THE ANSWER
PG. 7
KAWASAKI ENGINE MAINTENANCE SCHEDULE
INTERVAL
MAINTENANCE
Daily
First 8 hr.
Every 25 Hr.
Every 50 hr.
Every 100 hr.
Every 200 hr.
Every 300 hr.
Check and add engine oil
•
Check for loose or lost nuts and screws
•
Check for fuel and oil leakage
•
Check battery electrolyte level
•
Check or clean air intake screen
•
Clean air cleaner foam element
•
Clean air cleaner paper element
•
Clean dust and dirt from cylinder and
cylinder head fins
•
Tighten nuts and screws
•
Change engine oil
•
•
Clean and gap spark plugs
•
Change oil filter
•
Replace air cleaner paper element
•
Clean combustion chambers
•
Clean and adjust valve clearance
•
*
•
Clean and lap valve seating surface
•
*After the 1st 50 hours
ENGINE TROUBLESHOOTING
COMMON PROBLEMS & PROBABLE CAUSES
SOLUTIONS
Engine cranks but will not start
• Fuel cylinder is empty
Refill cylinder
• Shutoff valve is closed
Open valve
• Clogged, obstructed, kinked or cut fuel or vacuum line
Remove obstruction or replace line
• Spark plug lead disconnected
Connect lead to spark plug
• Faulty choke or throttle settings
Set controls to correct positions
• Faulty ignition coil
Replace coil
• Faulty kill switch
Replace switch
• Faulty regulator
Replace regulator
Engine starts hard
• Faulty choke or throttle settings
Set controls to correct position
• Clogged, obstructed, kinked or cut fuel or vacuum line
Remove obstruction or replace line
• Faulty regulator
Replace regulator
• Low compression
Valves need adjustment
Have engine serviced by a trained technician
Engine will not crank
• Battery is discharged
Charge or replace battery
• Loose or faulty connections or wires
Tighten, repair or replace wires
• Faulty ignition key switch or starter control switch
Repair or replace switch(es)
Engine overheats
• Incorrect fuel settings
Have engine serviced
• Air intake filter screen or cooling fins clogged
Clean and clear debris or replace filter
• Low oil level
Check and add oil
Exhaust emissions or propane odor
• Carburetor or regulator setting incorrect
Have engine serviced by a trained technician
• Dirty or clogged air filter
Replace air filter
• Choke engaged
Adjust to correct settings
• Loose fittings, clamps or hoses cracked, hoses cut or leaking
Tighten or seal; check with soap and water solution,
if bubbles appear, part is still leaking; replace
PG. 10 THE ANSWER
P
A
R
T
S
L
IS
T
F
O
R
B
U
F
F
E
R
H
A
N
D
L
E
A
S
S
E
M
B
LY
P
A
R
T
#
D
E
S
C
R
IP
T
IO
N
P
A
R
T
#
Q
T
Y
1
1
2
V
B
A
T
T
E
R
Y
2
7
6
-G
T
X
1
4
1
2
(+
)
B
A
T
T
E
R
Y
C
A
B
L
E
1
6
.5
"
1
5
3
-6
-1
6
.5
1
3
B
A
T
T
E
R
Y
B
O
X
B
O
T
T
O
M
C
O
V
E
R
2
8
3
-1
1
-2
1
2
7
B
1
4
3
/8
-1
6
X
1
/2
"
H
E
X
B
O
L
T
1
6
4
-1
0
1
0
7
2
5
B
A
T
T
E
R
Y
B
O
X
B
R
A
C
K
E
T
0
1
1
-6
-2
7
2
0
1
6
S
T
A
R
T
E
R
S
O
L
E
N
O
ID
2
9
6
-S
S
5
8
1
1
7
V
E
L
C
R
O
T
A
N
K
S
T
R
A
P
0
1
1
-6
-2
7
0
5
1
8
T
A
N
K
S
T
R
A
P
B
R
A
C
K
E
T
L
O
O
P
0
1
1
-6
-2
7
1
5
2
1
0
1
/4
-2
0
X
1
1
/2
"
H
E
X
B
O
L
T
1
6
4
-1
0
0
1
5
1
1
1
T
H
R
O
T
T
L
E
C
A
B
L
E
1
9
6
-6
0
3
1
4
1
1
2
2
0
L
B
.
L
P
G
C
Y
L
IN
D
E
R
2
9
3
-2
0
#
S
T
L
M
F
1
1
3
H
A
N
D
L
E
G
R
IP
2
2
4
-1
2
1
4
3
/8
-1
6
X
3
"
H
E
X
B
O
L
T
1
6
4
-1
0
1
3
1
1
1
5
L
O
C
K
P
IN
6
2
5
-9
8
4
0
4
A
3
8
5
1
1
6
L
E
F
T
H
A
N
D
L
E
B
R
A
C
K
E
T
2
8
3
-0
2
5
-4
0
0
1
1
7
T
-H
A
N
D
L
E
2
8
3
-0
2
5
-6
0
0
1
1
8
R
IG
H
T
H
A
N
D
L
E
B
R
A
C
K
E
T
2
8
3
-0
2
5
-5
0
0
1
1
9
3
/8
-1
6
X
1
"
H
E
X
B
O
L
T
1
6
4
-1
0
1
1
5
4
2
0
H
A
N
D
L
E
M
A
IN
F
R
A
M
E
0
1
1
-6
-2
7
1
0
1
2
1
3
/8
-1
6
S
T
O
V
E
R
L
O
K
N
U
T
1
6
4
-2
2
8
3
4
7
2
2
B
A
T
T
E
R
Y
B
O
X
T
O
P
C
O
V
E
R
2
8
3
-1
1
-2
1
2
7
T
1
2
3
(-
)
B
A
T
T
E
R
Y
C
A
B
L
E
2
6
"
1
5
3
-6
-2
6
1
2
4
K
E
Y
S
W
IT
C
H
3
1
2
-3
0
8
-0
3
8
5
1
2
5
W
IR
E
H
A
R
N
E
S
S
0
1
1
-7
6
2
-W
H
K
1
2
6
1
/4
-2
0
F
L
A
N
G
E
N
U
T
1
6
4
-1
4
F
N
1
