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FS481V
Kawasaki FS481V User Manual
185 pages
Manual
Specs
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FS481V
,
FS541V
,
FS600V
FX481V
,
FX541V
,
FX600V
4-Stroke
Air-Cooled
V
-T
win
Gasoline
Eng
ine
Service
Manual
2
Table of Contents
Periodic Maintenance
17
General Information
3
List of Abbreviations
6
Emission Control Information
7
How to Use this Manual
8
Before Servicing
10
Table of Contents
17
Periodic Maintenance Chart
18
Torque and Locking Agent
19
Periodic Maintenance
20
Torque and Locking Agent
20
Specifications
21
Special Tools
22
Periodic Maintenance Procedures
23
Fuel System
23
Low Idle Speed Adjustment
23
High Idle Speed Adjustment
23
Fuel System Cleanliness Inspection
24
Element Cleaning and Inspection
25
Engine Top End
25
Cylinder Head Cleaning
25
Valve Clearance Inspection
26
Valve Clearance Adjustment
26
Valve Seat Inspection
27
Valve Seat Repair
27
Lubrication System
30
Engine Oil Level Inspection
30
Engine Oil Change
30
Oil Filter Replacement
31
Electrical System
32
Spark Plug Cleaning and Inspection
32
Spark Plug Gap Inspection
32
Fuel System 3-1 Fuel System
33
Exploded View
34
Specifications
40
Governor Link Mechanism
42
Control Panel Assembly Removal
42
Control Panel Assembly Installation
42
Governor Arm Removal
43
Governor Arm Installation
43
Governor Assembly Removal
44
Governor Assembly Installation
44
Governor Assembly Inspection
44
Governor Shaft Removal
44
Governor Shaft Installation
45
Carburetor
46
Fuel and Air Flow
46
Fuel Shut off Solenoid Valve
48
Low Idle Speed Adjustment
48
High Idle Speed Adjustment
48
High Altitude Operation
48
Main Jet Replacement
48
Fuel System Cleanliness Inspection
49
Intake Pipe Removal
50
Intake Pipe Installation
50
Carburetor Removal
51
Carburetor Installation
52
Carburetor Disassembly/Assembly
53
Carburetor Cleaning
54
Carburetor Inspection
55
Fuel Shut off Solenoid Valve Test
56
Intake Manifold
57
Intake Manifold Removal
57
Intake Manifold Installation
57
Intake Manifold Inspection
57
Fuel Pump, Fuel Filter
58
Fuel Pump Removal
58
Fuel Pump Installation
58
Fuel Pump Inspection
58
Fuel Filter Removal/Installation
59
Fuel Filter Inspection
59
Air Cleaner
60
Element Removal
60
Element Installation
61
Element Cleaning and Inspection
62
Air Cleaner Body and Bracket Removal
62
Air Cleaner Body and Bracket Installation
63
Air Cleaner Housing (Cap and Body) Inspection
63
Cooling System
65
Exploded View
66
Cooling System
67
Cooling Fan
70
Cooling Fan Removal
70
Cooling Fan Installation
70
Cooling Fan Inspection
70
Engine Shroud
71
Engine Shroud Removal
71
Engine Shroud Installation
73
Engine Top End 5-1 Engine Top End
75
Exploded View
76
Engine Top End
77
Specifications
78
Engine Top End
78
Special Tools
80
Cylinder Head
81
Compression Measurement
81
Cylinder Head Assembly Removal
82
Cylinder Head Assembly Installation
83
Push Rod Removal
84
Push Rod Installation
84
Push Rod Inspection
84
Valve Mechanism Removal/Installation
84
Cylinder Head Cleaning
86
Cylinder Head Inspection
87
Rocker Arm Inspection
87
Valves
88
Valve Clearance Inspection
88
Valve Clearance Adjustment
88
Valve Seat Inspection
88
Valve Seat Repair
88
Valve Head Thickness
88
Valve Stem Runout
88
Valve Stem Diameter
88
Valve Guide Inside Diameter
89
Valve Spring Inspection
89
Cylinder, Piston
90
Piston Removal
