Kawasaki FH541V 4 Stroke Air Cooled V Twin Gasoline Engine

Product Information

Specifications

• Model: FH451V, FH500V, FH531V, FH541V, FH580V, FH601V, FH641V, FH661V, FH680V, FH721V
• Engine Type: 4-Stroke Air-Cooled V-Twin Gasoline Engine

Product Usage Instructions

General Information
The Kawasaki 4-Stroke Air-Cooled V-Twin Gasoline Engine is designed to provide reliable power for various applications. Before operating the engine, it is important to familiarize yourself with the general information provided in the user manual.

Periodic Maintenance
Regular maintenance is essential to ensure optimal performance and longevity of the engine. The user manual provides detailed instructions on the recommended maintenance schedule and procedures. It covers tasks such as oil changes, filter replacements, and spark plug inspections.

Fuel System
The fuel system of the engine plays a crucial role in delivering the necessary fuel for combustion. The user manual provides information on fuel requirements, fuel filter maintenance, and troubleshooting tips for fuel- related issues.

Cooling System
The cooling system of the engine helps regulate its temperature and prevent overheating. The user manual provides instructions on maintaining the cooling system, including coolant replacement and radiator cleaning.

Engine Top End
The top end of the engine includes components such as the cylinder head and valves. The user manual offers guidance oni nspecting and adjusting these components to ensure proper functioning.

Lubrication System
The lubrication system is responsible for reducing friction and wear within the engine. The user manual provides instructions on oil selection, oil level checks, and oil filter maintenance.

Camshaft/Crankshaft
The camshaft and crankshaft are vital components of the engine’s valve and piston motion. The user manual provides information on inspecting and adjusting these components for optimal performance.

Starter System
The starter system allows for easy engine starting. The user manual provides instructions on using the starter system and troubleshooting common starter-related issues.

Electrical System
The electrical system of the engine includes components such as the ignition system and charging system. The user manual provides information on electrical system maintenance, troubleshooting, and wiring diagrams.

Troubleshooting

In case of any issues or malfunctions, the user manual offers a troubleshooting section that provides step-by-step instructions to identify and resolve common engine problems.

FAQ

Q: Where can I purchase Kawasaki discountparts?
A: You can purchase Kawasaki discount parts by calling 606-678-9623 or 606-561-4983. You can also visit www.mymowerparts.com for more information.

Q: Can I reproduce or distribute the content of this user manual?
A: No, you cannot reproduce, store, or distribute the content of this user manual without prior written permission from Quality Division/Consumer Products & Machinery Company/Kawasaki Heavy Industries, Ltd., Japan.

Q: Are there any limitations or liabilities associated with this publication?
A: While every effort has been made to ensure the accuracy and completeness of this publication, no liability can be accepted for any inaccuracies or omissions. The right is reserved to make changes to the product without prior notice.

Q: Are the illustrations and photographs in the user manual accurate?
A: The illustrations and photographs in the user manual are intended for reference use only and may not depict actual model component parts.

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Quick Reference Guide

General Information Periodic Maintenance Fuel System Cooling System Engine Top End Lubrication System Camshaft/Crankshaft Starter System Electrical System Troubleshooting

1j 2j 3j 4j 5j 6j 7j 8j 9j 10 j

This quick reference guide will assist you in locating a desired topic or procedure. ·Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page. ·Refer to the sectional table of contents for the exact pages to locate the specific topic required.
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FH451V, FH500V, FH531V FH541V, FH580V, FH601V FH641V, FH661V, FH680V
FH721V

4-Stroke Air-Cooled V-Twin 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 Division/Consumer Products & Machinery Company/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.

© 2006 Kawasaki Heavy Industries, Ltd.

1 Edition (1):Mar. 31, 2006 (K)

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A ABDC AC ATDC BBDC BDC BTDC °C DC F °F ft g h L

LIST OF ABBREVIATIONS

ampere(s)

lb

pound(s)

after bottom dead center

m

meter(s)

alternating current

min

minute(s)

after top dead center

N

newton(s)

before bottom dead center

Pa

pascal(s)

bottom dead center

PS

horsepower

before top dead center

psi

pound(s) per square inch

degree(s) Celsius

r

revolution

direct current

rpm

revolution(s) per minute

farad(s)

TDC

top dead center

degree(s) Fahrenheit

TIR

total indicator reading

foot, feet

V

volt(s)

gram(s)

W

watt(s)

hour(s)

ohm(s)

liter(s)

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EMISSION CONTROL INFORMATION

To protect the environment in which we all live, Kawasaki has incorporated crankcase emission (1) and exhaust emission (2) control systems (EM) in compliance with applicable regulations of the United States Environmental Protection Agency and California Air Resources Board. 1. Crankcase Emission Control System
A sealed-type crankcase emission control system is used to eliminate blow-by gases. The blow-by gases are led to the breather chamber through the crankcase. Then, it is led to the air cleaner.
Oil is separated from the gases while passing through the inside of the breather chamber from the crankcase, and then returned back to the bottom of crankcase.
2. Exhaust Emission Control System The exhaust emission control system applied to this engine consists of a carburetor and an
ignition system having optimum ignition timing characteristics. The carburetor has been calibrated to provide lean air/fuel mixture characteristics and opti-
mum fuel economy with a suitable air cleaner and exhaust system.

TAMPERING WITH EMISSION CONTROL SYSTEM PROHIBITED
Federal law and California State law prohibits the following acts or the causing thereof: (1) the removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new engine for the purpose of emission control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the engine after such device or element of design has been removed or rendered inoperative by any person. Among those acts presumed to constitute tampering are the acts listed below: Do not tamper with the original emission related part:
Carburetor and internal parts
· Spark plugs · Magneto or electronic ignition system · Fuel filter element · Air cleaner elements · Crankcase · Cylinder heads · Breather chamber and internal parts ·· Inlet pipe and tube
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Foreword

This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and repair satisfactorily. Whenever the owner has insufficient experience or doubts as to his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics.
In order to perform the work efficiently and to avoid costly mistakes, read the text, thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substitute tools may adversely affect safe operation.
To get the longest life out of your engine:
· Follow the Periodic Maintenance Chart in the Service Manual.
· Be alert for problems and non-scheduled maintenance.
· Use proper tools and genuine Kawasaki engine parts. Genuine parts provided as spare parts are listed in the Parts Catalog.
· Follow the procedures in this manual carefully. Don’t take shortcuts.
· Remember to keep complete records of maintenance and repair with dates and any new parts installed.
How to Use This Manual
In preparing this manual, we divided the product into its major systems. These systems became the manual’s chapters. All information for a particular system from adjustment through disassembly and inspection is located in a single chapter.
The Quick Reference Guide shows you all of the product’s system and assists in locating their chapters. Each chapter in turn has its own comprehensive Table of Contents.
The Periodic Maintenance Chart is located in the General Information chapter. The chart gives a time schedule for required maintenance

operations. If you want spark plug information, for exam-
ple, go to the Periodic Maintenance Chart first. The chart tells you how frequently to clean and gap the plug. Next, use the Quick Reference Guide to locate the Electrical System chapter. Then, use the Table of Contents on the first page of the chapter to find the Spark Plug section.
Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices.
WARNING
This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life.

CAUTION

This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to or destruction of equipment.

This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information.

This

note

NOTE symbol indicates

points

of

par-

ticular interest for more efficient and con-

venient operation.

• Indicates a procedural step or work to be done.
  Indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a WARNING, CAUTION, or NOTE. Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows. In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly.

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GENERAL INFORMATION 1-1

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GENERAL INFORMATION

Before Servicing
Before starting to service the engine, carefully read the applicable section to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever necessary. Nevertheless, even a detailed account has limitations, a certain amount of basic knowledge is required for successful work.
Especially note the following: (1) Dirt
Before removal and disassembly, clean the engine. Any dirt entering the engine, carburetor, or other parts, will work as an abrasive and shorten the life of engine. For the same reason, before installing a new part, clean off any dust or metal filings. (2) Battery Ground
Remove the ground (­) lead from the battery before performing any disassembly operations on the equipment. This prevents: (a)the possibility of accidentally turning the engine over while partially disassembled. (b)sparks at electrical connections which will occur when they are disconnected. (c) damage to electrical parts. (3) Tightening Sequence
Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them evenly, in a staggered sequence. This is to avoid distortion of the part and/or causing gas or oil leakage. Conversely when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter of a turn and then remove them. Where there is a tightening sequence indication in this Service Manual, the bolts, nuts, or screws must be tightened in the order and method indicated. (4) Torque
When torque values are given in this Service Manual, use them. Either too little or too much torque may lead to serious damage. Use a good quality, reliable torque wrench. (5) Force
Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especially difficult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap lightly using a wooden or plastic-faced mallet. Use an impact driver for screws (particularly for the removal of screws held by a locking agent) in order to avoid damaging the heads. (6) Edges
Watch for sharp edges, especially during major engine disassembly and assembly. Protect your hands with gloves or a piece of thick cloth when lifting the engine or turning it over. (7) High-Flash Point Solvent
A high-flash point solvent is recommended to reduce fire danger. A commercial solvent commonly available in North America is Standard solvent (generic name). Always follow manufacturer and container directions regarding the use of any solvent. (8) Gasket, O-Ring
Do not reuse a gasket or O-ring once it has been in service. The mating surfaces around the gasket should be free of foreign material and perfectly smooth to avoid oil or compression leaks. (9) Liquid Gasket, Non-Permanent Locking Agent
Follow manufacturer’s directions for cleaning and preparing surfaces where these compounds will be used. Apply sparingly. Excessive amounts may block engine oil passages and cause serious damage. An example of a non-permanent locking agent commonly available in North America is Loctite Lock’n Seal (Blue). (10)Press
A part installed using a press or driver, such as a journal, should first be coated with oil on its outer or inner circumference so that it will go into place smoothly. (11) Ball Bearing
When installing a ball bearing, the bearing race which is affected by friction should be pushed by a suitable driver. This prevents severe stress on the balls and races, and prevents races and balls from being dented. Press a ball bearing until it stops at the stop in the hole or on the shaft. (12)Oil Seal and Grease Seal
Replace any oil or grease seals that were removed with new ones, as removal generally damages seals.
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GENERAL INFORMATION 1-3
Before Servicing
When pressing in a seal which has manufacturer’s marks, press it in with the marks facing out. Seals should be pressed into place using a suitable driver, which contacts evenly with the side of seal, until the face of the seal is even with the end of the hole. (13)Seal Guide
A seal guide is required for certain oil or grease seals during installation to avoid damage to the seal lips. Before a shaft passes through a seal, apply a little oil, preferably high temperature grease on the lips to reduce rubber to metal friction. (14)Circlip, Retaining Ring
Replace any circlips and retaining rings that were removed with new ones, as removal weakens and deforms them. When installing circlips and retaining rings, take care to compress or expand them only enough to install them and no more. (15)Cotter Pin
Replace any cotter pins that were removed with new ones, as removal deforms and breaks them. (16)Lubrication
Engine wear is generally at its maximum while the engine is warming up and before all the rubbing surfaces have an adequate lubricative film. During assembly, oil or grease (whichever is more suitable) should be applied to any rubbing surface which has lost its lubricative film. Old grease and dirty oil should be cleaned off. Deteriorated grease has lost its lubricative quality and may contain abrasive foreign particles.
Don’t use just any oil or grease. Some oils and greases in particular should be used only in certain applications and may be harmful if used in an application for which they are not intended. This manual makes reference to molybdenum disulfide grease (MoS2) in the assembly of certain engine parts. Always check manufacturer recommendations before using such special lubricants. (17)Electrical Wires
All the electrical wires are either single-color or two-color and, with only a few exceptions, must be connected to wires of the same color. On any of the two-color wires there is a greater amount of one color and a lesser amount of a second color, so a two-color wire is identified by first the primary color and then the secondary color. For example, a yellow wire with thin red stripes is referred to as a “yellow/red” wire; it would be a “red/yellow” wire if the colors were reversed to make red the main color.

(18)Replacement Parts When there is a replacement instruction, replace these parts with new ones every time they are
removed. There replacement parts will be damaged or lose their original function once removed. (19)Inspection
When parts have been disassembled, visually inspect these parts for the following conditions or other damage. If there is any doubt as to the condition of them, replace them with new ones.

Abrasion

Crack

Hardening

Warp

Bent

Dent

Scratch

Wear

Color change

Deterioration

Seizure

(20)Specifications Specification terms are defined as follows: “Standards” show dimensions or performances which brand-new parts or systems have. “Service Limits” indicate the usable limits. If the measurement shows excessive wear or deteri-
orated performance, replace the damaged parts.

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1-4 GENERAL INFORMATION Model Identification
Electric Starter Model-FH500V
Recoil Starter Model-FH500V
Cylinder Number Designation:
No.1 Cylinder is the left-hand cylinder viewed from the air cleaner. No.2 Cylinder is the right-hand cylinder viewed from the air cleaner.
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GENERAL INFORMATION 1-5 Model Identification
Electric Starter Model-FH580V
Electric Starter Model-FH680V
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1-6 GENERAL INFORMATION Model Identification
Heavy Duty Air Cleaner Type
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GENERAL INFORMATION 1-7 General Specifications

Item

FH451V, FH500V, FH531V

FH541V, FH580V

FH601V, FH641V, FH661V, FH680V

FH721V

Type

Forced air-cooled, vertical shaft, OHV, 4-stroke gasoline engine.

Cylinder Layout

90 V-Twin

Bore × Stroke

68 mm × 68 mm 74 mm × 68 mm 75.2 mm × 76 mm (2.68 in. × 2.68 in.) (2.91 in. × 2.68 in.) (2.96 in. × 2.99 in.)

Displacement

494 mL (30.1 cu. in.) 585 mL (35.6 cu. in.) 675 mL (41.19 cu. in.)

