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Kawasaki FJ100D - User Manual

Kawasaki FJ100D
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Kawasaki Heavy Industries, Ltd.
Motorcycle & Engine Company
  We wish to thank you for purchasing
this Kawasaki engine.
  Please read this Owner's manual
carefully before starting your new engine
so that you will be thoroughly familiar
with the proper operation of your
engine's control, its features, capabilities
and limitations.
  Also read the manual of the equipment
to which this engine is attached.
  To ensure a long, trouble-free life for
your engine, give it the proper care and
maintenance described in this manual.
  Always keep this manual at your
fingertip so that you can refer to it
whenever you need information.
  This manual should be considered a
permanent part of the engine and should
remain with the engine when it is sold.
  All rights reserved. No part of this
publication may be reproduced without
our prior written permission.
  This publication includes the latest
information available at the time of printing.
  However, there may be minor
differences between the actual product
and illustrations and text in this manual.
All products are subject to change
without prior notice or obligation.
1
OWNER
,
S MANUAL
Part No. 99976-2122-03
SAFETY AWARENESS
  Whenever you see the symbols
shown below, heed their instructions!
Always follow safe operating and
maintenance practices.
FOREWORD
SAFETY AWARENESS.........................1
FOREWORD..........................................1
READ THIS FIRST................................2
GENERAL INFORMATION....................3
FUEL AND OIL......................................5
RECOMMENDATIONS
Fuel...................................................5
Engine Oil.........................................5
Tune-up Specifications....................6
PREPARATION.....................................7
Fuel...................................................7
Engine Oil.........................................7
STARTINGSTOPPING......................9
MAINTENANCE...................................10
Periodic Maintenance Chart...........10
Oil Level Check...............................11
Oil Change......................................11
Fuel Tap Service............................11
Air Cleaner Service.........................12
Spark Plug Service.........................13
STORAGE...........................................14
TROUBLESHOOTING GUIDE............15
ENVIRONMENTAL PROTECTION.....16
SPECIFICATIONS...............................17
WIRING DIAGRAM.............................18
DANGER
DANGER indicates a hazardous
situation which, if not avoided, will
result in death or serious injury.
WARNING indicates a hazardous
situation which, if not avoided, could
result in death or serious injury.
NOTICE
NOTICE is used to address
practices not related to personal
injury.
This note symbol indicates points of
particular interest for more efficient
and convenient operation.
NOTE
TABLE OF CONTENTS
© 2004 Kawasaki Heavy Industries, Ltd. Sep. 2012
(
3
) (
M
)
FJ100D
4-Stroke air-cooled gasoline engine
WARNING
CAUTION indicates a hazardous
situation which, if not avoided, could
result in minor or moderate injury.
CAUTION

Other manuals for Kawasaki FJ100D

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Summary

Safety Awareness

Danger

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

Warning

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Caution

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

Notice

Used to address practices not related to personal injury.

Foreword

Read This First

Carbon Monoxide Danger

Exhaust gas contains deadly carbon monoxide. Operate only in well-ventilated areas.

Gasoline Flammability

Gasoline is flammable and explosive. Avoid sparks and flames during refueling and servicing.

Fire Hazard Precautions

Keep engine clear of combustible materials and maintain distance from buildings.

Electrical Safety

Avoid touching spark plugs, plug caps, or leads while the engine is running.

Burn Hazard Prevention

Avoid touching hot engine or muffler. Allow to cool before servicing.

Moving Parts Safety

Keep hands and feet away from moving or rotating parts like pulleys or couplings.

Speed Limit Warning

Do not operate the engine at excessive speeds to prevent injury.

Warning Label Check

Understand and ensure all warning labels are present and legible.

General Information

Location of Parts (Recoil Starter)

Identifies major engine components labeled A through S for the recoil starter model.

Location of Parts (Integrated Start)

Identifies major engine components labeled A through H for the integrated start model.

Location of Labels

Warning Label Details

Explains the meaning of warning symbols A, B, C, D on the engine labels.

Engine Serial Number Importance

The serial number is crucial for engine identification and parts ordering.

