearing in the f ollowing manner: • Remov e the oil seal. Do not reuse an oil seal once it has been remov ed. • Using a bear ing puller as shown in the diagram on the right, remove the bearing.
3-46 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Lubrication System Lubrication Method For FE120, 170, 250 As shown in the diag ram on the right, the rev olution of the crankshaft causes .
DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-47 Lubrication System Oil Pump Disassembly and Reassemb ly Disassembly • Remov e the six retaining bolts from the oil pump cover and remov e the oil pump cover , gasket, and plate, in that order .
3-48 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Lubrication System • The reassembly is the re verse order of disassemb ly . • Install the outer rotor and the inner rotor , in that order , making sure to prev ent dust from enter ing the oil pump.
DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-49 Lubrication System • Using a micrometer , measure the follo wing par ts: Inner Rotor Shaft Diameter (maximum) - for FE290, 350, 400 Service Limit: 12.627 mm (0.4971 in) Outer Rotor Diameter (maximum) - f or FE290, 350, 400 Service Limit: 40.
3-50 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Lubrication System Oil Level Sensor Switch If the oil lev el becomes lower than the preset value , the sensor switch [A] closes. As a result, the base current [IB1] passes through the Zener diode [Z1] and the resistor [R12] to flo w to [TR1] to maintain the circuit.
DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-51 Lubrication System • When the engine is tilted to a cer tain angle, the tester should read 0 . If the tester does not read 0 , but remains at ∞ , the oil lev el sensor switch is f aulty .
3-52 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Lubrication System Breather The function of the breather is to maintain a vacuum in the crankcase to pre vent the engine oil from being discharged outside the engine .
DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-53 Lubrication System Oil Filter Replacement Procedure NO TE Be careful with hot oil to prev ent bur ns . Alwa ys use a genuine Kaw asaki oil filter for replacement. Other brands of oil filters ma y also fit but they ma y be of poor quality .
3-54 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Crankshaft Disassembly • Remov e the crankcase cov er. • If axial play adjustment shims are provided for the crankshaft and the camshaft, remove the shims and identify them so that the y can be installed correctly during reassembly .
DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-55 Crankshaft Crankshaft Inspection • Inspect the crank pin and the journal for galling, wear , or rust. If the crank pin e xhibits damage as described above , carefully inspect and repair the big end of the connecting rod, or replace the connecting rod or the crankshaft with a new par t.
3-56 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Crankshaft For e xample, on the FE350, if measurement [A] is 15.87 mm and measurement [B] is 17.66 mm, the correct shim thickness is t = 1.53 mm. Crankshaft Axial Play Standard and Service Limit (maximum) (unit: mm) Standard Ser vice Limit FE120 0 ~ 0.
DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-57 Balancer Engine vibration is generated primar ily by the iner tia that is created through the reciprocal mov ement mass such as the piston, piston pin, piston ring, and the small end of the connecting rod.
3-58 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Balancer Reciprocal Mov ement Balancer (FE400, 350, 290, 250) Disassembly • Remov e the retaining nuts from the balancer guide and pull out the balancer guide from the crankcase. • Remov e the connecting rod bolt and remov e the connecting rod cap.
DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-59 Balancer • Using a micrometer , measure the balancer guide hole bore of the balance weight in sev eral places. Balancer Guide Hole Bore Service Limit (maximum) FE250, 290: 26.118 mm (1.0283 in) FE350, 400: 26.
3-60 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Balancer Balancer Shaft Journal Diameter Service Limit (minimum) PT O Side Flywheel Side FE170: 14.943 mm (0.5883 in) 14.933 mm (0.5879 in) If the measured value is smaller than the service limit, replace the balancer shaft.
DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-61 Camshaft Disassembly • Remov e the crankcase cov er. • If axial play adjustment shims are provided for the crankshaft and the camshaft, remove the shims and identify them so that the y can be installed correctly during reassembly .
3-62 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Camshaft • Using a micrometer , measure the camshaft jour nal in se ver al places. Camshaft Journal Diameter Ser vice Limit (minimum) (Unit: mm) PT O Side Flywheel Side T ype D T ype G T ype D , G 14.
DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-63 Camshaft A: Matching Marks Camshaft Axial Play Adjustment If a par t that aff ects the axial play has been replaced, the axial play must be adjusted as descr ibed below . Shim adjustment is not av ailable on the FE120 and 170.
3-64 DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE Camshaft.
DISASSEMBL Y , REASSEMBL Y , INSPECTION, AND MAINTENANCE 3-65 Camshaft Apply these measurements on the cr ankshaft shim selection table , and select the next thinner shim. For example , on the FE350D , if measurement [A] is 13.41 mm and measurement [B] is 14.
An important point after buying a device Kawasaki FE120 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Kawasaki FE120 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Kawasaki FE120 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Kawasaki FE120 you will learn all the available features of the product, as well as information on its operation. The information that you get Kawasaki FE120 will certainly help you make a decision on the purchase.
If you already are a holder of Kawasaki FE120, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Kawasaki FE120.
However, one of the most important roles played by the user manual is to help in solving problems with Kawasaki FE120. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Kawasaki FE120 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
