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Kawasaki FE350 - User Manual

Kawasaki FE350
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SAFETY AWARENESS
Whenever you see the symbols shown below,
heed their instructions! Always follow safe operat-
ing and mainten an ce pra ctices.
WARNING
This warning sym
bol identifies special in-
structions or procedures which, if not cor-
rectly followed, could result in personal
injury, or loss
of life.
CAUTION
This caution symbol identifies special in-
structions or p
rocedures which, if not strictly
observed, could result in damage to, or de-
struction of equipm ent.
NOTE
This note symbol indicates points of particular in-
terest for more efficient and convenient operation.

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Summary

SAFETY AWARENESS

Warning Symbols

Identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life.

Caution Symbols

Identifies special instructions or procedures which, if not strictly observed, could result in damage to, or destruction of equipment.

Note Symbol

Indicates points of particular interest for more efficient and convenient operation.

READ THIS FIRST

General Safety Precautions

Covers hazards like exhaust gas, flammable gasoline, fire risks, electrical shock, burns, moving parts, and proper servicing.

EMISSION CONTROL INFORMATION

Fuel Information

Specifies that the engine is certified for unleaded regular grade gasoline with a minimum of 87 octane.

Emission Control System Overview

Describes Kawasaki's exhaust and crankcase emission control systems for environmental protection.

Engine Emissions Compliance Period

Details compliance periods for California and other states based on engine size and model year.

High Altitude Performance Adjustment Information

High Altitude Adjustment Recommendations

Recommends EPA/CARB approved modifications for engines operating above 1000 meters.

Maintenance and Warranty

Maintenance Importance for Emissions and Warranty

Emphasizes proper maintenance for low emission levels and warranty compliance.

Tampering with Emission Control System Prohibited

Prohibited Tampering Acts

Outlines federal and state laws prohibiting tampering with emission control devices.

FOREWORD

Introduction and Manual Usage

Thanks the customer and advises reading the manual for proper operation and maintenance.

GENERAL INFORMATION

Location of Parts

Identifies key engine components for both recoil and electric starter models.

Engine Serial Number

Identification and Parts Ordering

Explains the serial number is key for identifying the engine and ordering parts.

Tune-up Specifications

Ignition, Spark Plugs, and Valve Clearance

Lists specifications for ignition timing, spark plug gap, idle speeds, and valve clearance.

Engine Oil Capacity

Oil Capacity for FE350 and FE400

Specifies the engine oil capacity for FE350 and FE400 models.

FUEL AND OIL RECOMMENDATIONS

Fuel Recommendations

Advises using clean, fresh, unleaded regular grade gasoline with specific octane and oxygenate guidelines.

Engine Oil

Recommended Engine Oils and Viscosity

Lists recommended API service classifications and viscosity charts based on temperature.

PREPARATION

Fueling Procedure

Details safe refueling steps, including turning off the engine, no smoking, and not overfilling the tank.

Fuel Strainer

Fuel Strainer Types and Fueling Level

Illustrates fuel strainer types and provides guidance on correct fuel level for standard and graduated types.

Engine Oil

Engine Oil Level Check Procedure

Explains how to check engine oil level daily to prevent damage from shortage.

Engine Oil Capacity

Specifies oil capacity for FE350 and FE400, noting difference when oil filter is removed.

Low Oil Level Sensor System

Types and Functionality of Low Oil Sensor

Describes the engine stop and alarm indicating types of low oil level sensors.

STARTING

Start Engine Safety Warnings

Warns about poisonous exhaust gases and combustible materials igniting from exhaust.

Starting Procedure Checklist

Provides steps for starting, including using proper oil, fresh fuel, and disconnecting external loads.

Engine Switch and Control Panel

Operating the Engine Switch and Throttle

Explains how to use the engine switch and control panel throttle lever for starting.

Choke Lever Operation

Choke Lever Usage for Starting

Details the use of the choke lever for starting the engine, including adjustments after starting.

[Electric Starter Model] Starting Procedure

Electric Starter Operation

Instructs on inserting the switch key and turning it to the START position, with caution for continuous operation.

[Recoil Starter Model] Starting Procedure

Recoil Starter Operation

Guides on pulling the recoil starter grip slowly until compression, then briskly.

Warming Up the Engine

Engine Warm-up Procedure and Precautions

Advises allowing the engine to warm up at idle before applying load and checking the oil warning lamp.

OPERATING

Engine Inclination Limits

States the engine can operate continuously at angles up to 15°, with a caution against exceeding it.