90
Piston Installation
91
Piston/Cylinder Seizure
93
Piston Cleaning
93
Piston Ring and Ring Groove Wear
94
Piston Ring End Gap
95
Piston Pin, Piston Pin Hole, and Connecting Rod Wear
95
Piston Diameter
96
Cylinder Inside Diameter
96
Cylinder Boring and Honing
96
Lubrication System
99
Exploded View
100
Engine Oil Flow Chart
102
Specifications
103
Special Tools
104
Engine Oil and Oil Filter
105
Engine Oil Level Inspection
105
Engine Oil Change
105
Oil Filter Removal
105
Oil Filter Installation
105
Pressurized Lubrication System
106
Oil Pressure Measurement
106
Oil Pump, Relief Valve
107
Oil Pump, Relief Valve Removal
107
Oil Pump, Relief Valve Installation
107
Oil Pump, Relief Valve Inspection
107
Oil Screen
109
Oil Screen Removal
109
Oil Screen Installation
109
Cleaning and Inspection
109
Camshaft/Crankshaft 7-1 Camshaft/Crankshaft
111
Exploded View
112
Specifications
114
Special Tool
115
Crankcase
116
Crankcase Cover Removal
116
Crankcase Cover Disassembly
116
Crankcase Cover Assembly
117
Crankcase Cover Installation
117
Crankcase Cover Inspection
118
Crankcase Disassembly
118
Crankcase Assembly
118
Crankcase Inspection
119
Crankcase and Crankcase Cover Cleaning
119
Breather
120
Breather Valve Removal
124
Breather Valve Installation
124
Breather Valve Inspection
125
Breather Pipe Removal
125
Breather Pipe Installation
125
Camshaft, Tappet
126
Camshaft, Tappet Removal
126
Camshaft, Tappet Installation
126
Camshaft Disassembly
126
Camshaft Assembly
127
Camshaft Inspection
127
Camshaft Bearing/Journal Wear
127
Crankshaft, Connecting Rod
129
Connecting Rod Removal
129
Connecting Rod Installation
129
Crankshaft Removal
129
Crankshaft Installation
129
Cleaning/Inspection
129
Connecting Rod Bend/Twist
130
Connecting Rod Big End/Crankpin Width Wear
130
Connecting Rod Big End Bearing/Crankpin Wear
131
Crankshaft Runout
131
Crankshaft Main Journal/Wear
132
Starter System
133
Exploded View
134
Starter System
135
Electric Starter System
138
Starter Motor Removal
139
Starter Motor Installation
139
Starter Solenoid and Circuit Test
139
Starter Motor Test
140
Starter Motor Disassembly
141
Starter Motor Assembly
143
Starter Motor Brush Inspection
146
Brush Spring Inspection
146
Armature Inspection
146
Yoke Assembly Inspection
148
Pinion Clutch Inspection
149
Recoil Starter Removal
149
Recoil Starter Installation
150
Recoil Starter Disassembly
150
Recoil Starter Assembly
151
Specifications
138
Electrical System
153
Exploded View
154
Specifications
158
Special Tool
159
Wiring Diagram
160
Precautions
163
Charging System
164
Flywheel and Stator Coil Removal
164
Flywheel and Stator Coil Installation
168
Charging System Operational Inspection
172
Stator Coil Resistance
172
Unregulated Stator Output
173
Regulator Removal
173
Regulator Installation
174
Regulator Resistance
174
Ignition System
175
Ignition Coil Removal
176
Ignition Coil Installation
177
Ignition Coil Inspection
178
Spark Plug Removal
178
Spark Plug Installation
178
Spark Plug Cleaning and Inspection
178
Spark Plug Gap Inspection
178
Troubleshooting
180
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Kawasaki FS481V Specifications
General
Compression Ratio
8.1:1
Fuel System
Carburetor
Displacement
603 cc
Bore x Stroke
73 x 72 mm (2.87 x 2.83 in)
Oil Capacity
1.8 L (1.9 US qt)
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