Direction of Rotation Counterclockwise facing the PTO shaft

Compression Release Automatic compression release

Low Idle Speed

1 550 rpm

High Idle Speed

3 600 rpm

Ignition System

Transistorized-fly wheel magneto

RFI

Per Canada and U.S.A. requirements

Starting System

Electric starter and/or recoil starter

Charging System

12 V – 13 amps with regulator

Spark Plug

CHAMPION RCJ8Y

NGK BPR4ES

Carburetor

Float type, fixed main jet

Float type, fixed main jet, two barrel

Fuel Pump

Diaphragm type pulse pump

Air Cleaner

Dual stage element, dry type/Heavy duty type

Governor

Flyweight all speed governor

Lubrication System Pressure feed by positive displacement pump

Oil Filter

Cartridge type full flow filter

Oil Pressure Switch ON-OFF switch (Option)

Oil Capacity (when 1.8 L (1.9 US-qt) engine is completely dry)

1.9 L (2.0 US-qt)

Cooling System

Forced air cooling by fan

Dimensions (L × W × H ) Electric Starter Model

425 mm × 359 mm × 425 mm × 359 mm ×

324 mm

324 mm

458 mm × 430 mm × 381 mm

(16.7 in. × 14.1 in. × (16.7 in. × 14.1 in. × (18.0 in. × 16.9 in. × 15.0 in.)

12.8 in.)

12.8 in.)

Recoil Starter Model 425 mm × 359 mm × 425 mm × 359 mm ×

361 mm

361 mm

(16.7 in. × 14.1 in. × (16.7 in. × 14.1 in. ×

­

14.2 in.)

14.2 in.)

Dry Weight

Electric Starter Model 34 kg (75 lbs) Recoil Starter Model 32 kg (71 lbs)

34 kg (75 lbs) 32 kg (71 lbs)

40.5 kg (89.3 lbs) 41.2 kg

­

(90.8 lbs)

Specifications are subject to change without notice.

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PERIODIC MAINTENANCE 2-1

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2-2 PERIODIC MAINTENANCE Periodic Maintenance Chart

To ensure satisfactory operation over an extended period of time, any engine requires normal maintenance regular intervals. The Periodic Maintenance Chart below shows periodic inspection and
· maintenance items and suitable intervals. The bullet mark ( ) designates that the corresponding item
should be performed at that interval. Some adjustments require the use of special tools or other equipment. An electronic tachometer
will facilitate setting idle and running speeds.

FH451V, FH500V, FH531V, FH541V, FH580V

INTERVAL

OPERATION

Daily

First 8 hr.

Every 25 hr.

Every 50 hr.

Every 100 hr.

Every 200 hr.

Every 250 hr.

Every 300 hr.

Every 500 hr.

Check and clean air inlet screen

Check and add engine oil

• • Check for fuel and oil leakage

Check for loose or lost nuts and screws

• • Check battery electrolyte level

Clean air cleaner foam element (1)

Clean air cleaner paper element (1)

Clean cylinder and cylinder head fins (1)

Tighten nut and screws

Change engine oil

Clean and re-gap spark plugs

Change oil filter

Change air cleaner paper element (1)

• · · ·
  · ·

Replace air cleaner element

(Heavy duty air cleaner model)

(1)

Cclheearcaknacend adjust valve

Csulerfaanceand lap valve seating

Clean combustion chambers

(1): Service more frequently under dusty conditions.

: These items must be performed with the proper tools. See your authorized Kawasaki Engine Dealer for service, unless you have the proper equipment and mechanical proficiency.

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PERIODIC MAINTENANCE 2-3 Periodic Maintenance Chart

FH601V, FH641V, FH661V, FH680V, FH721V

INTERVAL

OPERATION

Daily

First 8 hr.

Every 25 hr.

Every 50 hr.

Every 100 hr.

Every 200 hr.

Every 250 hr.

Every 300 hr.

Every 500 hr.

Check and clean air inlet screen

Check and add engine oil

• • Check for fuel and oil leakage

Check for loose or lost nuts and screws

• • Check battery electrolyte level

Clean air cleaner foam element (1)

Clean air cleaner paper element (1)

Replace air cleaner paper element (1)

Replace air cleaner primary

element (Heavy duty air

cleaner model) (1)

Check air cleaner secondary

element (Heavy duty air

cleaner model) (1)

Replace air cleaner secondary

element (Heavy duty air

cleaner model) (1)

Clean cylinder and cylinder head fins (1)

Tighten nut and screws

Change engine oil

Clean and re-gap spark plugs

Check and clean oil cooler fins (FH721V model)

Change oil filter

Cclehaercaknacend adjust valve

• · · · ·
  · ·

Csulerfaanceand lap valve seating

Clean combustion chambers

(1): Service more frequently under dusty conditions.

: These items must be performed with the proper tools. See your authorized Kawasaki Engine Dealer for service, unless you have the proper equipment and mechanical proficiency.

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2-4 PERIODIC MAINTENANCE Torque and Locking Agent

The following tables lists the tightening torque for the major fasteners, and the parts requiring use of a non-permanent locking agent or liquid gasket.
Letters used in the “Remarks” column mean: L : Apply a non-permanent locking agent to the threads. M : Apply a molybdenum disulfide lubricant (grease or oil) to the threads, seated surface, or washer. O: Apply oil to the threads, seated surface, or washer. S: Tighten the fasteners following the specified sequence. SS: Apply silicone sealant.

FH451V, FH500V, FH531V, FH541V, FH580V

Fastener
Fuel System Carburetor (FH451V, FH500V, FH531V) Choke Valve Screw Throttle Valve Screws Pilot Jet Main Jet Main Air Jet Main Nozzle Pilot Air Jet Drain Screw Ground Lead Screw (Carburetor Side) Fuel Shut Off Solenoid Valve Float Bowl Mounting Bolt Carburetor (FH541V, FH580V) Throttle Valve Screws Main Jet Fuel Shut off Solenoid Valve Float Chamber Mounting Screw Governor Arm Clamp Nut Governor Shaft Plate Screws Holder Plate Nuts (Air Cleaner, Carburetor Mounting) Inlet Manifold Mounting Bolts Air Cleaner Body Mounting Screws Air Cleaner Body Bracket Bolts (Heavy Duty Air Cleaner Type) Air Cleaner Body Bracket Nuts (Heavy Duty Air Cleaner Type) Control Panel Mounting Bolts
Cooling System Engine Shroud Bolt (M8) Engine Shroud Bolts (M6) Plug Bolt (Engine Shroud) Plug Screw (Engine Shroud)

FH451V, FH500V, FH531V, FH541V, FH580V

Torque

N·m

kgf·m

ft·lb

Remarks

0.7

0.07

6 in·lb

1.0

0.1

9 in·lb

1.7

0.17

15 in·lb

0.7

0.07

6 in·lb

0.7

0.07

6 in·lb

2.0

0.20

17 in·lb

0.7

0.07

6 in·lb

1.3

0.13

11 in·lb

3.4

0.35

30 in·lb

6.9

0.70

61 in·lb

8.8

0.90

78 in·lb

0.7

0.07

6 in·lb

L

2.3

0.23

20 in·lb

4.5

0.46

40 in·lb

4.5

0.46

40 in·lb

7.8

0.80

69 in·lb

2.0

0.20

18 in·lb

5.9

0.60

52 in·lb

5.9

0.60

52 in·lb

3.4

0.35

30 in·lb

5.9

0.60

52 in·lb

9.8

1.0

87 in·lb

5.9

0.60

52 in·lb

15

1.5

11

5.9

0.60

52 in·lb

5.9

0.60

52 in·lb

3.4

0.35

30 in·lb

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PERIODIC MAINTENANCE 2-5 Torque and Locking Agent

Fastener
Engine Top End Cylinder Head Bolts Valve Clearance Lock Screws Connecting Rod Big End Cap Bolts (FH541V, FH580V) Rocker Arm Bolts Rocker Cover Mounting Bolts Exhaust Pipe Flange Nuts Spark Plugs
Lubrication System Engine Drain Plugs (Plastic) Engine Drain Plug (Metal) Engine Drain Plug Joint (Plastic) Engine Drain Plug Joint (Metal) Oil Pressure Switch Oil Passage Plug Oil Pump Cover Plate Mounting Bolts Oil Filter
Camshaft/Crankshaft Crankcase Cover Bolts Breather Chamber Cover Bolts
Electrical System Stator Coil Screws Flywheel Bolt Fan Housing Bolts Screen Bolts Regulator Screws Ignition Coil Bolts (Studs) Ignition Coil Bolts (Bolts) Starter Motor Mounting Bolts Recoil Starter Mounting Nuts Recoil Starter Retainer Screw Spark Plugs

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2-6 PERIODIC MAINTENANCE Torque and Locking Agent

The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads.

Basic Torque for General Fasteners

Threads dia

Torque

(mm)

N·m

kgf·m

ft·lb

4

2.0

0.20

17 in·lb

5

3.4

0.35

30 in·lb

6

5.9

0.60

52 in·lb

8

15

1.5

11

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PERIODIC MAINTENANCE 2-7 Torque and Locking Agent

The following tables lists the tightening torque for the major fasteners, and the parts requiring use of a non-permanent locking agent or liquid gasket.
Letters used in the “Remarks” column mean: L: Apply a non-permanent locking agent to the threads. M: Apply a molybdenum disulfide lubricant (grease or oil) to the threads, seated surface, or washer. O: Apply oil to the threads, seated surface, or washer. S: Tighten the fasteners following the specified sequence.
SS: Apply silicone sealant.

FH601V, FH641V, FH661V, FH680V, FH721V

Fasteners

Fuel System Choke Valve Screw Throttle Valve Screws Pilot Jet Main Jet Main Jet, Plug Main Nozzle Main Air Jet Pilot Air Jet Drain Screw (Carburetor) Ground Lead Screw (Carburetor Side) Fuel Shut Off Solenoid Valve (Carburetor) Float Bowl Mounting Screw (Carburetor) Governor Arm Clamp Nut Governor Shaft Plate Screws Inlet Pipe Mounting Bolts and Nuts Inlet Manifold Mounting Bolts Air Cleaner Body Mounting Screws Air Cleaner Body Bracket Bolts (Heavy Duty Air Cleaner Type) Air Cleaner Body Bracket Nuts (Heavy Duty Air Cleaner Type) Control Panel Mounting Bolts
Cooling System Engine Shroud Bolt (M8) Engine Shroud Bolts (M6) Plug Bolt (Engine Shroud) Plug Screw (Engine Shroud)
Engine Top End Cylinder Head Bolts Valve Clearance Lock Screws Connecting Rod Big End Cap Bolts (For M7 × P1.0 screw thread spec.)

FH601V, FH641V, FH661V, FH680V, FH721V

Torque

N·m

kgf·m

ft·lb

Remarks

1.0

0.10

8.9 in·lb

L

1.0

0.10

8.9 in·lb

L

­

­

­

­

­

–

19

1.9

14

­

­

­

­

­

­

­

­

­

2.0

0.20

18 in·lb

­

­

­

20

2.0

15

3.9

0.40

35 in·lb

7.8

0.80

69 in·lb

2.0

0.20

18 in·lb

5.9

0.60

52 in·lb

5.9

0.60

52 in·lb

­

­

­

5.9

0.60

52 in·lb

9.8

1.0

87 in·lb

5.9

0.60

52 in·lb

15

1.5

11

5.9

0.60

52 in·lb

­

­

­

3.4

0.35

30 in·lb

25

2.6

19

S

6.9

0.70

61 in·lb

21

2.1

15

O

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2-8 PERIODIC MAINTENANCE Torque and Locking Agent

Fasteners

FH601V, FH641V, FH661V, FH680V, FH721V
Torque

Remarks

N·m

kgf·m

ft·lb

Connecting Rod Big End Cap Bolts (For M6 × P1.0 screw thread spec.)

9.8

1.0

87 in·lb

O

Rocker Arm Bolts

28

2.8

20

Rocker Cover Mounting Bolts

5.9

0.60

52 in·lb

Exhaust Pipe Flange Nuts

15

1.5

11

Spark Plugs

22

2.2

16

Lubrication System

Engine Drain Plugs (Plastic)

6.9

0.70

61 in·lb

Engine Drain Plug (Metal)

20

2.0

14.5

Engine Drain Plug Joint (Plastic)

17

1.7

12

Engine Drain Plug Joint (Metal)

39

4.0

29

Oil Pressure Switch

9.8

1.0

87 in·lb

SS

Oil Passage Plug

3.9

0.40

35 in·lb

Oil Pump Cover Plate Mounting Bolts

5.9

0.60

52 in·lb

Oil Filter

in the text

Oil Cooler Mounting Joint (FH721V)

44

4.5

33

Camshaft/Crankshaft

Crankcase Cover Bolts

25

2.6

19.0

S

Breather Chamber Cover Bolts

5.9

0.60

52 in·lb

Electrical System

Stator Coil Screws

3.4

0.35

30 in·lb

Flywheel Bolt

56

5.7

41

Fan Housing Bolts

5.9

0.60

52 in·lb

Screen Bolts

5.9

0.60

52 in·lb

Regulator Screws

3.4

0.35

30 in·lb

Ignition Coil Bolts (Studs)

7.8

0.80

69 in·lb

Ignition Coil Bolts (Bolts)

5.9

0.60

52 in·lb

Starter Motor Mounting Bolts

15

1.5

11

Recoil Starter Mounting Nuts

­

­

­

Recoil Starter Retainer Screw

­

­

­

Spark Plugs

22

2.2

16

The table below, relating tightening torque to thread diameter, lists the basic torque for the bolts and nuts. Use this table for only the bolts and nuts which do not require a specific torque value. All of the values are for use with dry solvent-cleaned threads.