STOPPING

Ordinary Stop Procedure

Details lowering engine speed to idle for one minute before shutting off to prevent damage.

Emergency Stop Procedure

Instructs to immediately turn the engine switch off and close the fuel valve.

Key Removal Warning

Warns to always remove the engine key when leaving equipment unattended.

ADJUSTMENT

Engine Speed Adjustment

Advises against tampering with governor or carburetor settings and recommends dealer service for adjustments.

MAINTENANCE

Periodic Maintenance Chart Overview

Provides a chart of maintenance tasks and their recommended service intervals.

Spark Plug Cap Removal Warning

Warns to always remove the spark plug cap before servicing to prevent accidental starting.

Oil Level Check

Daily Oil Level Check Procedure

Emphasizes checking oil level daily and before operation to prevent engine damage.

Oil Change

Oil Change Intervals and Procedure

Details when to change oil (first 8 hours, then 50/100 hours) and the draining process.

Hot Engine Oil Warning

Warns that hot engine oil can cause severe burns and advises allowing it to cool before draining.

Oil Filter Change

Oil Filter Replacement Procedure

Explains how to change the oil filter every 200 hours, including preparation and post-replacement checks.

Hot Engine Oil Warning for Filter Change

Warns about hot engine oil during filter removal and advises allowing the engine to cool.

Air Cleaner Service

Air Cleaner Service Precautions

Warns against running the engine with the air cleaner removed and advises safe cleaning practices.

Dual Filtration Type Air Cleaner

Dual Filtration Air Cleaner Components

Identifies wing bolts and air cleaner cover for the dual filtration type.

Lower Inhale Type Air Cleaner

Lower Inhale Type Removal

Describes removing the cover and elements for the lower inhale type air cleaner.

Upper Inhale Type Air Cleaner

Upper Inhale Type Removal

Explains how to remove the upper inhale type air cleaner element using a clamp.

Air Cleaner Element Maintenance

Foam and Paper Element Care

Covers cleaning and oiling foam elements and cleaning/replacing paper elements.

Air Cleaner Element Replacement

Specifies changing the air cleaner element every 300 hours.

Fuel Filter Service

Fuel Filter Cleaning Procedure

Details loosening the sediment bowl, removing the screen, cleaning, and reinstalling the assembly.

Fuel Filter Service Interval

Specifies cleaning the fuel filter element every 50 hours.

Fuel Valve Operation for Service

Instructs to close the fuel valve to shut off fuel flow before servicing the filter.

Spark Plug Service

Spark Plug Maintenance and Replacement

Covers cleaning, gap adjustment, replacement, installation, and recommended plug type.

STORAGE

Fuel System Draining for Storage

Details draining the fuel system to prevent gum deposits when storing for over 30 days.

Fuel Draining Safety Precautions

Warns about flammable gasoline and advises draining in a well-ventilated area away from sparks.

Engine Storage Preparation

Includes cylinder protection and body cleaning for long-term storage.

TROUBLESHOOTING GUIDE

Insufficient Compression Issues

Lists causes and remedies for insufficient compression, such as faulty parts or loose bolts.

Engine Wont Start or Low Output

Covers causes like no fuel, blocked filters, or faulty carburetor for starting issues.

Spark Plug Fouled by Fuel

Addresses issues of spark plugs fouled by fuel, including clogged air cleaners and incorrect fuel grade.

Engine Performance Problems

Spark Issues and Remedies

Covers no spark or weak spark, identifying causes like faulty plugs or igniters.

Operational Issues

Overheating, Low Output, and Speed Problems

Addresses overheating, low output, and speed issues due to dirt, oil, carbon, or governor faults.

ENVIRONMENTAL PROTECTION

Proper Disposal of Components

Advises consulting dealers or agencies for proper disposal of used batteries, oil, and other components.

SPECIFICATIONS

Engine Specifications (FE350 and FE400)

Provides key specifications for FE350 and FE400 engines, including type, bore, displacement, and weight.

WIRING DIAGRAM

Recoil Starter Model Wiring

Shows the wiring diagram for the recoil starter model with an engine stop type oil level sensor.

[Electric Starter Model] Wiring Diagrams

Electric Starter Wiring (Alarm Type)

Presents the wiring diagram for electric start with alarm type oil level sensor.

Electric Starter Wiring (Stop Type)

Shows the wiring diagram for electric start with engine stop type oil level sensor.

