EasyManua.ls Logo

Kawasaki KBL23A - User Manual

Kawasaki KBL23A
19 pages
Save Page as PDF
Print Icon
To Next Page IconTo Next Page
To Next Page IconTo Next Page
Loading...
KBL23A/26A
KBL33A/34A/43A/48A
KBH26A/33A/34A/43A/48A
Trimmer/Brushcutter
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
taken 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.
Illustrations and photographs in this publication are intended for reference use only and may not depict actual model
component parts.
© Kawasaki Heavy Industries, Ltd., 1997, 1999 Second Edition (1) : May 31, 1999 (K)

Table of Contents

Question and Answer IconNeed help?

Do you have a question about the Kawasaki KBL23A and is the answer not in the manual?

Summary

Emission Control Information

Tampering With Emission Control System Prohibited

Prohibits tampering with emission control systems, listing presumed acts.

Foreword

How to Use This Manual

Explains how to interpret symbols and use the manual effectively.

General Information

Before Servicing Precautions

Covers cleaning, tightening, torque, force, handling sharp edges, solvents, and component installation.

Lubrication, Replacement, and Inspection

Details proper lubrication, using new replacement parts, and inspection criteria.

Specifications Definitions

Explains terms like "Standards" and "Service Limits" used in specifications.

Idling Speed Adjustment

Step-by-step guide on how to adjust the engine's idling speed for optimal performance.

General Specifications Overview

Presents key technical specifications for various Kawasaki trimmer/brushcutter models.

Periodic Maintenance Chart

Outlines recommended maintenance tasks and their intervals (daily, first 20 hrs, etc.).

Tightening Torque Guide

Lists required tightening torques for major fasteners across different models.

Clearance Table

Provides service limits for critical component clearances for various engine models.

Setting Table

Details standard settings for engine speed, ignition timing, and gear ratios for different models.

Power Train

Complete Engine Removal

Instructions for removing the complete engine from the trimmer/brushcutter unit.

Summary

Emission Control Information

Tampering With Emission Control System Prohibited

Prohibits tampering with emission control systems, listing presumed acts.

Foreword

How to Use This Manual

Explains how to interpret symbols and use the manual effectively.

General Information

Before Servicing Precautions

Covers cleaning, tightening, torque, force, handling sharp edges, solvents, and component installation.

Lubrication, Replacement, and Inspection

Details proper lubrication, using new replacement parts, and inspection criteria.

Specifications Definitions

Explains terms like "Standards" and "Service Limits" used in specifications.

Idling Speed Adjustment

Step-by-step guide on how to adjust the engine's idling speed for optimal performance.

General Specifications Overview

Presents key technical specifications for various Kawasaki trimmer/brushcutter models.

Periodic Maintenance Chart

Outlines recommended maintenance tasks and their intervals (daily, first 20 hrs, etc.).

Tightening Torque Guide

Lists required tightening torques for major fasteners across different models.

Clearance Table

Provides service limits for critical component clearances for various engine models.

Setting Table

Details standard settings for engine speed, ignition timing, and gear ratios for different models.

Power Train

Complete Engine Removal

Instructions for removing the complete engine from the trimmer/brushcutter unit.

Overview

  1. Function Description
  2. Important Technical Specifications
  3. Usage Features
  4. Maintenance Features

This document is a Service Manual for Kawasaki Trimmer/Brushcutter models KBL23A/26A, KBL33A/34A/43A/48A, and KBH26A/33A/34A/43A/48A. It provides comprehensive information for trained mechanics and owners to perform maintenance and repair tasks.

Function Description

The devices covered are gasoline-powered trimmers and brushcutters, designed for cutting vegetation. They utilize a forced air-cooled 2-stroke, horizontal shaft gasoline engine. The cutting mechanism can be either a nylon string cutter or a blade, depending on the model and application. The engine drives a shaft that connects to the cutting head or blade through a gear case assembly.

Important Technical Specifications

The manual details specifications across various models, categorized by handle type (Loop handle or Double handles) and engine displacement.

Engine Type: All models feature a forced air-cooled 2-stroke, horizontal shaft gasoline engine.