Basic Torque for General Fasteners

Threads dia

Torque

(mm)

N·m

kgf·m

ft·lb

4

2.0

0.20

17 in·lb

5

3.4

0.35

30 in·lb

6

5.9

0.60

52 in·lb

8

15

1.5

11

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PERIODIC MAINTENANCE 2-9 Specifications

Item Fuel System
Idle Speed: (1) Low Idle Speed High Idle Speed
Air Cleaner: Type Pre-cleaner Second-stage cleaner
Type Cleaner Pre-cleaner Second-stage cleaner Engine Top End Valve Clearance: Inlet, Exhaust Valve Seating Surface Angle: Inlet, Exhaust Valve Seating Surface Width: Inlet, Exhaust Lubrication System Engine Oil: Type Viscosity Capacity
Level Electrical System
Spark Plug Spark Plug Gap

Standard

1 550 r/min (rpm) 3 600 r/min (rpm)

Dual stage filtration system

Foam element

Paper element

FH451V, FH500V, FH531V

FH541V, FH580V

FH601V, FH641V, FH661V, FH680V, FH721V

Heavy duty type

­

Paper element

­

­

­

Primary element

­

­

Secondary element

0.10 0.15 mm (0.004 0.006 in.) 45° 0.6 0.9 mm (0.024 0.035 in.)

SF, SG, SH, SJ or SL class SAE 40, SAE 30, SAE 10W-30/SAE 10W-40, or SAE 5W-20 1.5 L (1.6 US qt) (When the oil filter is not removed) 1.7 L (1.8 US qt) (When the oil filter is removed) except FH721 1.8 L (1.9 US qt) (When the oil filter is removed) FH721 Operating range (grid area) on dipstick
CHAMPION RCJ8Y, NGK BPR4ES 0.75 mm (0.030 in.)

Item

Service Limit

Engine Top End

Cylinder Head Warp

0.05 mm (0.002 in.)

(1) Idle speeds may vary depending on each equipment. Refer to the equipment specification.

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2-10 PERIODIC MAINTENANCE Special Tools

Valve Seat Cutter, 45° – 35: 57001-1116

Valve Seat Cutter, 32° – 33: 57001-1199

Valve Seat Cutter, 32° – 30: 57001-1120

Oil Filter Wrench: 57001-1249

Valve Seat Cutter Holder Bar: 57001-1128

Valve Seat Cutter Holder, 6: 57001-1360

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PERIODIC MAINTENANCE 2-11 Periodic Maintenance Procedures Fuel System
NOTE High and low idle speeds may vary depending on the equipment on which the engine is used. Refer to the equipment specification.
Low Idle Speed Adjustment Disconnect all possible external loads from the engine.
·· Start and warm up the engine thoroughly.
WARNING
Always keep your hands clear of the moving parts.
· Move the throttle lever at a dash to the idle position, and hold the throttle lever on the carburetor in closed position (turn the governor arm clockwise all the way) and adjust the low idle speed screw [A] until the engine idles at specified speed.
· For FH601V, FH641V, FH661V, FH680V, FH721V model; adjust the low idle speed screw [C] with Phillips Head Screwdriver [D] until the engine idles at specified speed. Low Idle Speed (Carburetor idle rpm) 1 450 rpm
· Release the throttle lever and adjust the low idle speed set screw [A] on the control plate to obtain the specified governor low idle speed. Low Idle Speed (Governor idle rpm) 1 550 rpm
High Idle Speed Adjustment
NOTE High idle speed adjustment should be made after the low idle speed adjustment is performed. CAUTION Do not adjust high idle speed with the air cleaner removed.
· Start and warm up the engine thoroughly.
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2-12 PERIODIC MAINTENANCE Periodic Maintenance Procedures
WARNING
Always keep your hands clear of the moving parts.
· Move the throttle lever at a dash to the high idle position and match the lever hole position with the panel hole by inserting 6 mm dia. pin or bolt [A].
· Loosen two M6 control panel mounting bolts [B] enough to move the control panel assembly.
· Carefully move the control panel assembly right side [C] up or down to obtain the specified high idle speed. High Idle Speed 3 600 rpm
· Tighten the M6 Mounting bolts.
Torque – Control Panel Mounting Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb)
Remove the 6 mm dia. pin or bolt.
·· Check the high idle speed, and readjust the high idle speed if necessary. CAUTION Be sure to make the low idle speed and high idle speed respectively correspond to those of the equipment.
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PERIODIC MAINTENANCE 2-13 Periodic Maintenance Procedures
Fuel System Cleanliness Inspection
WARNING
Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
Remove the air cleaner (see Air Cleaner Body Removal).
·· Place a suitable container [A] under the drain screw (B) on the carburetor.
· Turn out the drain screw a few turns to drain the carburetor and check if water or dirt has accumulated in the carburetor.
· For FH541V, FH580V model; remove the float bowl to drain the carburetor and check if water or dirt has accumulated in the carburetor.
· Tighten the drain screw.
Torque – [FH451V, FH500V, FH531V] Drain Screw: 1.3 N·m (0.13 kgf·m, 11 in·lb)
[FH601V, FH641V, FH661V, FH680V, FH721V] Drain Screw: 2.0 N·m (0.20 kgf·m, 18 in·lb)
· For FH541V, FH580V model; tighten the solenoid valve or float bowl mounting screw. Torque – Solenoid Valve: 4.5 N·m (0.46 kgf·m, 40 in·lb) Float Bowl Mounting Screw: 4.5 N·m (0.46 kgf·m, 40 in·lb)
· If any water or dirt is found, clean the carburetor (see Carburetor Cleaning) and fuel tank. And check the fuel filter.
Element Cleaning and Inspection Standard Type FH451V, FH500V, FH531V, FH541V, FH580V Models
NOTE In dusty areas, clean the elements more frequently than the recommended intervals.
WARNING
Because of the danger of highly flammable liquids, do not use gasoline or a low-flash point solvent to clean the element. Remove the foam element and the paper element.
·· Clean the foam element [A] in a bath of detergent and water, and dry the element by air thoroughly before installation.
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2-14 PERIODIC MAINTENANCE Periodic Maintenance Procedures
· Clean the paper element [A] by tapping it gently on a flat surface to remove dust. If the element is very dirty, replace it with a new one. CAUTION Do not use compressed air to clean the paper element. Do not oil the paper element or the foam element.
FH601V, FH641V, FH661V, FH680V, FH721V Models
· Remove the foam and paper elements (see Air Cleaner Element Removal).
· Clean the foam element [A] in a bath of detergent and water, and let the element air-dry thoroughly.
· Clean the paper element [B] by tapping it gently on a flat surface to remove dust. If the element is very dirty, replace it with a new one.
Heavy Duty Air Cleaner Type For FH541V and FH580V Models
This air cleaner element is not recommended to be cleaned, and the air cleaner element should be replaced with a new one at the maintenance time as shown in the maintenance chart.
NOTE Operating in dusty condition may require more frequent maintenance than above.
· Remove the element (see Element Removal in the Fuel System chapter).
· Replace the element [A] every 250 hrs.
CAUTION Do not wash air cleaner element. Do not oil air cleaner element. Do not use pressurized air to clean air cleaner element.
FH601V, FH641V, FH661V, FH680V, FH721V Models Air cleaner elements are not recommended to be cleaned,
and each air cleaner element should be replaced with new ones at the maintenance time as shown in the maintenance chart.
NOTE Operating in dusty condition may require more frequent maintenance than above.
· Remove the elements (see Element Removal in the Fuel System chapter).
· Replace the primary element [A] every 250 hrs.
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Periodic Maintenance Procedures

PERIODIC MAINTENANCE 2-15

• Replace the secondary element [A] with a new one if dirty when primary element is checked.
  · Replace the secondary element every 500 hrs.
  CAUTION

Do not wash air cleaner elements. Do not oil air cleaner elements. Do not use pressurized air to clean air cleaner elements.

Housing (Cap and Body) Inspection
· Clean the housing with detergent and water and dry the housing thoroughly. Check the housing for deformation or other damage.
·Seal the housing well and permit only filtered air to reach the carburetor. If the housing is damaged, replace the housing with a new one.
· Check that no foreign material obstructs the air passage.
Engine Top End
Cylinder Head Cleaning and Inspection
· Scrape the carbon deposits from the cylinder head and the exhaust port with a suitable tool [A].
· To avoid gouging, use scrapers that material will not damage the cylinder head and the exhaust pipe.
· Clean the head in a bath of high-flash point solvent and dry it with compressed air.
WARNING
Clean the cylinder head in a well ventilated area, and take care that there are no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Do not use gasoline or a low-flash point solvent to clean the cylinder head. A fire or explosion could result.
· Lay a straight edge [A] across the mating surface of the cylinder head at several different points, and measure the warp by inserting a thickness gauge [B] between the straight edge and the cylinder head. If the warp exceeds the service limit, repair the mating surface. Replace the cylinder head with a new one if the mating surface is badly damaged or warped.
Cylinder Head Warp Service Limit: 0.05 mm (0.002 in.)

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2-16 PERIODIC MAINTENANCE Periodic Maintenance Procedures
Check the cylinder head for cracks or other damage.
·· Cracks not visible to the eye may be detected by coating the suspected area with mixture of 25% kerosene and 75% light engine oil.
· Wipe the area dry and immediately apply a coating of zinc oxide dissolved in wood alcohol. If a crack is present, the coating will become discolored at the detected area.
· If a crack is present in the cylinder head, replace it with a new one.
· Inspect the mating surface for burrs or nicks. · Clean and inspect the rocker arm where it touches the
push rod and the valve stem. If the contact points [A] are worn or damaged, replace the rocker arm with a new one.
Valve Clearance Inspection
NOTE Check the valve clearance when the engine is cold (at room temperature). Remove the rocker cover (see Cylinder Head Removal).
·· Place the piston at the top dead center (TDC) of the compression stroke by turning the crankshaft clockwise facing the flywheel. No.1 Cylinder:
The left projection [A] on the flywheel is faced with the right leg [B] on the

1 ignition coil [C] as shown in the figure.

Check the inlet and exhaust valves are closed completely, if they are not closed, turn the flywheel one turn (360°) clockwise and face the left projection with the right leg again. No.2 Cylinder:
The left projection [A] on the flywheel is faced with the right leg [B] on the

2 ignition coil [C] as shown in the figure. Follow No.1 Cylinder alignment.

Check the valve clearance.
·Using a thickness gauge [A], measure the valve clearance between the rocker arm [B] and the valve stem end. If the valve clearance is no correct, adjust it. Valve Clearance (when cold) Inlet, Exhaust 0.10 0.15 mm (0.004 0.006 in.)
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PERIODIC MAINTENANCE 2-17 Periodic Maintenance Procedures

Valve Clearance Adjustment

· Since valve repairs change the valve clearance, adjust the valve clearance as specified.
· Assemble the cylinder head and install the cylinder head assembly on the block (see Cylinder Head Installation).
· Turn the crankshaft in proper direction until the piston is at the TDC of the compression stroke (as described above).
· Loosen the lock screws [A] and the valve clearance adjusting nuts [B].
· Insert a 0.10 mm (0.04 in.) thickness gauge [C] between the rocker arm and valve stem. Tighten the adjusting nut until the thickness gauge begins to bind between the rocker arm and valve stem end. Sweep the thickness gauge during this adjustment.

Valve Clearance (when cold) Inlet, Exhaust: 0.10 0.15 mm (0.004 0.006 in.)
· Holding the adjusting nut with a spanner, tighten the lock screw to the specified torque.
Torque – Valve Clearance Lock Screws: 6.9 N·m (0.70 kgf·m, 61 in·lb)
Do not overtighten the valve clearance lock screws.
·· After the valve clearance adjustment, measure the valve clearance again. Readjust the valve clearance if necessary.

Valve Seat Inspection
· Remove the valve (see Valve Mechanism Removal/Installation).
· Inspect the valve seats for damage. If the seats are warped or distorted beyond reconditioning, replace the cylinder head with a new one.
· Pitted or worn valve seats can be refaced. Lap the valves to the seats after refacing. Coat the valve seat with machinist’s dye.
· Push the valve into the guide. · Rotate the valve against the seat with a lapping tool. ·· Pull the valve out, and check the seating pattern on the
valve head. It must be the correct width [A] and even all the way around.
NOTE The valve stem and guide must be in good condition or this check will not be valid.
If the valve seating pattern is not correct, repair the seat.

Valve Seating Surface Width (STD) [FH451V, FH500V, FH531V, FH541V, FH580V]

Inlet, Exhaust 0.6 0.9 mm (0.024 0.035 in.)

[FH601V, FH641V, FH661V, FH680V, FH721V]

Inlet

0.8 1.4 mm (0.03 0.05 in.)

Exhaust

1.1 1.6 mm (0.04 0.06 in.)

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2-18 PERIODIC MAINTENANCE Periodic Maintenance Procedures

Valve Seat Repair
· Follow the manufacture’s instructions for use of valve seat cutters

Special Tools Inlet Valve:

Valve Seat Cutter

45° – 35

Valve Seat Cutter

32° – 33

Exhaust Valve:

Valve Seat Cutter

45° – 30

Valve Seat Cutter

32° – 30

Valve Seat Cutter Holder

6

Valve Seat Cutter Holder Bar:

57001-1116 57001-1199
57001-1187 57001-1120 57001-1360 57001-1128

If the manufacture’s instructions are not available, use the following procedure. Seat Cutter Operating Cares 1. This valve seat cutter is designed only for valve seat re-
pair. Do not use the valve seat cutter for other purpose. 2. Do not drop or hit the valve seat cutter, or the diamond
particles may fall off. 3. Be sure to apply engine oil to the valve seat cutter before
grinding the seat surface. Also wash off ground particles sticking to the cutter with washing oil.
NOTE Do not use a wire brush to remove the metal particles from the cutter. It will take off the diamond particles.
4. Setting the valve seat cutter holder [A] in position, operate the cutter [B] with one hand [C]. Do not apply too much force to the diamond portion.
NOTE Prior to grinding, apply oil to the cutter, and during the operation wash off any ground particles sticking to the cutter with washing oil.
5. After use, wash the cutter with washing oil and apply thin layer of engine oil before storing.

