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Kawasaki FE120 - Service Manual

Kawasaki FE120
102 pages
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FE120 FE170
FE250 FE290
FE350 FE400
4–stroke air-cooled gasoline engine
Service Manual
All rights reserved. No parts 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
Quality Assurance Department/Consumer Products & Machinery Group/Kawasaki Heavy Industries, Ltd., Japan.
No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been
tak
en to make it as complete and accurate as possible.
The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such
changes
to products manufactured previously.
All information contained in this publication is based on the latest product information available at the time of publication.
Illustr
ations and photographs in this publication are intended for reference use only and may not depict actual model
component parts.
© Kawasaki Heavy Industries, Ltd., 2000 First
Edition (1) : Sep. 1, 2000 (K)

Table of Contents

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Summary

Emission Control Information

Crankcase Emission Control System

System to eliminate blow-by gasses via breather chamber and return to air cleaner.

Exhaust Emission Control System

System comprising carburetor and ignition for optimum timing and fuel economy.

Tampering With Emission Control System Prohibited

Foreword

How to Use This Manual

Guide on navigating the manual, understanding symbols, and performing maintenance.

General Information

Before Servicing

Precautions and advice before starting engine service.

General Specifications

Technical data and specifications for different engine models.

Periodic Maintenance Chart

Schedule of recommended maintenance tasks and intervals.

Special Tools

List of specialized tools required for maintenance and repair.

Exploded View

Diagrams showing engine components and their assembly.

Service Data

Service Specifications

Detailed measurements and limits for engine parts.

Adjustment Specifications

Key settings for engine operation like idle speed and gaps.

Tightening Torque Specifications

Critical torque values for fasteners during assembly.

Wiring Diagram

Electrical schematics for engine systems.

Troubleshooting

Guidance for diagnosing and fixing common engine problems.

Starter Motor Troubleshooting and Actions

Specific troubleshooting for the starter system.

Disassembly Sequence (FE120, 170)

Step-by-step guide for taking apart FE120 and 170 models.

Disassembly Sequence (FE250, 290, 350, 400)

Step-by-step guide for taking apart FE250-400 models.

Disassembly, Reassembly, Inspection, and Maintenance

Carburetor

Procedures for disassembling, cleaning, inspecting, and adjusting the carburetor.

Air Cleaner

Maintenance and cleaning instructions for the air cleaner element.

Cooling System

Procedures for inspecting and maintaining the engine cooling fan.

Fuel Tank and Filter

Steps for servicing the fuel tank and filter components.

Ignition System

Inspection and testing procedures for the ignition coil and igniter.

Starter System

Procedures for inspecting and testing the starter motor and solenoid.

Cylinder Head

Steps for inspecting and disassembling the cylinder head.

Valve System

Procedures for inspecting, adjusting, and disassembling valves.

Crankshaft

Inspection and maintenance procedures for the crankshaft.

Balancer

Information on reciprocal and uniaxial rotation balancers.

Camshaft

Inspection and maintenance procedures for the camshaft.

Summary

Emission Control Information

Crankcase Emission Control System

System to eliminate blow-by gasses via breather chamber and return to air cleaner.

Exhaust Emission Control System

System comprising carburetor and ignition for optimum timing and fuel economy.

Tampering With Emission Control System Prohibited

Foreword

How to Use This Manual

Guide on navigating the manual, understanding symbols, and performing maintenance.

General Information

Before Servicing

Precautions and advice before starting engine service.

General Specifications

Technical data and specifications for different engine models.

Periodic Maintenance Chart

Schedule of recommended maintenance tasks and intervals.

Special Tools

List of specialized tools required for maintenance and repair.

Exploded View

Diagrams showing engine components and their assembly.

Service Data

Service Specifications

Detailed measurements and limits for engine parts.

Adjustment Specifications

Key settings for engine operation like idle speed and gaps.

Tightening Torque Specifications

Critical torque values for fasteners during assembly.

Wiring Diagram

Electrical schematics for engine systems.

Troubleshooting

Guidance for diagnosing and fixing common engine problems.

Starter Motor Troubleshooting and Actions

Specific troubleshooting for the starter system.

Disassembly Sequence (FE120, 170)

Step-by-step guide for taking apart FE120 and 170 models.

Disassembly Sequence (FE250, 290, 350, 400)

Step-by-step guide for taking apart FE250-400 models.

Disassembly, Reassembly, Inspection, and Maintenance

Carburetor

Procedures for disassembling, cleaning, inspecting, and adjusting the carburetor.

Air Cleaner

Maintenance and cleaning instructions for the air cleaner element.

Cooling System

Procedures for inspecting and maintaining the engine cooling fan.

Fuel Tank and Filter

Steps for servicing the fuel tank and filter components.

Ignition System

Inspection and testing procedures for the ignition coil and igniter.

Starter System

Procedures for inspecting and testing the starter motor and solenoid.

Cylinder Head

Steps for inspecting and disassembling the cylinder head.

Valve System

Procedures for inspecting, adjusting, and disassembling valves.

Crankshaft

Inspection and maintenance procedures for the crankshaft.

Balancer

Information on reciprocal and uniaxial rotation balancers.

Camshaft

Inspection and maintenance procedures for the camshaft.

Kawasaki FE120 Specifications

General IconGeneral
Fuel SystemCarburetor
Cooling SystemAir-cooled
FuelGasoline
Engine Cycle4-stroke
Lubrication SystemSplash lubrication
Engine Type4-stroke, single cylinder
Displacement118 cc
Bore x Stroke60.0 x 42.0 mm
Power Output2.6 kW (3.5 HP) @ 3600 rpm
Ignition SystemMagneto ignition
Oil Capacity0.6 liters
Starting SystemRecoil starter
Valve TrainOHV

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