Displacement:

  • KBL23A: 22.5 ml (1.37 cu. in.)
  • KBH26A/KBL26A: 25.4 ml (1.55 cu. in.)
  • KBH33A/KBL33A/KBH34A/KBL34A: 33.3 ml (2.03 cu. in.)
  • KBH43A/KBL43A: 43.2 ml (2.64 cu. in.)
  • KBH48A/KBL48A: 48.6 ml (2.97 cu. in.)

Carburetor: Diaphragm type for all models.

Ignition: Solid state ignition for all models.

Spark Plug: NGK BPMR6A for all models.

Starter: Recoil starter for all models.

Clutch: Automatic centrifugal type.

  • KBL23A/KBH26A/KBL26A: Clutch drum diameter Ø54 mm (2.1 in.)
  • KBH33A/KBL33A/KBH34A/KBL34A/KBH43A/KBL43A/KBH48A/KBL48A: Clutch drum diameter Ø78 mm (3.1 in.)

Fuel: Regular unleaded gasoline mixed with 2-stroke engine oil at a 50:1 ratio.

Tank Capacity:

  • KBL23A: 0.5 litre
  • KBH26A/KBL26A/KBH33A/KBL33A/KBH34A/KBL34A: 0.6 litre
  • KBH43A/KBL43A/KBH48A/KBL48A: 1.0 litre

Cutter: Nylon string (Ø2.4 mm / 0.095 in.) or 5-plane blade.

Drive Shaft Assembly & Gear Housing:

  • Bearing of shaft: 5 plane.
  • Rotation: Counterclockwise.
  • Lubrication: High quality lithium grease.
  • Drive shaft diameter: Ø6 mm (0.24 in.) for KBL23A/KBH26A/KBL26A; Ø8 mm (0.31 in.) for all other models.
  • Drive shaft material: High tensile steel.
  • Reduction ratio: 14:19 for KBL23A/KBH26A/KBL26A; 17:21 for all other models.
  • Guard: Plastic guard on the pipe assembly.

Clearance Table (Service Limits):

  • Cylinder bore: Ranges from 32.1 mm (1.263 in.) to 44.1 mm (1.736 in.) depending on model. Replace if over limit.
  • Piston-to-cylinder clearance: 0.15 mm (all models). Replace if over.
  • Piston ring-to-groove clearance: 0.17 mm (all models). Replace if over.
  • Piston ring end-gap: 0.7 mm (all models). Replace if over.
  • Piston-to-piston pin clearance: 0.1 mm (all models). Replace if over.
  • Connecting rod big-end axial play: 0.5 mm (all models). Replace if over.
  • Connecting rod big-end radial play: 0.15 mm (all models). Replace if over.
  • Piston pin-to-needle bearing radial play: 0.15 mm (all models). Replace if over.
  • Ball bearing axial play: 0.5 mm (all models). Replace if over.
  • Crankshaft axial play: 0.05 ~ 0.295 mm (all models). Adjust if over.

Setting Table (Standard Setting):

  • Engine speed at which clutch engages:
    • KBL23A/KBH26A/KBL26A: about 4000 rpm at 4.0 N·m (0.4 kg·m) of drag torque.
    • KBH33A/KBL33A/KBH34A/KBL34A: about 3800 rpm at 4.0 N·m (0.4 kg·m) of drag torque.
    • KBH43A/KBL43A/KBH48A/KBL48A: about 3500 rpm at 4.0 N·m (0.4 kg·m) of drag torque.
  • Max. engine speed: 3000 ± 200 rpm (different depending on matching machine).
  • Idling speed:
    • KBL23A/KBH26A/KBL26A/KBH43A/KBL43A/KBH48A/KBL48A: 0.3 to 0.5 mm (0.011 to 0.019 in.).
    • KBH33A/KBL33A/KBH34A/KBL34A: 0.4 to 0.5 mm (0.015 to 0.019 in.).
  • Ignition coil air-gap: 25° B.T.D.C. @7000 rpm.
  • Gear ratio: 14:19 for KBL23A/KBH26A/KBL26A; 17:21 for all other models.
  • Jet needle clip location: 2/3 (all models).
  • Main adjust screw turning out: 1 1/2 ± 1/2 (all models).
  • Gear case grease capacity (full case): 8 to 10 grams for KBL23A/KBH26A/KBL26A; 13 to 17 grams for all other models.