Marks Stamped on the Cutter The marks stamped on the back of the cutter represent the following.

1

Cutter number, selected from 1 to 12

32°

Cutter angle [A]

37.5 Cutter diameter [B]

KS8B Manufactured lot number

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PERIODIC MAINTENANCE 2-19 Periodic Maintenance Procedures
Operating Procedures Clean the seat area carefully.
·· Recondition the valve seats with the valve seat cutters (45°, 32°) and lap the valves.
· Check the seats for good contact all the way around with machinist’s dye.
· Measure the seat width [A]. If it is greater than the STD width, reface the seating surface.
· If the valve seating pattern is not correct, repair the seat.
Coat the seat with machinist’s dye.
·· Fit a 45° cutter [A] to the holder and slide it into the valve guide.
Resurface the valve seat with a 45° cutter, removing only enough material to produce a smooth and concentric seat. CAUTION Do not grind the seat too much. Overgrinding will reduce valve clearance by sinking the valve into the head. If the valve sinks too far into the head, it will be impossible to adjust the clearance, and the cylinder head must be replaced. Do not turn the cutter counterclockwise or drop it against the seat, or it will be dulled.
· Use a 32° seat cutter [A] to narrow the seat width to the STD width.
Turn the seat cutter one turn at a time while pressing down very lightly. Check the seat width after each turn. CAUTION The 32° cutter removes material very quickly. Check the seat width frequently to prevent over grinding.
NOTE Keep the seat width as close as possible to the STD width.
· Make a light contact on the valve seat with the 45° cutter to remove any possible burrs at the edge of the seat. After resurfacing the seat, inspect for even valve seating.
·Apply a machinist’s dye to the valve face, insert the valve, and snap it closed against the seat several times. The valve surface should show good contact all the way around. Be sure the valve seat is centered on the valve face. The position of the valve in the seat is evident after lapping the valve. If the seat does not make proper contact, lap the valve into seat with a vacuum cap tool.
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2-20 PERIODIC MAINTENANCE Periodic Maintenance Procedures
· Coat the valve face sparingly with a fine lapping compound.
· Use the vacuum cap tool [A], to grip the top of the valve [B]. Rotate the valve in a circular motion to lap the valve to the seat.
· Lift the valve slightly from the seat every 8 to 10 strokes, continue lapping operation until a uniform ring appears around entire surface of the valve face.
· When lapping is completed, wash all parts in solvent to remove lapping compound. Dry the parts thoroughly.
· Note the position of the lapping mark on the valve face. The lapping mark should appear on or near the center of the valve face.
· When the engine is assembled, be sure to adjust the valve clearances (see Valve Clearance Adjustment).
Lubrication System
Oil Level Inspection Place the engine on a level surface.
·· Remove the oil filler cap [A] and wipe its dipstick [B] with a clean cloth.
· Insert the dipstick into tube [C] without screwing it in, then check the oil level.
· The oil level should be the operating range [A] (grid area) on the dipstick [D]. If the oil level is “ADD” range [B], add enough engine oil to bring oil level to the operating range [A]. CAUTION Do not add more oil above the operating range. Excess oil will cause a smoking condition.
Use the same type and make of oil that is already in the engine. NOTE If the engine oil type and make are unknown, use any brand of the specified oil to top up the level in preference to running the engine with the oil level low. Then at your earliest convenience, change the oil completely. If the oil level is “FULL” range [C], drain the excess oil by loosening the drain plug. Oil Level Gauge: Before 2002/2 produce model [E] Oil Level Gauge: On and after 2002/2 produce model [F] www.mymowerparts.com

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PERIODIC MAINTENANCE 2-21 Periodic Maintenance Procedures

Oil Change
· Change the oil after first 8 hours of operation. Thereafter change oil every 100 hours of operation.
Start and warm up the engine to drain the oil easily.
· Stop the engine. · Place the engine on a level surface. · Place a suitable container under the engine. ·· Remove the oil drain plug [A] and drain the oil.
WARNING

Be careful of hot oil when draining. It may be hot enough to burn you severely.
· Check the O-ring [B] at the oil drain plug for damage. Replace the O-ring with a new one if it is damaged. If the oil drain plug joint is removed, tighten it.
Torque – Oil Drain Plug Joint (Plastic) :17 N·m (1.7 kgf·m, 12.0 ft·lb)
Oil Drain Plug Joint (Metal) :39 N·m (4.0 kgf·m, 29 ft·lb)
· Install the oil drain plug with the O-ring and tighten it.
Torque – Oil Drain Plug (Plastic) : 6.9 N·m (0.70 kgf·m, 61 in·lb)
Oil Drain Plug (Metal) : 20 N·m (2.0 kgf·m, 14.5 ft·lb)

• Remove the oil filler cap and pour in the specified type and the amount of oil.

Engine Oil : Grade: Viscosity:
Capacity:

SF, SG, SH, SJ or SL Class SAE40, SAE30, SAE10W-30/SAE10W-40, or SAE5W-20 [When the oil filter is not removed] 1.5 L (1.6 US qt) [When the oil filter is removed] 1.7 L (1.8 US qt) ··· except FH721V 1.8 L (1.9 US qt) ··· FH721V

• Check the O-ring [A] on the oil filler cap for damage. Replace the O-ring with a new one if it is damaged. When checking the oil level, do not turn oil filler cap on threads.
  NOTE Some increase in oil consumption may be expected when a multi grade engine oil (10W-30/10W-40, 5W-20) is used. Check the oil level more frequently than recommended interval.

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2-22 PERIODIC MAINTENANCE Periodic Maintenance Procedures
Oil Filter Replacement Drain the engine oil (see Oil Change).
·· Remove the oil filter [A] with the oil filter wrench [B] or strap wrench. Special Tool – Oil Filter Wrench: 57001-1249
When unscrewing the oil filter, place a suitable container beneath the oil drip tray to receive oil from the oil filter and oil passages in the engine.
Replace the oil filter [A] with a new one.
· Apply light film of engine oil to the seal [B]. · Install the oil filter. ·Turn the filter until the seal contacts mounting surface [C] of the engine. Then turn the filter BY HAND (S) 3/4 turn more. Run the engine at slow idle speed for 2 minutes.
·While running the engine, check for oil leaks around it. · Stop the engine and check the oil level (see Oil Level
Inspection). Oil Cooler Cleaning
· Clean dirt off the outside fins with brush or with compressed air.
Electrical System
Spark Plug Cleaning and Inspection
· Carefully pull the plug cap from the spark plug, and remove the spark plug. If the plug is oily or has carbon built up on it, clean the plug using a high- flash point solvent and a wire brush or other suitable tools. If the spark plug electrodes are corroded or damaged, or if the insulator is cracked replace the plug with a new one. Use the standard spark plug or its equivalent. Insulator [A] Center Electrode [B] Plug Gap [C] Side Electrode [D] Spark Plug Gap Inspection
· Measure the gap with a wire-type thickness gauge. If the gap is not correct, carefully bend the side electrode with a suitable tool to obtain the correct gap. Spark Plug Gap Standard: 0.75 mm (0.030 in.)
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FUEL SYSTEM 3-1

Fuel System

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3-2 3-14 3-15
3-15 3
3-15 3-15 3-16 3-16 3-17 3-17 3-17 3-17 3-18 3-18 3-20 3-20 3-20 3-20 3-20 3-21 3-21 3-22 3-24 3-25 3-26 3-27 3-29 3-30 3-31 3-32 3-32 3-32 3-33 3-34 3-34 3-34 3-35 3-35 3-35 3-35 3-35 3-35 3-36 3-38 3-38 3-38 3-38 3-39 3-40 3-41

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3-2 FUEL SYSTEM Exploded View
[FH451V, FH500V, FH531V] www.mymowerparts.com

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FUEL SYSTEM 3-3 Exploded View
[FH451V, FH500V, FH531V] 1. Pilot Screw 2. Pilot Air Jet 3. Main Air Jet 4. Main Jet 5. Pilot Jet 6. Solenoid Valve 7. Out Vent Tube (Before 2003/5 Product model)
T1: 0.7 N·m (0.07 kgf·m, 6 in·lb) T2: 1.0 N·m (0.10 kgf·m, 9 in·lb) T3: 1.3 N·m (0.13 kgf·m, 11 in·lb) T4: 1.7 N·m (0.17 kgf·m, 15 in·lb) T5: 2.0 N·m (0.20 kgf·m, 17 in·lb) T6: 3.4 N·m (0.35 kgf·m, 30 in·lb) T7: 5.9 N·m (0.60 kgf·m, 52 in·lb) T8: 6.9 N·m (0.70 kgf·m, 61 in·lb) T9: 8.8 N·m (0.90 kgf·m, 78 in·lb)
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3-4 FUEL SYSTEM Exploded View
[FH541V, FH580V] www.mymowerparts.com

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FUEL SYSTEM 3-5 Exploded View
[FH541V, FH580V] 1. Pilot Screw 2. Main Jet 3. Solenoid Valve
T1: 0.7 N·m (0.07 kgf·m, 6 in·lb) T2: 2.3 N·m (0.23 kgf·m, 20 in·lb) T3: 4.5 N·m (0.46 kgf·m, 40 in·lb) T4: 3.4 N·m (0.35 kgf·m, 30 in·lb) T5: 5.9 N·m (0.60 kgf·m, 52 in·lb)
L: Apply non-permanent locking agent.
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3-6 FUEL SYSTEM Exploded View
[Heavy Duty Air Cleaner Type] www.mymowerparts.com

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FUEL SYSTEM 3-7 Exploded View
[Heavy Duty Air Cleaner Type] 1. Pilot Screw 2. Main Jet 3. Solenoid Valve
T1: 0.7 N·m (0.07 kgf·m, 6 in·lb) T2: 2.3 N·m (0.23 kgf·m, 20 in·lb) T3: 4.5 N·m (0.46 kgf·m, 40 in·lb) T4: 5.9 N·m (0.60 kgf·m, 52 in·lb) T5: 9.8 N·m (1.0 kgf·m, 87 in·lb)
L: Apply non-permanent locking agent.
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3-8 FUEL SYSTEM Exploded View
[FH601V, FH641V, FH661V, FH680V, FH721V] www.mymowerparts.com

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FUEL SYSTEM 3-9 Exploded View
[FH601V, FH641V, FH661V, FH680V, FH721V] 1. Pilot Screw 2. Pilot Air Jet 3. Main Air Jet 4. Main Jet 5. Pilot Jet 6. Solenoid Valve 7. Out Vent Tube (Before 2003/5 Product model)
T1: 1.0 N·m (0.10 kgf·m, 9 in·lb) T2: 3.9 N·m (0.40 kgf·m, 35 in·lb) T3: 2.0 N·m (0.20 kgf·m, 18 in·lb) T4: 19 N·m (1.9 kgf·m, 14 ft·lb) T5: 20 N·m (2.0 kgf·m, 15 ft·lb) T6: 5.9 N·m (0.60 kgf·m, 52 in·lb)
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3-10 FUEL SYSTEM Exploded View
[Heavy Duty Air Cleaner Type] www.mymowerparts.com

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FUEL SYSTEM 3-11 Exploded View
[Heavy Duty Air Cleaner Type] 1. Main Jet 2. Pilot Screw 3. Solenoid Valve R: Replacement Parts
T1: 1.0 N·m (0.10 kgf·m, 9 in·lb) T2: 3.9 N·m (0.40 kgf·m, 35 in·lb) T3: 2.0 N·m (0.20 kgf·m, 18 in·lb) T4: 2.5 N·m (0.25 kgf·m, 22 in·lb) T5: 6.9 N·m (0.70 kgf·m, 61 in·lb) T6: 9.8 N·m (1.0 kgf·m, 87 in·lb) T7: 5.9 N·m (0.60 kgf·m, 52 in·lb)
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3-12 FUEL SYSTEM Exploded View
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FUEL SYSTEM 3-13 Exploded View
[FH451V, FH500V, FH531V] T1: 5.9 N·m (0.60 kgf·m , 52 in·lb) T2: 2.0 N·m (0.20 kgf·m , 17 in·lb) T3: 7.8 N·m (0.80 kgf·m , 69 in·lb)
[FH541V, FH580V] T1: 5.9 N·m (0.60 kgf·m , 52 in·lb) T2: 2.0 N·m (0.20 kgf·m , 17 in·lb) T3: 7.8 N·m (0.80 kgf·m , 69 in·lb)
[FH601V, FH641V, FH661V, FH680V, FH721V] T1: 5.9 N·m (0.60 kgf·m , 52 in·lb) T2: 2.0 N·m (0.20 kgf·m , 17 in·lb) T3: 7.8 N·m (0.80 kgf·m , 69 in·lb) A: Separate Choke Type B: Associate Choke Type O: Apply engine oil. 1. Fuel Tube for FH680V Late Model 2. Fuel Tube for FH680V Early Model
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3-14 FUEL SYSTEM Specifications

Standard

Item

FH451V, FH500V

FH531V

FH541V

FH601V, FH641V, FH580V FH661V, FH680V,
FH721V

Carburetor Specifications:

Make/Type

MIKUNI B24T1

Walbro LMF

Nikki 621266

Throttle Bore Diameter 24 mm (0.94 in.)

26 mm (1.02 in.)

Venturi Diameter

16 mm (0.63 in.) 18 mm 16 mm (0.71 in.) (0.63 in.)

18 mm 21 mm (0.83 in.) (0.71 in.) *18 mm (0.71 in.)