[Electric Starter Model] Wiring Diagram (Engine Stop Type)

Detailed Electric Starter Wiring

Presents a detailed wiring diagram for electric start with engine stop type oil level sensor.

Summary

SAFETY AWARENESS

Warning Symbols

Identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life.

Caution Symbols

Identifies special instructions or procedures which, if not strictly observed, could result in damage to, or destruction of equipment.

Note Symbol

Indicates points of particular interest for more efficient and convenient operation.

READ THIS FIRST

General Safety Precautions

Covers hazards like exhaust gas, flammable gasoline, fire risks, electrical shock, burns, moving parts, and proper servicing.

EMISSION CONTROL INFORMATION

Fuel Information

Specifies that the engine is certified for unleaded regular grade gasoline with a minimum of 87 octane.

Emission Control System Overview

Describes Kawasaki's exhaust and crankcase emission control systems for environmental protection.

Engine Emissions Compliance Period

Details compliance periods for California and other states based on engine size and model year.

High Altitude Performance Adjustment Information

High Altitude Adjustment Recommendations

Recommends EPA/CARB approved modifications for engines operating above 1000 meters.

Maintenance and Warranty

Maintenance Importance for Emissions and Warranty

Emphasizes proper maintenance for low emission levels and warranty compliance.

Tampering with Emission Control System Prohibited

Prohibited Tampering Acts

Outlines federal and state laws prohibiting tampering with emission control devices.

FOREWORD

Introduction and Manual Usage

Thanks the customer and advises reading the manual for proper operation and maintenance.

GENERAL INFORMATION

Location of Parts

Identifies key engine components for both recoil and electric starter models.

Engine Serial Number

Identification and Parts Ordering

Explains the serial number is key for identifying the engine and ordering parts.

Tune-up Specifications

Ignition, Spark Plugs, and Valve Clearance

Lists specifications for ignition timing, spark plug gap, idle speeds, and valve clearance.

Engine Oil Capacity

Oil Capacity for FE350 and FE400

Specifies the engine oil capacity for FE350 and FE400 models.

FUEL AND OIL RECOMMENDATIONS

Fuel Recommendations

Advises using clean, fresh, unleaded regular grade gasoline with specific octane and oxygenate guidelines.

Engine Oil

Recommended Engine Oils and Viscosity

Lists recommended API service classifications and viscosity charts based on temperature.

PREPARATION

Fueling Procedure

Details safe refueling steps, including turning off the engine, no smoking, and not overfilling the tank.

Fuel Strainer

Fuel Strainer Types and Fueling Level

Illustrates fuel strainer types and provides guidance on correct fuel level for standard and graduated types.

Engine Oil

Engine Oil Level Check Procedure

Explains how to check engine oil level daily to prevent damage from shortage.

Engine Oil Capacity

Specifies oil capacity for FE350 and FE400, noting difference when oil filter is removed.

Low Oil Level Sensor System

Types and Functionality of Low Oil Sensor

Describes the engine stop and alarm indicating types of low oil level sensors.

STARTING

Start Engine Safety Warnings

Warns about poisonous exhaust gases and combustible materials igniting from exhaust.

Starting Procedure Checklist

Provides steps for starting, including using proper oil, fresh fuel, and disconnecting external loads.

Engine Switch and Control Panel

Operating the Engine Switch and Throttle

Explains how to use the engine switch and control panel throttle lever for starting.

Choke Lever Operation

Choke Lever Usage for Starting

Details the use of the choke lever for starting the engine, including adjustments after starting.

[Electric Starter Model] Starting Procedure

Electric Starter Operation

Instructs on inserting the switch key and turning it to the START position, with caution for continuous operation.

[Recoil Starter Model] Starting Procedure

Recoil Starter Operation

Guides on pulling the recoil starter grip slowly until compression, then briskly.

Warming Up the Engine

Engine Warm-up Procedure and Precautions

Advises allowing the engine to warm up at idle before applying load and checking the oil warning lamp.

OPERATING

Engine Inclination Limits

States the engine can operate continuously at angles up to 15°, with a caution against exceeding it.

STOPPING

Ordinary Stop Procedure

Details lowering engine speed to idle for one minute before shutting off to prevent damage.

Emergency Stop Procedure

Instructs to immediately turn the engine switch off and close the fuel valve.

Key Removal Warning

Warns to always remove the engine key when leaving equipment unattended.