Usage Features

The manual emphasizes the importance of reading the OWNER'S MANUAL before operating the device. It also includes an "EMISSION CONTROL INFORMATION" section, highlighting Kawasaki's compliance with environmental regulations. The exhaust emission control system consists of a carburetor and an ignition system with optimized timing. The carburetor is calibrated for lean air/fuel mixture and fuel economy. Tampering with the emission control system, including the carburetor, spark plugs, ignition system, fuel filter, and air cleaner elements, is prohibited by federal and California State law.

The "Idling Speed Adjustment" section provides clear instructions for setting the idling speed to prevent the cutting head or blade from rotating when the engine is idling. This is a crucial safety feature.

Maintenance Features

The service manual is designed for trained mechanics but also provides sufficient detail for owners to perform basic maintenance. It stresses the importance of proper tools, genuine Kawasaki parts, and following procedures carefully.

General Servicing Guidelines:

  • Cleanliness: Clean the engine before removal and disassembly to prevent dirt from acting as an abrasive.
  • Tightening Sequence: Follow specific tightening sequences for parts with multiple fasteners to avoid distortion and leaks. Use a reliable torque wrench according to specified torque values.
  • Force: Use appropriate force during assembly and disassembly, avoiding excessive force that could cause damage.
  • Edges: Exercise caution around sharp edges during engine disassembly and assembly.
  • Solvents: Use high-flash point solvents to reduce fire danger.
  • Gaskets and O-Rings: Always replace used gaskets and O-rings with new ones. Ensure mating surfaces are clean and smooth.
  • Liquid Gasket/Locking Agent: Apply sparingly, following manufacturer's directions.
  • Press-Fit Parts: Coat parts with oil before pressing them into place.
  • Ball Bearings: Press on the bearing race affected by friction to prevent damage to balls and races.
  • Oil/Grease Seals: Replace removed seals with new ones. Press seals with manufacturer's marks facing out. Apply oil or high-temperature grease to seal lips before passing a shaft through.
  • Circlips/Retaining Rings/Cotter Pins: Always replace removed circlips, retaining rings, and cotter pins with new ones as removal weakens them.
  • Lubrication: Apply oil or grease to rubbing surfaces during assembly. Clean off old, deteriorated grease. Use specified lubricants.
  • Replacement Parts: Replace parts as instructed, as they may be damaged or lose function after removal.
  • Inspection: Visually inspect disassembled parts for abrasion, bent, color change, crack, dent, deterioration, hardening, scratch, seizure, warp, or wear. Replace if condition is doubtful.

Periodic Maintenance Chart: The manual provides a detailed chart outlining maintenance tasks and their recommended intervals (Daily, First 20 hours, Every 20 hours, Every 50 hours, Every 100 hours). These intervals are guides, and service may be needed more frequently depending on operating conditions.

Daily Checks:

  • Check and replenish fuel.
  • Check for fuel leakage.
  • Check bolts, nuts, and screws for looseness and loss.
  • Check throttle lever operation.
  • Check engine switch operation.
  • Check guard assembly condition.
  • Check hook of shoulder harness condition.

Every 20 Hours (First):

  • Clean fuel filter.
  • Clean air filter element.
  • Tighten bolts, nuts, and screws.

Every 20 Hours:

  • Clean spark plug and adjust electrode gap.

Every 50 Hours:

  • Remove dust and dirt from cylinder fins.

Every 100 Hours:

  • Remove carbon deposits on piston head and inside cylinder.
  • Remove carbon deposits in the exhaust pipe of muffler.
  • Check gear case assembly lubrication.
  • Check drive shaft lubrication.
  • Check the sliding portion of crankshaft, connecting rod, etc.

Fuel Tube: Recommended to replace every 3 years.

Safety Precautions: A critical safety warning is highlighted: "Accidental engine starting can cause injury. Always remove the spark plug cap before servicing the engine to prevent accidental starting." This underscores the importance of safety during all maintenance procedures.

Kawasaki KBL23A Specifications

General IconGeneral
BrandKawasaki
ModelKBL23A
CategoryTrimmer
LanguageEnglish