Main Jet (MJ)

125

116.3 #100

105

L: #122, R: #128 *L: #104, R: #108

Pilot jet (PJ)

48.8

43.8 #48

50

L: #46, R: #44

*#52

Main air jet (MAJ)

1.7

1.4

150

110

1.7, * 1.6

Pilot air jet (PAJ)

1.2

0.8

170

140

1.1, * 1.4

Pilot Air Screw Turns out 2 1/4 (PS) (Idle Mixture Screw Turns Out)

1 3/8 2 1/2

1 7/8

L: 2 1/4, R: 1 1/4 *L: 3, R: 2 1/4

Float Level

Float parallel to carburetor body

Idle Speed: (1)

Low Idle Speed

1 550 r/min (rpm)

High Idle Speed

3 600 r/min (rpm)

Air Cleaner:

Standard Model:

Type

Dual stage filtration system

Pre-cleaner

Foam element

Second-stage cleaner Paper element

Heavy Duty Model:

Type

­

­

Heavy duty type

Cleaner

­

­

Paper element

­

Pre-cleaner

­

­

­

­

Primary element

Second-stage cleaner

­

­

­

­

Secondary

element

Fuel:

Fuel Requirement

Unleaded regular grade gasoline

Fuel Pump:

Type

Pulse-diaphragm pump

Governor:

Type

Flyweight all speed governor

(1) Idle speeds may vary depending on each equipment. Refer to the equipment specification. *: For FH680V and FH721V Late Models

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FUEL SYSTEM 3-15 Governor Link Mechanism
Control Panel Assembly Removal
· Remove: Air Cleaner (see Air Cleaner Body Removal) Air Cleaner Mount Bracket Bolts [A] Air Cleaner Mount Bracket [B] Ground Lead (Electric Starter Model) Control Panel Mounting Bolts [C] · Remove the control panel assembly [A] while unhooking the governor spring [B] end loop at the panel bracket.
· Clear the choke link rod lower end [C] from the choke lever.
Control Panel Assembly Installation
· Before installing the control panel assembly, check to see that the choke lever [A] and engine speed control lever [B] move smoothly in all directions. If any part is worn or damaged, replace the control panel assembly with a new one.
· After installation, adjust the low idle speed and high idle speed to the specifications (see Low Idle Speed and High Idle Speed adjustment in the Periodic Maintenance chapter).
· For separate choke type; the control panel assembly is as shown in the figure.
Governor Arm Removal
· Remove: Control Panel Assembly
· Loosen the clamp nut [A] and take off the governor arm [B].
· Unhook the throttle link rod spring [C] end loop and clear the throttle link rod lower end [D].
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3-16 FUEL SYSTEM Governor Link Mechanism
· For FH541V, FH580V model; the governor arm is as shown in the figure.
Governor Arm Installation
· Install the governor arm [A] onto the governor shaft [B] temporarily.
· Be sure the link spring [C] around the throttle link rod [D] is in place and that it pulls the governor arm and throttle lever [E] each other.
· Loosen the clamp nut [F] on the governor arm enough to move the governor shaft.
· Turn the top end of the governor arm counterclockwise to fully open the carburetor [G] throttle valve and hold it there.
· Turn the governor shaft counterclockwise fully to the end of its travel.
· Tighten the clamp nut.
Torque – Governor Arm Clamp Nut: 7.8 N·m (0.80 kgf·m, 69 in·lb)
· Be sure the governor shaft extension from the governor arm is approximately 7 mm (0.3 in) [H] as shown in the figure.
· Install the control panel assembly, and connect the governor arm with the governor spring. Governor Assembly Removal
· Remove the crankcase cover (see Camshaft/Crankshaft chapter). Remove the push rod (see Engine Top End chapter).
·· Remove the camshaft [A].
· Remove: Washer [A] Snap Ring [B] Sleeve [C] Governor Plate [D] Snap Ring [B] Steel Balls [E] Ball Guide [F] Ball Plate [G] www.mymowerparts.com

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FUEL SYSTEM 3-17 Governor Link Mechanism
Governor Assembly Installation Fit the snap ring [A] into the groove securely.
·· Turn the governor plate by hand and check that the steel balls and governor plate move freely.
Governor Assembly Inspection
Visually check all governor parts for wear or damage. If any parts are worm or damaged, replace them with new ones. Governor Shaft Removal
Split the crankcase (see Camshaft/Crankcase chapter).
·· Unscrew the governor shaft plate screws [A], and pull out the governor shaft [B]. NOTE Remove the governor shaft only if the replacement of the governor shaft is necessary.
· Replace the oil seal with a new one only if the lip shows signs of leakage or it has been damaged.
· Assemble the oil seal [A]. Be sure that the seal lip must face the inside of the engine.
· Press in the oil seal 0 1.0 mm (0.04 in.) [B] flush or below the crankcase cover surface [C].
Governor Shaft Installation Apply engine oil to the governor shaft.
· Insert the governor shaft into the crankcase. ·· Install the governor shaft plate [A] to the shaft [B] as
shown in the figure.
Torque – Governor Shaft Plate Screws: 2.0 N·m (0.20 kgf·m, 17 in·lb)
· Check that the governor shaft moves freely in its operating range. NOTE If the oil seal is removed, install the governor shaft first, then install the oil seal.
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3-18 FUEL SYSTEM Carburetor
Fuel and Air Flow The main system of the carburetor consists of the main jet [A], valve seat [B] main nozzle [C], and
the main air passage [D] (main air jet [E]). The main system meters fuel to the engine during moderate to heavy load conditions. Fuel flows through the main jet and into the main nozzle, where it is joined by air from the main air passage (main air jet). The resulting mixture flows out of the main nozzle end into the carburetor bore, where it is atomized by the high speed air flow, and carried into the engine.
Main Fuel Flow
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FUEL SYSTEM 3-19 Carburetor
The pilot system includes the pilot jet [F], pilot screw [G] (Idle mixture screw), pilot air jet [H], pilot outlet [I], and the bypass holes [J]. The pilot system meters the fuel/air mixture while the engine is idling and running under a light load. Under these conditions there is very little air flow through the carburetor bore; so little that it is not enough to draw fuel through the main system of the carburetor and to atomize it. Instead, the fuel is drawn through the pilot system, since the nearly closed throttle valve [K] causes high speed air flow through the pilot outlet and bypass holes (even at low engine speed).
Fuel flow in the pilot system is metered by the pilot jet. Air for better atomization is admitted via the pilot air jet in the mouth of the carburetor. The fuel/air mixture passes into the bore of the carburetor side stream of the throttle valve through the bypass holes and pilot outlet. While the throttle valve is almost closed, it covers the small bypass holes opening into the bore from the pilot system. As the throttle valve begins to open, it uncovers the bypass holes, allowing more fuel/air mixture to flow. The extra flow is needed because the engine starts to run faster as the throttle is opened. The pilot screw controls the amount of fuel/air mixture allowed through the pilot outlet, but does not meter the bypass holes. A moderate amount of air comes in around the throttle valve at an idle, so adjusting the pilot screw changes the fuel/air ratio. Turning the pilot screw (idle mixture screw) out (counterclockwise) enriches the mixture; turning it in (clockwise) leans the mixture.
Pilot Fuel Flow
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3-20 FUEL SYSTEM
Carburetor
Fuel Shut Off Solenoid Valve (Electric Starter Model)
To avoid after firing when stopping the engine, a solenoid actuated fuel shut off solenoid valve [A] is installed in the carburetor bowl. The valve shuts off the fuel supply to the valve seat [B] simultaneously when the switch key turned to the “OFF” position.
The valve opens automatically when the switch key is turned to the “Run” position.

Low Idle Speed Adjustment
· Refer to the Low Idle Speed Adjustment in the Periodic Maintenance chapter.
High Idle Speed Adjustment
· Refer to the High Idle Speed Adjustment in the Periodic Maintenance chapter.
High Altitude Operation At high altitude, the standard carburetor air-fuel mixture
will be excessively rich. Performance will decrease, and fuel consumption will increase. High altitude performance can be improved by installing a smaller diameter main-jet in the carburetor and adjusting the idle speed.
NOTE The main jet high altitude kits are available for the equipment used in the high altitude. The main jet numbers are stamped on the ends of the main jets.

High Altitude Main Jet

Main Jet No.

Altitude

FH451V FH500V

FH531V

FH541V

FH580V

FH601V FH641V FH680V FH661V FH721V

FH680V and FH721V Late
Models

0 1 000 m (0 3 000 ft)

125 #116.3 #100 #105 L: #122 R: #128 L: #104 R: #108

1 000 2 000 m (3 000 6 000 ft) #122.5 #113.8 #98 #100 L: #119 R: #125 L: #101 R: #105

2 000 m (6 000 ft) and higher

120 #111.3 #96

98 L:# 116 R: #122 L: #98 R: #102

Main Jet Replacement Place the engine (equipment) on a level surface.
· Close the fuel shut off valve in the equipment. ·· Drain the fuel in the carburetor completely by unscrewing
the drain screw at the bottom of the float chamber. Remove the carburetor (see Carburetor Removal).
·· Unscrew the float chamber bolt [A] and take off the float bowl [B].
· For Electric Starter model, unscrew the solenoid valve and take off the valve and gasket.

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Carburetor

FUEL SYSTEM 3-21

• Using a proper standard tip screwdriver, carefully replace the main jet (A) with a new one for expected altitude.
  · Tighten the main jet to the specified torque (see Carburetor Disassembly Assembly Notes). Install the float chamber, gasket and float bowl bolt.
  ·· For Electric Stater model, install the float chamber, gasket and solenoid valve.

• For FH601V, FH641V, FH661V, FH680V, FH721V model; note the following.
  Remove the carburetor (see Carburetor Removal). Unscrew the main jet plugs [C] and take off the main jet
  plugs and gaskets.
  Make sure that “L” [L] or “R” [R] mark on the float shows the main jet position.
  Using a proper standard tip screwdriver, carefully replace the main jet [D] with a new one for expected altitude.
  Tighten the main jet to the specified torque (see Carburetor Disassembly/Assembly).
  Install the gasket and the main jet plug.
  Torque – Main Jet Plug: 19 N·m (1.9 kgf·m, 14 ft·lb)

Fuel System Cleanliness Inspection
· Refer to the Fuel System Cleanliness Inspection in the Periodic Maintenance chapter.
Carburetor Removal
WARNING
Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
· Remove: Air Cleaner and Related Parts (see Air Cleaner Body) Turn the fuel shut off valve to the OFF position.
· Drain the carburetor. ·· Disconnect the fuel tube at the fuel inlet joint [A] of the
carburetor.
· For Electric Starter model, disconnect the solenoid valve lead terminal and remove the ground terminal.
· Unhook the throttle link spring [B] at the throttle shaft lever top end [C] with a long nose plier.
· Unhook the throttle [D] and choke link rods [E] at the top ends of their arms while pulling off the carburetor.
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3-22 FUEL SYSTEM Carburetor
· For FH541V, FH580V model; see the figure.
· For FH601V, FH641V, FH661V, FH680V, FH721V model; note the following.
Unhook the throttle link spring [B] at the link clip [F] with a long nose plier.
Unhook the link clip [F] and remove the throttle link rod [D] and choke link rods [E] at the ends of their arms while pulling off the carburetor.
Carburetor Installation
· Clean the mating surfaces of the carburetor and inlet manifold, and fit the new gaskets.
· Install the inlet manifold, the new gaskets, the insulator, the carburetor, the new gasket and the inlet pipe in the sequence as shown.
· For FH451V, FH500V, FH531 model; Inlet Manifold [A] Gaskets [B] Insulator [C] Carburetor [D] Gasket [E] Stud Bolt [F] · For FH541V, FH580V model; Inlet Manifold [A] Gaskets [B] Insulator [C] Carburetor [D] Gasket [E] Stud Bolt [F] www.mymowerparts.com

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FUEL SYSTEM 3-23 Carburetor
· For FH601V, FH641V, FH661V, FH680V, FH721V model; Inlet Manifold [A] Gaskets [B] Insulator [C] Carburetor [D] Gasket [E] Install the air cleaner (see Air Cleaner Body Installation).
·· Take care not to bend the throttle link rod and choke link rods during installation. Make sure that the link spring around the throttle link rod is in place and that it pulls the governor arm and carburetor throttle shaft lever toward each other.
· Be sure that the fuel tube clip ends [A] face horizontal direction. WARNING Improper installation of the fuel inlet hose clamp can result in gasoline leakage and potential fire hazard. Be sure the clip ends of the hose clamp face in a horizontal direction. In a vertical position (see illustration), the clip ends [A] can come into contact with the inlet pipe and become loose.
· Adjust: Carburetor Pilot Screw Idle Speed
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3-24 FUEL SYSTEM Carburetor

Carburetor Disassembly/Assembly-FH451V, FH500V, FH531V
Refer to the illustration for disassembly and assembly.
·· There are several passage plugs (Ball plugs) in the carburetor body. Do not remove them.
· Before disassembly, mark the out side of choke valve and throttle valves for assembling them.
· Replace the pilot screw with a new one if necessary in accordance with the following procedure.
Carefully mark the position of the pilot screw limiter on the carburetor body so that it can be installed and set to its original position later.
Remove the limiter. Be careful not to turn the pilot screw at this point.
Turn the pilot screw clockwise and count the number of turns until screw is gently seated in the pilot passage. Record the number of turns needed to close the screw.
Turn out the pilot screw to replace it with a new one. Install the new pilot screw until the screw is gently
seated. Then open the screw the same number of turns as recorded prior to removal.
Align the limiter with the mark on the carburetor body to install, taking care not to turn the pilot screw.
· Install the choke valve and throttle valve on the shaft as the outside mark of them facing outside.
· Drive the float pin into the carburetor body. The big diameter side of the float pin must face the engine flange side.
· The fuel inlet valve seat is pressed into the carburetor body and is not replaceable.
· Assemble carburetor parts with recommended tightening torque (see Exploded View).