Fuel and Oil Recommendations

Recommended Fuel

Use clean, fresh, unleaded regular grade gasoline with E10 or less ethanol.

Recommended Octane Rating

Minimum 91 RON. Use higher octane if knocking or pinking occurs.

Recommended Engine Oil

API SF, SG, SH, or SJ classification oils are recommended.

Oil Viscosity Selection

Guide for selecting appropriate SAE oil viscosity based on ambient temperature.

Tune-up Specifications

Ignition Timing Setting

Ignition timing is fixed and not adjustable.

Spark Plug Gap

Recommended gap for the spark plug is 0.60-0.70 mm (0.024-0.028 in.).

Engine Speed Settings

Specifies low idle speed (1600 r/min) and high idle speed (4000 r/min).

Valve Clearance

Intake and exhaust valve clearance is set at 0.12 mm (0.005 in.).

Low Oil Level Sensor

Capacities

Starting the Engine

Set Speed Control Lever

Move speed control lever to halfway position for starting.

Set Choke Lever

Set choke lever to "||" (Close) position for cold start.

Open Fuel Tap

Turn fuel tap lever to "ON" (Open) position to supply fuel.

Turn On Engine Switch

Set engine switch to "I" or "ON" position to enable starting.

Operate Recoil Starter

Pull starter grip slowly to compression, then pull fast and steady.

Operate Electric Starter

Press the start button to engage the electric starter.

Stopping the Engine

Set Speed Control Lever

Move speed control lever to "" position before stopping.

Turn Off Engine Switch

Set engine switch to "O" or "OFF" position to stop the engine.

Close Fuel Tap

Turn fuel tap lever to "OFF" (Close) position to shut off fuel supply.

Adjust Choke Lever

After engine starts, gradually move choke lever to "|" (Open) position.

Periodic Maintenance Schedule

Daily Checks

Check oil level, loose parts, leaks, and speed control lever.

8-Hour Interval

Check/clean air intake screen, clean foam air cleaner element.

25-Hour Interval

Clean foam air cleaner element.

50-Hour Interval

Change engine oil, clean fuel tap, tighten fasteners.

100-Hour Interval

Clean/regap spark plug, clean paper air cleaner element.

250-Hour Interval

Replace paper air cleaner, clean cylinder/head/chamber.

Oil Level Check Procedure

Engine Oil Change

Prepare for Oil Change

Warm engine, level unit, stop engine, remove plug and gasket.

Drain and Refill Oil

Drain old oil, replace gasket, refill with new oil to correct level.

Fuel Tap Service

Fuel Tap Cleaning Safety

Perform in ventilated area, away from ignition sources. Do not use flammable solvents.

Fuel Tap Cleaning Steps

Close tap, disassemble, clean filter and cup, reassemble.

Air Cleaner Maintenance

Air Cleaner Cleaning Safety

Perform in ventilated area away from ignition sources. Do not use gasoline for cleaning.

Foam Element Care

Wash foam element with detergent and water, dry, and replace if dirty. Do not oil.

Paper Element Care

Tap paper element to remove dust. Replace if very dirty or after 250 hours. Do not wash or oil.

Air Cleaner Assembly

Reassemble all parts securely to prevent engine damage from dirt ingestion.

Spark Plug Maintenance

Spark Plug Safety Precautions

Engine components can be hot; allow to cool before servicing the spark plug.

Spark Plug Cleaning and Gapping

Clean electrodes, check and adjust gap to 0.6-0.7 mm.

Spark Plug Inspection and Replacement

Inspect for damage. Replace with the same type of plug if necessary.

Spark Plug Installation

Install spark plug, torque to 23 N·m, and securely attach the spark plug cap.

Engine Storage Procedure

Fuel System Preparation

Drain all fuel from the tank and carburetor to prevent gumming during storage.

Engine Oil Treatment for Storage

Add oil to cylinder via spark plug hole, turn engine, reinstall plug.

Post-Storage Maintenance

Change engine oil after the engine has been stored.

Troubleshooting Guide

Engine Start;Output Issues

Addresses low compression, no fuel, fouled plug, or carburetor problems.

Low Output Causes

Solutions for clogged air cleaner, incorrect fuel, or water contamination.