ADJUSTMENT

Engine Speed Adjustment

Advises against tampering with governor or carburetor settings and recommends dealer service for adjustments.

MAINTENANCE

Periodic Maintenance Chart Overview

Provides a chart of maintenance tasks and their recommended service intervals.

Spark Plug Cap Removal Warning

Warns to always remove the spark plug cap before servicing to prevent accidental starting.

Oil Level Check

Daily Oil Level Check Procedure

Emphasizes checking oil level daily and before operation to prevent engine damage.

Oil Change

Oil Change Intervals and Procedure

Details when to change oil (first 8 hours, then 50/100 hours) and the draining process.

Hot Engine Oil Warning

Warns that hot engine oil can cause severe burns and advises allowing it to cool before draining.

Oil Filter Change

Oil Filter Replacement Procedure

Explains how to change the oil filter every 200 hours, including preparation and post-replacement checks.

Hot Engine Oil Warning for Filter Change

Warns about hot engine oil during filter removal and advises allowing the engine to cool.

Air Cleaner Service

Air Cleaner Service Precautions

Warns against running the engine with the air cleaner removed and advises safe cleaning practices.

Dual Filtration Type Air Cleaner

Dual Filtration Air Cleaner Components

Identifies wing bolts and air cleaner cover for the dual filtration type.

Lower Inhale Type Air Cleaner

Lower Inhale Type Removal

Describes removing the cover and elements for the lower inhale type air cleaner.

Upper Inhale Type Air Cleaner

Upper Inhale Type Removal

Explains how to remove the upper inhale type air cleaner element using a clamp.

Air Cleaner Element Maintenance

Foam and Paper Element Care

Covers cleaning and oiling foam elements and cleaning/replacing paper elements.

Air Cleaner Element Replacement

Specifies changing the air cleaner element every 300 hours.

Fuel Filter Service

Fuel Filter Cleaning Procedure

Details loosening the sediment bowl, removing the screen, cleaning, and reinstalling the assembly.

Fuel Filter Service Interval

Specifies cleaning the fuel filter element every 50 hours.

Fuel Valve Operation for Service

Instructs to close the fuel valve to shut off fuel flow before servicing the filter.

Spark Plug Service

Spark Plug Maintenance and Replacement

Covers cleaning, gap adjustment, replacement, installation, and recommended plug type.

STORAGE

Fuel System Draining for Storage

Details draining the fuel system to prevent gum deposits when storing for over 30 days.

Fuel Draining Safety Precautions

Warns about flammable gasoline and advises draining in a well-ventilated area away from sparks.

Engine Storage Preparation

Includes cylinder protection and body cleaning for long-term storage.

TROUBLESHOOTING GUIDE

Insufficient Compression Issues

Lists causes and remedies for insufficient compression, such as faulty parts or loose bolts.

Engine Wont Start or Low Output

Covers causes like no fuel, blocked filters, or faulty carburetor for starting issues.

Spark Plug Fouled by Fuel

Addresses issues of spark plugs fouled by fuel, including clogged air cleaners and incorrect fuel grade.

Engine Performance Problems

Spark Issues and Remedies

Covers no spark or weak spark, identifying causes like faulty plugs or igniters.

Operational Issues

Overheating, Low Output, and Speed Problems

Addresses overheating, low output, and speed issues due to dirt, oil, carbon, or governor faults.

ENVIRONMENTAL PROTECTION

Proper Disposal of Components

Advises consulting dealers or agencies for proper disposal of used batteries, oil, and other components.

SPECIFICATIONS

Engine Specifications (FE350 and FE400)

Provides key specifications for FE350 and FE400 engines, including type, bore, displacement, and weight.

WIRING DIAGRAM

Recoil Starter Model Wiring

Shows the wiring diagram for the recoil starter model with an engine stop type oil level sensor.

[Electric Starter Model] Wiring Diagrams

Electric Starter Wiring (Alarm Type)

Presents the wiring diagram for electric start with alarm type oil level sensor.

Electric Starter Wiring (Stop Type)

Shows the wiring diagram for electric start with engine stop type oil level sensor.

[Electric Starter Model] Wiring Diagram (Engine Stop Type)

Detailed Electric Starter Wiring

Presents a detailed wiring diagram for electric start with engine stop type oil level sensor.

Kawasaki FE350 Specifications

General IconGeneral
Cooling SystemAir-cooled
Ignition SystemCDI
Fuel SystemCarburetor
Starting SystemElectric starter
Engine Type4-stroke, single cylinder

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