1. Limiter 2. Pilot Screw 3. Spring 4. Low Idle Speed
   Screw 5. Spring 6. Seal 7. Ring 8. Throttle Shaft 9. Throttle Valve 10. Screws

2. Pilot Jet 12. Screw 13. Choke Valve 14. Choke Shaft 15. Spring 16. Collar

3. Main jet 18. Float 19. Main Nozzle 20. Valve Seat

4. Float Bowl 22. Gasket 23. Bolt (Other than Solenoid
   Valve Type) 24. Gasket 25. Solenoid Valve (Electric
   Starter Model) 26. Drain Screw 27. Gasket 28. Float Pin 29. Snap Ring 30. Float Valve 31. Main Air Jet 32. Air Jet 33. Washer 34. E Type Circlip 35. Cap

5. Ground Lead (Electric
   Starter Model)

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FUEL SYSTEM 3-25
Carburetor
Carburetor Disassembly/Assembly-FH541V, FH580V
Refer to the illustration for disassembly and assembly.
·· There are several passage plugs (Ball plugs) in the carburetor body. Do not remove them.
· Before disassembly, mark the out side of choke valve and throttle valves for assembling them.
· Replace the pilot screw with a new one if necessary in accordance with the following procedure.
Carefully mark the position of the pilot screw limiter on the carburetor body so that it can be installed and set to its original position later.
Remove the limiter. Be careful not to turn the pilot screw at this point.
Turn the pilot screw clockwise and count the number of turns until screw is gently seated in the pilot passage. Record the number of turns needed to close the screw.
Turn out the pilot screw to replace it with a new one. Install the new pilot screw until the screw is gently
seated. Then open the screw the same number of turns as recorded prior to removal.
Align the limiter with the mark on the carburetor body to install, taking care not to turn the pilot screw.
· Install the choke valve and throttle valve on the shaft as the outside mark of them facing outside.
· Drive the float pin into the carburetor body. The big diameter side of the float pin must face the choke value side.
· Assemble carburetor parts with recommended tightening torque (see Exploded View). 1. Limiter 2. Pilot Screw 3. Spring 4. Spacer 5. Low Idle Speed Screw 6. Spring 7. Screws 8. Throttle Valve 9. Throttle Shaft 10. Dust Seal 11. Choke Valve 12. Choke Shaft 13. Dust Seal 14. Solenoid Valve (Electric Starter Model) 15. Gasket 16. Float Bowl 17. Gasket 18. Float Pin 19. Float 20. Main Jet 21. Main Nozzle 22. Float Valve 23. Gasket 24. Screw (Other than Solenoid Valve Type)
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3-26 FUEL SYSTEM Carburetor
Carburetor Disassembly/Assembly-FH601V, FH641V, FH661V, FH680V, FH721V
Refer to the illustration for disassembly and assembly.
·· There are several passage plugs (Ball plugs) in the carburetor body. Do not remove them.
· Before disassembly, mark the out side of choke valve and throttle valves for assembling them. 1. Plug Pilot Screw 2. Pilot Screw 3. Low Idle Speed Screw 4. Spring 5. Seal 6. Collar 7. Throttle Valve 8. Screws 9. Throttle Shaft 10. Choke Valve 11. Choke Shaft 12. Seal 13. Float Valve 14. Float Pin 15. Float 16. Gasket 17. Float Bowl 18. Screw 19. Clamp 20. Plug Main Jet 21. Gasket 22. Main Jet: L 23. Main Jet: R 24. Slow Jet 25. Drain Screw 26. Spring 27. Gasket 28. Solenoid Valve
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FUEL SYSTEM 3-27 Carburetor
Carburetor Disassembly/Assembly-FH680V and FH721V Late Models
Refer to the illustration for disassembly and assembly.
·· There are several passage plugs (Ball plugs) in the carburetor body. Do not remove them.
· Before disassembly, mark the out side of choke valve and throttle valves for assembling them. 1. Plug Pilot Screw 2. Pilot Screw 3. Gasket 4. Cover Plate 5. Screws 6. Low Idle Speed Screw 7. Spring 8. Seal 9. Collar 10. Throttle Valve 11. Screws 12. Throttle Shaft 13. Choke Valve 14. Choke Shaft 15. Seal 16. Main Jet (L) 17. Main Jet (R) 18. O-rings 19. Gasket 20. O-ring 21. Spacer 22. Pin 23. Float Valve 24. Float 25. O-ring 26. Gasket 27. Screws 28. Gasket 29. Solenoid Valve 30. Drain Screw 31. Spring
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3-28 FUEL SYSTEM Carburetor
· Replace the pilot screw [A] with a new one if necessary in accordance with the following procedure.
Remove the pilot screw plug [B] (material: Stainless steel) as follows: Punch a hole in the plug and pry it out with an awl or other suitable tool.
Turn in the pilot screw and count the number of turns until it seats fully but not tightly, then remove the screw. This is to set the screw to its original position when assembling.
Turn in the new pilot screw [A] fully but not tightly, then back it out the same number of turns counted during disassembly.
Install a new pilot screw plug [B] in the pilot screw hole by pressing with the rod [C], and apply a small amount of a bonding agent [D] around the plug to fix the plug.
· Install the choke valve and throttle valve on the shaft as the outside mark of them facing outside, and apply a small amount of a bonding agent to the valve screw threads. CAUTION Do not apply too much bonding agent to the valve. Screws themselves may be fixed.
· Drive the float pin into the carburetor body. The big side of the float pin must face the throttle shaft lever side.
· The fuel inlet valve seat is pressed into the carburetor body and is not replacable.
· Assemble carburetor parts with specified tightening torque (see Exploded View).
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FUEL SYSTEM 3-29 Carburetor
Carburetor Cleaning
WARNING
Clean the carburetor in a well ventilated area, and take care that there is no sparks or flame anywhere near the working area; this includes any appliance with a pilot light. Because of the danger of highly flammable liquids, do not use gasoline or low-flash point solvents to clean the carburetors.
CAUTION Do not use compressed air on an assembled carburetor, or the floats may be crushed by the pressure. Remove as many rubber or plastic parts as possible from the carburetor before cleaning the carburetor with a cleaning solution. This will prevent from damage or deterioration of the parts. The carburetor body has plastic parts that cannot be removed. Do not use a strong carburetor cleaning solution which could attack these parts; instead, use a mild high-flash point cleaning solution safe for plastic parts. Do not use wire or any other hard instrument to clean carburetor parts, especially jets, as they may be damaged. Disassemble the carburetor.
·· Immerse all the carburetor metal parts in a carburetor cleaning solution and clean them.
· Rinse the parts in water and dry them with compressed air.
· Do not use rags or paper to dry parts. Lint may plug the holes or passages.
· Blow air through the holes and fuel passages with the compressed air. All holes must be open.
· Assemble the carburetor.
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3-30 FUEL SYSTEM Carburetor
Carburetor Inspection
WARNING
Gasoline is extremely flammable and can be explosive under certain. Turn the ignition switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.
· Inspect the carburetor body for damage. Flange sealing surfaces should be smooth and free of burns and nicks. Replace the gasket with a new one if necessary.
· Turn the throttle and choke shafts to check that the throttle and choke butterfly valves move smoothly. If the valves do not move smoothly, replace the carburetor body and/or throttle shaft and choke shaft assembly with new ones.
· Check the gasket on the carburetor body. If the gasket is not in good condition, replace it with a new one.
· Check the other parts of the carburetor for any wear or damage. Replace the part with a new one if necessary.
· Clean and check the float level as follows.
CAUTION Do not push down on the float during float level checking.
· With the float [A] assembly installed onto the carburetor body [B], hold the carburetor upside down at eye level. Gently support the float with a finger and bring it down slowly so that the float arm tab [C] just touches the float valve [D]. The float lower surface [E] should be parallel with the carburetor body mating surfaces [F]. If the float position is not correct, replace the float with a new one.
· Inspect the float valve for excessive wear or damage. The tip should be smooth, without any grooves, scratches, or tears. The rod at the other end of the needle should move smoothly when pushed in and released. If either the needle or the seat is worn or damaged, replace the float assembly and carburetor body as a set with a new one.
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Carburetor

FUEL SYSTEM 3-31

• Inspect the tapered portion [A] of the pilot screw [B] for wear or damage. If the pilot screw is worn or damaged on the taper portion, replace it with a new one.
  · Check the spring condition, replace it with a new one if necessary.

• For FH601V, FH641V, FH661V, FH680V, FH721V model; the pilot screw is as shown in the figure.

Fuel Shut Off Solenoid Valve Test (Electric Starter Model)
Unscrew the fuel shut off valve and remove the valve.
·· Connect a 12 VDC source to the solenoid as shown in the figure. If the actuated solenoid plunger (Needle Valve) does not pop out when the Test Voltage is applied, replace it with a new one.
NOTE If necessary, push the plunger slightly for the plunger to withdraw.

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3-32 FUEL SYSTEM Inlet Manifold
Inlet Manifold Removal
· Remove: Air Cleaner (see Air Cleaner Body Removal) Engine Upper Cover
· Cut off the band [A] and release the harness and/or lead from the inlet manifold.
· Unscrew the manifold mounting bolts [B].
· Then lifting up the inlet manifold middle section [A] then pull out the inlet manifold from the carburetor [B] as shown in the figure.
Inlet Manifold Installation Replace the inlet manifold gaskets with new ones.
·· Clean the mating surfaces of the cylinders and inlet manifolds and fit new gaskets [A]. [B] Distance (FH451V, FH500V, FH531V): 6 mm (0.24 in.) [B] Distance (FH541V, FH580V): 0 mm (0 in.) [B] Distance (FH601V, FH641V, FH661V, FH680V, FH721V): 12 mm (0.47 in.)
· Clean the mating surfaces of the carburetor and inlet manifolds and install the new gaskets [A] and insulator [B] in the sequence as shown in the figure. Install the inlet manifold.
·· Tighten the mounting bolts.
Torque – Inlet Manifold Mounting Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb)
· Install and tighten the band [A] around the manifold [B] and the lead [C] and/or the harness [D].
Position the lead and/or the harness on top of the manifold as shown in the figure. Cut the excessive band off.
·· Install the other removed parts in the reverse order of the disassembly.
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FUEL SYSTEM 3-33 Inlet Manifold
Inlet Manifold Inspection Inspect the inlet manifold for cracks or porous casting.
·· Cracks not visible to the eye may be detected by using a metal crack detection system (Visual color check: commonly found at automotive parts stores). If a crack is present in the inlet manifold, replace it with a new one.
· Inspect the gasket surfaces for burns and nicks.
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3-34 FUEL SYSTEM Fuel Pump, Fuel Filter
The fuel pump cannot be disassembled. If any damage of the pump is noticed replace it with a new one.
Fuel Pump Inspection
· Check the vent hole [A] and the filter [B] for plugging or clogging. If the vent hole and the filter are plugged or clogged, remove the foreign material from them.

Fuel Flow Test:

WARNING

Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.

Disconnect the fuel pump outlet nozzle from the tube.
· Connect a suitable hose [A] to the outlet nozzle. · Run the lower end of the hose into a container. ·· Start the engine. Check the fuel flow.
If fuel flow is none or little, replace the fuel pump with a new one. Check the tubes and the fuel filter for clogging or damage. Replace the clogged or damaged tubes of fuel filter with new ones.

Fuel Filter Inspection
· Visually inspect the fuel filter [A]. If the filter is clear with no signs of dirt or other contamination, replacement of the fuel filter is not necessary. If the filter is dark or looks dirty, replace it with a new one. Also check the rest of the fuel system for contamination.