Ignition System Problems

Troubleshoots no spark, weak spark, faulty spark plug, or ignition coil.

Low Oil Level Sensor Operation

Red warning light indicates low engine oil; check and fill oil.

Engine Overheating Causes

Identifies causes like clogged air cleaner, insufficient oil, or poor ventilation.

Speed Limitation Issues

Addresses problems with engine speed not increasing, possibly due to governor or air cleaner.

Environmental Protection

Engine Specifications

Engine Type and Configuration

Air-cooled, 4-stroke OHV, single cylinder, gasoline engine.

Bore and Stroke Dimensions

Bore is 56 mm and stroke is 40 mm (2.2 x 1.57 in.).

Engine Displacement

The engine displacement is 99 mL (5.97 cu.in.).

Ignition and Starting Systems

Features solid-state ignition and recoil/electric starter systems.

Engine Dry Weight

The dry weight of the engine is 10.5 kg (23 lb).

Wiring Diagrams

Recoil Starter Model Wiring

Electrical diagram illustrating components and connections for the recoil starter model.

Integrated Start Model Wiring

Electrical diagram showing components and connections for the integrated electric/recoil start model.

Summary

Safety Awareness

Danger

Indicates a hazardous situation which, if not avoided, will result in death or serious injury.

Warning

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

Caution

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

Notice

Used to address practices not related to personal injury.

Foreword

Read This First

Carbon Monoxide Danger

Exhaust gas contains deadly carbon monoxide. Operate only in well-ventilated areas.

Gasoline Flammability

Gasoline is flammable and explosive. Avoid sparks and flames during refueling and servicing.

Fire Hazard Precautions

Keep engine clear of combustible materials and maintain distance from buildings.

Electrical Safety

Avoid touching spark plugs, plug caps, or leads while the engine is running.

Burn Hazard Prevention

Avoid touching hot engine or muffler. Allow to cool before servicing.

Moving Parts Safety

Keep hands and feet away from moving or rotating parts like pulleys or couplings.

Speed Limit Warning

Do not operate the engine at excessive speeds to prevent injury.

Warning Label Check

Understand and ensure all warning labels are present and legible.

General Information

Location of Parts (Recoil Starter)

Identifies major engine components labeled A through S for the recoil starter model.

Location of Parts (Integrated Start)

Identifies major engine components labeled A through H for the integrated start model.

Location of Labels

Warning Label Details

Explains the meaning of warning symbols A, B, C, D on the engine labels.

Engine Serial Number Importance

The serial number is crucial for engine identification and parts ordering.

Fuel and Oil Recommendations

Recommended Fuel

Use clean, fresh, unleaded regular grade gasoline with E10 or less ethanol.

Recommended Octane Rating

Minimum 91 RON. Use higher octane if knocking or pinking occurs.

Recommended Engine Oil

API SF, SG, SH, or SJ classification oils are recommended.

Oil Viscosity Selection

Guide for selecting appropriate SAE oil viscosity based on ambient temperature.

Tune-up Specifications

Ignition Timing Setting

Ignition timing is fixed and not adjustable.

Spark Plug Gap

Recommended gap for the spark plug is 0.60-0.70 mm (0.024-0.028 in.).

Engine Speed Settings

Specifies low idle speed (1600 r/min) and high idle speed (4000 r/min).

Valve Clearance

Intake and exhaust valve clearance is set at 0.12 mm (0.005 in.).

Low Oil Level Sensor

Capacities

Starting the Engine

Set Speed Control Lever

Move speed control lever to halfway position for starting.

Set Choke Lever

Set choke lever to "||" (Close) position for cold start.

Open Fuel Tap

Turn fuel tap lever to "ON" (Open) position to supply fuel.

Turn On Engine Switch

Set engine switch to "I" or "ON" position to enable starting.

Operate Recoil Starter

Pull starter grip slowly to compression, then pull fast and steady.

Operate Electric Starter

Press the start button to engage the electric starter.

Stopping the Engine

Set Speed Control Lever

Move speed control lever to "" position before stopping.

Turn Off Engine Switch

Set engine switch to "O" or "OFF" position to stop the engine.

