Kawasaki FC150V 4 Stroke Air Cooled Gasoline Engine Service Workshop Manual

KAWASAKI FC150V ENGINE MANUAL Table of Contents ­ Page 1 of 3 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 ELECTRIC STARTER & CHARGING TROUBLE SHOOTING STARTER MOTOR CHECK COMPONENTS RING GEAR CHECK STARTER MOTOR REASSEMBLY STATOR OUTPUT 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 PISTON & CON-ROD REMOVAL PISTON AND PISTON RING VISUAL CHECK PISTON CLEANING PISTON SERVICE LIMIT PISTON PIN SERVICE LIMIT PISTON RING SERVICE LIMIT PISTON RING INSTALLATION CON-ROD VISUAL CHECK CON-ROD SERVICE LIMIT PISTON AND CON-ROD ASSEMBLY PISTON/CON-ROD ASSY 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 mechanics in a properly equipped shop.

In order to perform the work efficiently to and avoid costly mistakes, read the text thoroughly, familiarize yourself with the procedures before starting work, and then do the work carefullyin a clean area. Whenever special tools or equipments are specified. do not use makeshift tools or equipment. Precision measurements can only be made the propif er instruments are used, and the use of substitute tools may adversely affect safe operation. Whenever you see these W A R N I N G AND C A U T I 0 N symbols, heed their instructions! Always follow safe operation and maintenance pract ices. The term “Replace ” and some abbreviations are used as follows: Replace = Usually means replace with a new part = Minimum = Maximum = Assembly Assy STD = Standard PTO = Power takeoff Approx. = Approximately (Approximate) Carb. = Carburetor Con-rod = Connecting rod = Cylinder Cyl. Dia. = Diameter MIN MAX A W A R N I N G :This safety alert symbol identifies important safety messages in this manual and on the equipment. When you see this symbol, read the message that followsvery carefully to avoid fire, personal injury, or loss of life. C A U T I 0 N :This identifies special instructions or procedures to avoid equipment damageor destruct ion. N 0 T E : Indicates messageor points of particular interest for more efficientand convenient operat ion. A l l rights reserved. NO part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise. without the prior written permission of Engine Division/Kawasaki Heavy Industries, Ltd. No liabilior ty can be accepted for any inaccuracies omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible.

Wikipedia’s page for Toro Company

Company Web Site: www.toro.com