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FUEL SYSTEM 3-35 Air Cleaner (Standard Type)
Element Removal FH451V, FH500V, FH531V, FH541V, FH580V
· Pull the hooks [A] to outside and remove the air cleaner cover [B].
· Remove: Wing Bolt [A] Foam Element [B] Paper Element [C] Element Removal FH601V, FH641V, FH661V, FH680V, FH721V
· Remove Air Cleaner Case Nut Air Cleaner Case Wing Nut [A] Foam Element [B] Paper Element [C] Element Installation Install the element correctly on the air cleaner body.
·· Be sure to install the paper element into the air cleaner body.
· Be sure to install the foam element on the paper element.
Element Cleaning and Inspection
· Refer to the Element Cleaning and Inspection in the Periodic Maintenance chapter. Air Cleaner Body Removal FH451V, FH500V, FH531V, FH541V, FH580V
Remove the elements (see Element Removal).
·· Remove the air cleaner body mounting screws [A], the holder plate nuts [B] and the holder plate [C].
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3-36 FUEL SYSTEM Air Cleaner (Standard Type)
· Pull the breather tube [A] off the pipe at the back of the body, and remove the air cleaner body [B].
FH601V, FH641V, FH661V, FH680V, FH721V Remove the element (see Element Removal).
· Remove the clamp [A], and pull off the breather tube [B]. ·· Loosen the nuts [C] and remove the solenoid valve lead
[D].
· Unscrew the bolts [E] and remove the inlet pipe [F].
Air Cleaner Body Installation FH451V, FH500V, FH531V, FH541V, FH580V
· Connect the breather tube from the crankcase to the pipe at the back of the air cleaner body.
· Tighten the holder plate nuts and the air cleaner body mounting screws. Torque – Holder Plate Nuts: 5.9 N·m (0.60 kgf·m, 52 in·lb) Air Cleaner Body Mounting Screws 3.4 N·m (0.35 kgf·m, 30 in·lb) FH601V, FH641V, FH661V, FH680V, FH721V
Replace the inlet pipe gaskets with new ones.
·· Clean the mating surfaces of the carburetor and the inlet pipe. Install the inlet pipe and solenoid valve lead.
·· Tighten the mounting bolts and nuts.
Torque – Inlet Pipe Mounting Bolts and Nuts: 5.9 N·m (0.60 kgf·m, 52 in·lb)
Install the sleeve on the inlet pipe.
·· Press in the sleeve [A] to the inlet pipe [B] fixing the groove [C] to the projection [D] as shown in the figure.
· Connect the breather tube to the pipe at the inlet pipe and clip it with a clamp.
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FUEL SYSTEM 3-37 Air Cleaner (Standard Type)
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3-38 FUEL SYSTEM Air Cleaner (Heavy Duty Type)
Element Removal
· Unhook the two retaining clamps [A] and remove the cap [B] from the air cleaner body.
· Remove: Primary Element [A] Secondary Element [B] For FH541V, FH580V
· Remove: Element [A] Element Installation
· Slide the secondary element and primary element into place in the air cleaner body.
· Install the cap [A] direction as shown. Mark [B] Upside [C] · Fasten the two retaining clamps [D].
For FH541V, FH580V Slide the element into place in the air cleaner body.
·· Install the cap [A] direction as shown. Mark [B] Upside [C] 15° [D] · Fasten the two retaining clamps [E].
Element Cleaning and Inspection
· Refer to the Element Cleaning and Inspection in the Periodic Maintenance chapter. www.mymowerparts.com

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FUEL SYSTEM 3-39 Air Cleaner (Heavy Duty Type)
Air Cleaner Body Removal
· Remove the air cleaner elements (see Element Removal). Loosen the clamps [A], and remove the inlet hose [B].
· Remove the bolt [C]. ·· Take out the air cleaner body [D] from the arrow side [E] in the figure. Air Cleaner Body Bracket Bolts [F] Air Cleaner Body Bracket [G] For FH541V,FH580V Clamps [A] Inlet Hose [B] Bolt [C] Air Cleaner Body [D] Arrow Side [E] Air Cleaner Body Bracket Bolts [F] Air Cleaner Body Bracket [G] www.mymowerparts.com

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3-40 FUEL SYSTEM Air Cleaner (Heavy Duty Type)
Air Cleaner Body Installation
· Install the air cleaner body bracket with the bolts to the specified torque. Torque – Air Cleaner Body Bracket Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb)
· Set the air cleaner body [A] onto the bracket so that the air inlet duct [B] is facing upward.
· Install the inlet hose [C], and position the clamps [D] pinch heads as shown.
· Install the air cleaner body clamp bolt [A] as shown and tighten it. Collar [B] Spring [C] Nut [D] Install the air cleaner elements (see Element Installation).
·· Install the cap as shown.
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FUEL SYSTEM 3-41 Air Cleaner (Heavy Duty Type)
Air Cleaner Body Clamp Bolt [A] Collar [B] Spring [C] Nut [D] 15° [E] Housing (Cap and Body) Inspection
· Refer to the Housing (Cap and Body) Inspection in the Periodic Maintenance chapter.
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COOLING SYSTEM 4-1

Cooling System
Table of Contents
Exploded View………………………………………………………………………………………………………… Cooling Fan …………………………………………………………………………………………………………….
Cooling Fan Removal …………………………………………………………………………………………. Cooling Fan Installation ………………………………………………………………………………………. Cooling Fan Inspection ……………………………………………………………………………………….. Screen Clearance Adjustment ………………………………………………………………………………

4-2 4-4 4-4 4-4 4-4
4-4 4

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4-2 COOLING SYSTEM Exploded View
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COOLING SYSTEM 4-3 Exploded View
[FH451V, FH500V, FH531V] T1: 3.9 N·m (0.40 kgf·m, 35 in·lb) T2: 5.9 N·m (0.60 kgf·m, 52 in·lb) T3: 17 N·m (1.7 kgf·m, 12.0 ft·lb) T4: 56 N·m (5.7 kgf·m, 41 ft·lb) T5: 7.8 N·m (0.80 kgf·m, 69 in·lb)
[FH541V, FH580V] T1: 3.9 N·m (0.40 kgf·m, 35 in·lb) T2: 5.9 N·m (0.60 kgf·m, 52 in·lb) T3: 17 N·m (1.7 kgf·m, 12.0 ft·lb) T4: 56 N·m (5.7 kgf·m, 41 ft·lb) T5: 7.8 N·m (0.80 kgf·m, 69 in·lb)
[FH601V, FH641V, FH661V, FH680V, FH721V] T1: 3.9 N·m (0.40 kgf·m, 35 in·lb) T2: 5.9 N·m (0.60 kgf·m, 52 in·lb) T3: 17 N·m (1.7 kgf·m, 12.0 ft·lb) T4: 56 N·m (5.7 kgf·m, 41 ft·lb) T5: 7.8 N·m (0.80 kgf·m, 69 in·lb) 1. Stud (Before 2002/4 Product Model) 2. Stud (On and after 2002/5 Product Model) 3. Cooling Fan (Late Model) 4. Cooling Fan (Early Model) A: Recoil Starter Model B: Electric Starter Model
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4-4 COOLING SYSTEM Cooling Fan
Cooling Fan Removal
· Refer to the Flywheel Removal in Electrical System chapter. Cooling Fan Installation
· Refer to the Flywheel Installation in Electrical System chapter. Cooling Fan Inspection
· Visually inspect the blades [A] in the cooling fan [B]. If they have any crack, warp or damage, replace the cooling fan with a new one. If any mud or dust have stuck to the cooling fan, clean it.
· Wash the cooling fan in detergent and water.
CAUTION Do not clean the cooling fan in oil solvent. It may be damage by oil solvent. Screen Clearance Adjustment
· Check the clearance between the screen [A] and the fan housing [B]. If the clearance is less than 1 mm (0.04 in.), add proper number of the spacer [C] between the screen and the bracket comp [D] to adjust the clearance [G] 1 3 mm (0.04 0.12 in.). Screws [F] Clearance 1 3 mm (0.04 0.12 in.) [G] www.mymowerparts.com

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ENGINE TOP END 5-1

Engine Top End

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5-2 ENGINE TOP END Exploded View
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ENGINE TOP END 5-3 Exploded View
[FH451V, FH500V, FH531V] T1: 5.9 N·m (0.60 kgf·m, 52 in·lb) T2: 6.9 N·m (0.70 kgf·m, 61 in·lb) T3: 25 N·m (2.6 kgf·m, 19.5 ft·lb) T4: 28 N·m (2.8 kgf·m, 20 ft·lb) T5: 22 N·m (2.2 kgf·m, 16 ft·lb)
[FH541V, FH580V] T1: 9.8 N·m (1.0 kgf·m, 87 in·lb) T2: 6.9 N·m (0.70 kgf·m, 61 in·lb) T3: 25 N·m (2.6 kgf·m, 19.5 ft·lb) T4: 28 N·m (2.8 kgf·m, 20 ft·lb) T5: 22 N·m (2.2 kgf·m, 16 ft·lb)
[FH601V, FH641V, FH661V, FH680V, FH721V] T1: 21 N·m (2.1 kgf·m, 15 ft·lb) (For M7 × P1.0 screw thread spec.) T1: 9.8 N·m (1.0 kgf·m, 87 in·lb) (For M6 × P1.0 screw thread spec.) T2: 6.9 N·m (0.70 kgf·m, 61 in·lb) T3: 25 N·m (2.6 kgf·m, 19.5 ft·lb) T4: 28 N·m (2.8 kgf·m, 20 ft·lb) T5: 22 N·m (2.25 kgf·m, 16 ft·lb) G: Apply grease. O: Apply engine oil. S: Follow the specified tightening sequence.
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5-4 ENGINE TOP END Exploded View
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ENGINE TOP END 5-5 Exploded View
[FH451V, FH500V, FH531V] T2: 15 N·m (1.5 kgf·m, 11.0 ft·lb)
[FH541V, FH580V] T2: 15 N·m (1.5 kgf·m, 11.0 ft·lb)
[FH601V, FH641V, FH661V, FH680V, FH721V] T2: 15 N·m (1.5 kgf·m, 11.0 ft·lb) 1. Muffler Comp for Late Models. 2. Muffler Comp for Early Models.
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5-6 ENGINE TOP END Specifications

Item

Service Limit

FH451V, FH500V, FH531V

FH541V, FH580V

Cylinder Head

Cylinder Compression (MIN)

[390 kPa (57 psi)] (MIN)

Cylinder Head Warp

0.05 mm (0.002 in.)

Valves

Valve Head Thickness

Inlet, Exhaust

0.35 mm (0.014 in.)

Valve Stem Runout

Inlet, Exhaust

0.05 mm (0.002 in.)

Valve Stem Diameter

Inlet

5.95 mm (0.0234 in.)

Exhaust

5.93 mm (0.0233 in.)

Valve Clearance

(Standard)

Inlet, Exhaust

0.10 0.15 mm (0.004 0.006 in.)

Valve Seating Surface Angle

(Standard)

Inlet, Exhaust

45°

Valve Seating Surface Width

(Standard)

Inlet, Exhaust

0.6 0.9 mm (0.024 0.035 in.)

Valve Guide Inside Diameter

Inlet, Exhaust

6.08 mm (0.239 in.)

Valve Spring Free Length

Inlet, Exhaust

31.0 mm (1.22 in.)

Rocker Arm Push Rod Runout

Inlet, Exhaust

0.5 mm (0.02 in.)

Cylinder, Piston

Piston Diameter

67.79 mm (2.669 in.)

73.79 mm (2.905 in.)

Piston Ring/Groove Clearance

Top

0.15 mm (0.006 in.)

Second

0.12 mm (0.005 in.)

Piston Ring Thickness

Top, Second

1.40 mm (0.055 in.)

Piston Ring End Gap

Top

0.70 mm (0.028 in.)

Second

0.78 mm (0.031 in.)

Oil

1.05 mm (0.041 in.)

Piston Pin Outside Diameter

15.96 mm (0.628 in.)

Piston Pin Hole Inside Diameter 16.08 mm (0.633 in.)

Connecting Rod Small End Inside Diameter

16.05 mm (0.632 in.)

Cylinder Inside Diameter:

Standard Cylinder

68.10 mm (2.681 in.)

74.10 mm (2.917 in.)

0.50 mm Oversize

68.60 mm (2.701 in.)

74.60 mm (2.937 in.)

Cylinder Inside Diameter Out Round 0.056 mm (0.0022 in.)

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ENGINE TOP END 5-7 Specifications

Item
Cylinder Head Cylinder Compression (MIN) Cylinder Head Warp
Valves Valve Head Thickness Inlet, Exhaust Valve Stem Runout Inlet, Exhaust Valve Stem Diameter Inlet Exhaust Valve Clearance Inlet, Exhaust Valve Seating Surface Angle Inlet, Exhaust Valve Seating Surface Width Inlet Exhaust Valve Guide Inside Diameter Inlet, Exhaust Valve Spring Free Length Inlet, Exhaust Rocker Arm Push Rod Runout Inlet, Exhaust
Cylinder, Piston Piston Diameter Piston Ring/Groove Clearance Top Second Piston Ring Thickness Top, Second Piston Ring End Gap Top Second Oil Piston Pin Outside Diameter Piston Pin Hole Inside Diameter Connecting Rod Small End Inside Diameter Cylinder Inside Diameter: Standard Cylinder 0.50 mm Oversize Cylinder Inside Diameter Out Round

Service Limit FH601V, FH641V, FH661V, FH680V, FH721V
[390 kPa (57 psi)] (MIN) 0.05 mm (0.002 in.)
0.35 mm (0.014 in.)
0.05 mm (0.002 in.)
5.95 mm (0.0234 in.) 5.93 mm (0.0233 in.) (Standard) 0.10 0.15 mm (0.004 0.006 in.) (Standard) 45° (Standard) 0.8 1.4 mm (0.03 0.06 in.) 1.1 1.6 mm (0.04 0.06 in.)
6.08 mm (0.239 in.)
31.0 mm (1.22 in.)
0.5 mm (0.02 in.)
74.99 mm (2.952 in.)
0.18 mm (0.007 in.) 0.16 mm (0.006 in.)
1.40 mm (0.055 in.)
0.65 mm (0.026 in.) 0.78 mm (0.031 in.) 1.05 mm (0.041 in.) 15.96 mm (0.628 in.) 16.08 mm (0.633 in.) 16.05 mm (0.632 in.)
75.28 mm (2.964 in.) 75.78 mm (2.983 in.) 0.056 mm (0.0022 in.)