Close Fuel Tap

Turn fuel tap lever to "OFF" (Close) position to shut off fuel supply.

Adjust Choke Lever

After engine starts, gradually move choke lever to "|" (Open) position.

Periodic Maintenance Schedule

Daily Checks

Check oil level, loose parts, leaks, and speed control lever.

8-Hour Interval

Check/clean air intake screen, clean foam air cleaner element.

25-Hour Interval

Clean foam air cleaner element.

50-Hour Interval

Change engine oil, clean fuel tap, tighten fasteners.

100-Hour Interval

Clean/regap spark plug, clean paper air cleaner element.

250-Hour Interval

Replace paper air cleaner, clean cylinder/head/chamber.

Oil Level Check Procedure

Engine Oil Change

Prepare for Oil Change

Warm engine, level unit, stop engine, remove plug and gasket.

Drain and Refill Oil

Drain old oil, replace gasket, refill with new oil to correct level.

Fuel Tap Service

Fuel Tap Cleaning Safety

Perform in ventilated area, away from ignition sources. Do not use flammable solvents.

Fuel Tap Cleaning Steps

Close tap, disassemble, clean filter and cup, reassemble.

Air Cleaner Maintenance

Air Cleaner Cleaning Safety

Perform in ventilated area away from ignition sources. Do not use gasoline for cleaning.

Foam Element Care

Wash foam element with detergent and water, dry, and replace if dirty. Do not oil.

Paper Element Care

Tap paper element to remove dust. Replace if very dirty or after 250 hours. Do not wash or oil.

Air Cleaner Assembly

Reassemble all parts securely to prevent engine damage from dirt ingestion.

Spark Plug Maintenance

Spark Plug Safety Precautions

Engine components can be hot; allow to cool before servicing the spark plug.

Spark Plug Cleaning and Gapping

Clean electrodes, check and adjust gap to 0.6-0.7 mm.

Spark Plug Inspection and Replacement

Inspect for damage. Replace with the same type of plug if necessary.

Spark Plug Installation

Install spark plug, torque to 23 N·m, and securely attach the spark plug cap.

Engine Storage Procedure

Fuel System Preparation

Drain all fuel from the tank and carburetor to prevent gumming during storage.

Engine Oil Treatment for Storage

Add oil to cylinder via spark plug hole, turn engine, reinstall plug.

Post-Storage Maintenance

Change engine oil after the engine has been stored.

Troubleshooting Guide

Engine Start;Output Issues

Addresses low compression, no fuel, fouled plug, or carburetor problems.

Low Output Causes

Solutions for clogged air cleaner, incorrect fuel, or water contamination.

Ignition System Problems

Troubleshoots no spark, weak spark, faulty spark plug, or ignition coil.

Low Oil Level Sensor Operation

Red warning light indicates low engine oil; check and fill oil.

Engine Overheating Causes

Identifies causes like clogged air cleaner, insufficient oil, or poor ventilation.

Speed Limitation Issues

Addresses problems with engine speed not increasing, possibly due to governor or air cleaner.

Environmental Protection

Engine Specifications

Engine Type and Configuration

Air-cooled, 4-stroke OHV, single cylinder, gasoline engine.

Bore and Stroke Dimensions

Bore is 56 mm and stroke is 40 mm (2.2 x 1.57 in.).

Engine Displacement

The engine displacement is 99 mL (5.97 cu.in.).

Ignition and Starting Systems

Features solid-state ignition and recoil/electric starter systems.

Engine Dry Weight

The dry weight of the engine is 10.5 kg (23 lb).

Wiring Diagrams

Recoil Starter Model Wiring

Electrical diagram illustrating components and connections for the recoil starter model.

Integrated Start Model Wiring

Electrical diagram showing components and connections for the integrated electric/recoil start model.

Kawasaki FJ100D Specifications

General IconGeneral
Valve TrainOHV
Compression Ratio8.1:1
Maximum Power3, 600 rpm
Maximum Torque2, 400 rpm
FuelGasoline
Ignition SystemMagneto
Starting SystemRecoil starter
CoolingForced air-cooled

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