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5-8 ENGINE TOP END Specifications
Special Tools – Piston Ring Pliers: 57001-115 Compression Gauge, 20 kgf/cm²: 57001-221 Piston Ring Compressor Grip: 57001-1095 Piston Ring Compressor Belt, 67 79: 57001-1097 Compression Gauge Adapter, M14 × 1.25: 57001-1159 Valve Seat Cutter Holder Bar: 57001-1128 Valve Seat Cutter Holder, 6: 57001-1360 Valve Seat Cutter, 45° – 35: 57001-1116 Valve Seat Cutter, 32° – 33: 57001-1199 Valve Seat Cutter, 45° – 30: 57001-1187 Valve Seat Cutter, 32° – 30: 57001-1120
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ENGINE TOP END 5-9
Cylinder Head
Compression Measurement Before measuring compression, check the following.
·Be sure the battery is fully charged.
Thoroughly warm up the engine so that engine oil between the piston and cylinder wall will help sealing the compression as it does during normal running.
Stop the engine.
· Disconnect the spark plug caps of each cylinder and remove the spark plugs.
· Attach the compression gauge assembly firmly into one plug hole.
Special Tools – Compression Gauge, 20 kgf/cm²: 57001-221 [A] Compression Gauge Adapter, M14 × 1.25: 57001-1159
· Ground the spark plugs to the engine.
WARNING
To avoid fire, do not ground the spark plugs in proximity to the plug holes. Keep the plugs as far away as possible from the plug holes.
· Open the throttle fully. Run the engine by pulling the recoil starter grip several times until the compression gauge stops rising. Read the highest compression value. (Recoil starter model)
Cylinder Compression (MIN) 390 kPa (57 psi)
· Open the throttle fully. Run the engine by turning the engine switch key several times until the compression gauge stops rising. Read the highest compression value. (Electric starter model)
Cylinder Compression (MIN) 390 kPa (57 psi)
· Repeat the measurement on the other cylinder. If the compression is higher than the specified value, the piston rings, cylinder and valves are probably in good condition. If the compression is too high, check the following. 1. Carbon build-up on the piston crown and cylinder head
– clean off any carbon on the piston crown and cylinder head. 2. Cylinder head gasket – use only the proper gasket. The use of a gasket of incorrect thickness will change the compression. 3. Valve guides and piston rings – worn valve guides and/or worn piston oil rings may cause rapid carbon accumulation in the combustion chamber. This may be indicated by white exhaust smoke. If the cylinder compression is lower than the (MIN), check the following: 1. Gas leakage around the cylinder head – replace the damaged gasket with a new one and check the cylinder head warp. 2. Condition of the valve seating. 3. Valve clearance. 4. Piston/cylinder wear, piston seizure. 5. Piston ring, piston ring groove.
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5-10 ENGINE TOP END Cylinder Head
Cylinder Head Assembly Removal
· Remove: Air Cleaner and Carburetor (see Fuel System chapter) Muffler (see Muffler Exhaust Pipe Removal) Inlet Manifold (see Fuel System chapter) Spark Plug
· Unscrew the rocker cover mounting bolts [A], and remove the cover [B] and the gasket.
· When removing the #1, #2 cylinder head, set each piston at the top dead center (T.D.C) [A] of the compression stroke.
· Loosen the cylinder head bolts 1/4 turn in the sequence as shown in the figure. CAUTION If the above procedure is not followed, the cylinder head may be warped during removal.
· Repeat the sequence until all bolts are removed and lift off the cylinder head assembly. NOTE Mark the push rods to reinstall in their original position during assembly. Cylinder Head Assembly Installation
· Clean the mating surfaces of the cylinder heads and cylinders.
· Install the push rods in their original positions on each cylinder (see Push Rod Installation). Install the knock pins.
·· Set each piston at the T.D.C [A] of the compression stroke.
· Put new gaskets and the cylinder head assemblies on each cylinder, then let the cylinder heads with push rods aligned under the rocker arms. NOTE As the head gaskets are coated with sealing agents, be careful not to damage the surfaces.
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Cylinder Head

ENGINE TOP END 5-11

• Tighten the cylinder head bolts following the tightening sequence in the figure. Torque – Cylinder Head Bolts: 25 N·m (2.6 kgf·m, 19.0 ft·lb)

CAUTION

A torque wrench must be used to assure proper torque. Improper tightening of the head bolts may result in warping of the cylinder head.

Check and adjust the valve clearance.
·· Install the gaskets and rocker covers.
Torque – Rocker Cover Mounting Bolts:
kgf·m, 52 in·lb)
· Install the other removed parts.

5.9 N·m (0.60

Push Rod Removal Set each piston at the T.D.C of the compression stroke.
·· Remove the rocker covers (see Cylinder Head Assembly Removal). Loosen the valve clearance adjusting nuts [A].
·· Move the rocker arms [B] to clear the push rod upper ends.
· Pull out the push rods.
NOTE Mark the push rods to reinstall in their original position during assembly.

Push Rod Installation Set each piston at the T.D.C of the compression stroke.
·· Install the push rods [A] in their original positions on each cylinder.
To Install the push rod in a correct position on the tappet [B], insert the push rod so that the end of the push rod is sliding down [C] along inside wall [D] of the crankcase and position the push rod end on to the tappet.
· Check that both inlet and exhaust push rods on each cylinder are at lowest position on the cam lobes [E]. If the piston is not at the T.D.C of the compression stroke, turn the flywheel clockwise one turn (360°) and reset each piston at the T.D.C of the compression stroke.
· Be sure the end of the push rods are correctly seated on the tappets. Tighten the valve clearance adjusting nuts.
·· Check and adjust the valve clearance.

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5-12 ENGINE TOP END Cylinder Head
Push Rod Inspection
· Place the push rod on V blocks as far apart as possible, and set a dial gauge on the rod at a halfway point between the blocks. Turn the rod to measure the runout. The difference between the highest and the lowest dial readings is the amount of runout. If the runout exceeds the service limit, replace the rod with a new one. Rocker Arm Push Rod Runout Service Limit: 0.5 mm (0.02 in.)
Valve Mechanism Removal/Installation
· Remove the cylinder head assembly (see Cylinder Head Assembly Removal). NOTE When removing the valve mechanism parts, record their position to reinstall in their original position during assembly.
· Remove: Valve Clearance Adjusting Nuts [A] Rocker Arms [B] · Support the valve head in the combustion chamber with a suitable block.
· To remove the collets [A], push down the valve retainer [B] with thumbs and remove the collets.
· Remove the spring [C] and the valve [D] .
· Remove the stem seals [A].
NOTE Remove the stem seals only if the replacement of the
stem seals is necessary. Valve guide [B] is not replaceable, do not remove it.
Valve Installation.
·Apply engine oil to the valve stems to avoid damaging the stem seals.
Check to see that the valve moves up and down smoothly in the guide .
Check the valve seating surface [A] between the valve [B] and the valve seat [C]. Rocker Arm Installation
·Soak the valve clearance adjusting nuts and the rocker arm in the engine oil.
Install the rocker arm.
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ENGINE TOP END 5-13 Valves
Cylinder Head Cleaning and Inspection
· Refer to the Cylinder Head Cleaning and Inspection in the Periodic Maintenance chapter. Valve Clearance Inspection
· Refer to the Valve Clearance Inspection in the Periodic Maintenance chapter. Valve Clearance Adjustment
· Refer to the Valve Clearance Adjustment in the Periodic Maintenance chapter. Valve Seat Inspection
· Refer to the Valve Seat Inspection in the Periodic Maintenance chapter. Valve Seat Repair
· Refer to the Valve Seat Repair in the Periodic Maintenance chapter. Valve Head Thickness
· Remove the valve (see Valve Mechanism Removal/Installation).
· Measure the valve head thickness. If the valve head thickness (valve margin) [A] is less than the service limit, replace the valve with a new one. Valve Head Thickness Service Limit (Inlet, Exhaust): 0.35 mm (0.014 in)

Valve Stem Runout Support the valve on V blocks at each end of the stem.
· Position a dial gauge perpendicular to the stem. ·· Turn the valve and read the variation on the dial gauge.
If the stem runout is greater than service limit, replace the valve.
Valve Stem Runout Service Limit (Inlet, Exhaust): 0.05 mm (0.002 in.)

Valve Stem Diameter
· Measure the diameter of the valve stem [A] in two directions at proper angles, at four different positions on the stem. If any single measured valve stem diameter is less than the service limit, replace the valve with a new one.

Valve Stem Diameter Service Limit:

Inlet:

5.95 mm (0.234 in.)

Exhaust: 5.93 mm (0.233 in.)

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5-14 ENGINE TOP END Valves
Valve Guide Inside Diameter
· Use a small bore gauge or a micrometer to measure the inside diameter [A] of the valve guide [B] at three positions down the guide length. If the measured valve diameter is greater than the service limit, replace the cylinder head with a new one. Valve Guide Inside Diameter Service Limit: Inlet, Exhaust 6.08 mm (0.239 in.) Valve Spring Inspection
· Inspect the valve spring for pitting, cracks, rusting, and burns. Replace the spring with a new one if necessary.
· Measure the free length [A] of the spring. If the measured free length is less than the service limit, replace the spring with a new one. Valve Spring Free Length Service Limit: 31.0 mm (1.22 in.)
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ENGINE TOP END 5-15 Cylinder, Piston
Piston Removal Split the crankcase (see Camshaft/Crankshaft chapter).
·· Remove the camshaft (see Camshaft/Crankshaft chapter).
· Turn the crankshaft to expose the connecting rod cap bolts [A].
· Remove the bolts and take off the connecting rod caps [B]. NOTE Record the positions of the connecting rod caps for reinstalling the caps.
· Push the connecting rod end into the cylinder, and pull the piston and connecting rod out of the cylinder. CAUTION Note a location of the arrow match mark [A] on the piston head in relation to K Mark [B] on the connecting rod. No.1 cylinder K Mark on the connecting rod is face to face with No.2 cylinder K Mark on the connecting rod. Keep parts together as a set.
· Remove the piston pin snap ring [A] with needle nose pliers [B].
· Remove the piston by pushing the piston pin [A] to the direction from which the snap ring was removed.
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5-16 ENGINE TOP END Cylinder, Piston
· Remove the top and second rings with piston ring pliers.
Special Tool – Piston Ring Pliers: 57001-115
· If the special tool is not available, carefully spread the ring opening with your thumbs, then push up to the opposite side of the ring [A] to remove it.
· Remove the 3-piece oil ring with your thumbs in the same manner.
Piston Installation
· Install the expander [A] in the piston oil ring groove so that the expander ends [B] touch together, never overlap them.
· Install the upper and lower steel rails. There is no UP or Down to the rails. They can be installed either way.
Do not mix up the top and second rings.
·· Install the top and second rings as shown in the figure.
The rings should turn freely in the grooves. Piston Head [A] Top Ring for FH451V, 500V, 531V, 541V, 580V [B] Second Ring for FH451V, 500V, 531V, 541V, 580V [C] Top Ring for , FH601V, 641V, 661V, 680V, 721V [D] Second Ring for FH601V, 641V, 661V, 680V, 721V [E] · Align the piston and rings with the piston ring end gap as shown in the figure. Arrow Match Marks [A] Top Ring End Gap, Upper Steel Rail End Gap [B] 30° 45° [C] Second Ring End Gap, Lower Steel Rail End Gap [D] Apply engine oil to the piston pins.
·· Assemble the pistons onto the connecting rods as follow: No.1 cylinder piston; align the arrow match mark on the piston crown with the K mark on the connecting rod. Both marks must face the PTO side. No.2 cylinder piston; align the arrow match mark on the piston head with K Mark on the connecting rod to face the magnet side. No.1 cylinder Piston [A] No.2 cylinder Piston [B] Arrow Match Marks [C] K Mark [D] Opposite K Mark [E] www.mymowerparts.com

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Cylinder, Piston

ENGINE TOP END 5-17

• When installing a piston pin snap ring, compress it only enough to install it. Do not compress the piston pin snap ring too hard.
  · Fit a new piston pin snap ring into the side of the piston so that the ring opening [A] does not coincide with the notch [B] on the edge of the piston pin hole.
  CAUTION

Do not reuse the snap rings, as removal weakens and deforms them. They could fall out and score the cylinder wall.

• Apply engine oil to the piston skirt and the cylinder bore. Using the piston ring compressor grip [A] and the belt [B], lightly tap the top of the piston with a plastic mallet [C] to insert the piston and connecting rod into the cylinder.
  Special Tools – Piston Ring Compressor Grip: 57001-1095 Piston Ring Compressor Belt, 67 79: 57001-1097

• Insert the piston and the connecting rod so that the arrow match mark [A] on the piston crown faces the flywheel side [B].

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5-18 ENGINE TOP END Cylinder, Piston
CAUTION The connecting rod and the connecting rod big end cap are machined at the factory in the assembled state, so they must be replaced together as a set.
· Apply engine oil to the inner surface [A] of the connecting rod big end [B] and caps [C].
· Install the connecting rod big end caps on their original position on each connecting rod big ends.
· Apply a thin layer of engine oil to the thread [D] and seating surface [E] of the cap bolts.
· Tighten the cap bolts.
Torque – [FH451V, 500V, 531V] Connecting Rod Big End Cap Bolts: 5.9 N·m (0.60 kgf·m, 52 in·lb) [FH541V, 580V] Connecting Rod Big End Cap Bolts: 9.8 N·m (1.0 kgf·m, 87 in·lb) [FH601V, 641V, 661V, 680V, 721V] Connecting Rod Big End Cap Bolts (For M7 × P1.0 screw thread spec.: 21 N·m, 2.1 kgf·m, 15 in·lb) Connecting Rod Big End Cap Bolts (For M6 × P1.0 screw thread spec.: 9.8 N·m, 1.0 kgf·m, 87 in·lb)
· Install: Camshaft (see Camshaft/Crankshaft chapter) Crankcase Cover (see Camshaft/Crankshaft chapter) Piston/Cylinder Seizure
In case of seizure, remove the piston.
·· Visually inspect the cylinder and piston for damage. If there is only light damage, repair the damaged piston surface with #400 emery cloth. Remove the small aluminum deposits from the cylinder with #400 emery cloth or light honing. If the damage is severe, the both cylinders must be bored to fit bigger size piston and install the oversized pistons.
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ENGINE TOP END 5-19 Cylinder, Piston
Piston Cleaning
· Remove the piston and the piston rings (see Piston Removal). CAUTION
Never clean the piston head with the engine assembled. Carbon particles will fall between the piston and cylinder, and damage the crankshaft bearings.
Scrape the carbon off [A] the piston head.
·· Use the scraping tools carefully. Do not gouge the piston head. To avoid gouging, use scrapers that material will not damage the piston head.
· Clean the piston ring grooves [A] with a broken piston ring or other suitable tools. CAUTION
Be careful not to widen the ring grooves. Damaged ring grooves will require piston replacement.

Piston Ring and Ring Groove Wear Clean the piston (see Piston Cleaning).
·· Visually inspec

References

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