Kawasaki FA76-FA130-FA210 4-stroke air-cooled gasoline engine WORKSHOP MANUAL

A. General Specifications

This section details the general specifications for the FA76D, FA130D, and FA210D engines.

FA76D

• Air cooling: Large capacity, curved vane blower casting integrated with flywheel. Air passes through deep fins to maintain optimum operating temperature.
• Ignition: Magneto with waterproof molded ignition coil and dustproof breaker point enclosure. Breaker system standard. Electronic ignition system available as optional.
• Lubrication: Splash type.
• Carburetor: Pulse pump type with idle mixture adjustment. Float type with anti-erosion aluminum alloy, idle mixture adjustment, and fuel shut-off valve.
• Air cleaner: Semi-dry type, washable polyurethane element with nylon brush.
• Fuel tank: Sheet metal for pulse pump carburetor models; Polyethylene for Float carburetor models.
• Governor: Mechanical fly-weight type, running in crankcase oil.
• Governor control: Adjustable speed control. Wire joint and outer wire clamp optional for remote speed control.
• Cylinder and crankcase: One-piece hypereutectic aluminum-silicon alloy die-casting with plateau honing.
• Piston: Hard-chrome plated aluminum alloy.
• Piston rings: Two compression rings (including silicon carbide on iron base) plated top ring. One oil control ring.
• Connecting rod: I-beam cross section, heat-treated aluminum alloy with large bearings.
• Crankshaft: Heat-treated ductile iron integrated with counter-balance weights and camshaft drive gear. Induction hardened crankpin and main journals.
• Main bearings: Durable bush type, lead bronze sintered alloy plain bearings with steel back metal.
• Valves: Forged 21-4N austenitic stainless steel exhaust valve. Forged heat-resisting steel intake valve.
• Valve seats: Exhaust: Sintered alloy insert (Co-W-Ni-Cr-Mo) on an iron base. Intake: Sintered alloy insert (Cu-Mo) on an iron base.
• Valve guides: Exhaust: Sintered alloy insert (Cu-P-Sn) on an iron base. Intake: Directly borne by cylinder/crankcase, die-casted hypereutectic aluminum-silicon alloy, machined.
• Valve tappets: Wear-resisting stamp-forged steel, hardened and ground.
• Breather: Vacuum type, vented through air cleaner to prevent oil spill.
• Muffler: Sheet metal painted with heat-resisting paint for noise suppression. (Optional parts available.)
• Starter: Recoil starter with safety cover as standard. (Optional parts available.)
• Direction of rotation: Counterclockwise, viewed from power take-off side.
• Finish: Anti-rust, painted.

FA130D

• Air cooling: Large capacity, curved vane blower casting integrated with flywheel. Air passes through deep fins to maintain optimum operating temperature.
• Ignition: Magneto with waterproof molded ignition coil and dustproof breaker point enclosure. Breaker system standard. Electronic ignition system available as optional.
• Lubrication: Splash type.
• Carburetor: Pulse pump type with idle mixture adjustment.
• Air cleaner: Semi-dry type, washable polyurethane element with nylon brush.
• Fuel tank: Sheet metal.
• Governor: Mechanical fly-weight type, running in crankcase oil.
• Governor control: Adjustable speed control. Remote speed control joint optional.
• Cylinder and crankcase: One-piece hypereutectic aluminum-silicon alloy die-casting with plateau honing.
• Piston: Hard-chrome plated aluminum alloy.
• Piston rings: Two compression rings (including silicon carbide on iron base) plated top ring. One oil control ring.
• Connecting rod: I-beam cross section, heat-treated aluminum alloy with large bearings.
• Crankshaft: Heat-treated ductile iron integrated with counter-balance weights and camshaft drive gear. Induction hardened crankpin and main journals.
• Main bearings: PTO side, ball bearing. Magneto side, lead bronze sintered alloy plain bearing with steel back metal.
• Valves: Forged 21-4N austenitic stainless steel exhaust valve. Forged heat-resisting steel intake valve.
• Valve seats: Exhaust: Sintered alloy insert (Co-W-Ni-Cr-Mo) on an iron base. Intake: Sintered alloy insert (Cu-Mo) on an iron base.
• Valve guides: Exhaust: Sintered alloy insert (Cu-P-Sn) on an iron base. Intake: Directly borne by cylinder/crankcase. Die-casted hypereutectic aluminum-silicon alloy, machined.
• Valve tappets: Wear-resisting stamp-forged steel, hardened and ground.
• Breather: Vacuum type, vented through air cleaner to prevent oil spill.
• Muffler: Sheet metal painted with heat-resisting paint for noise suppression. (Optional parts available.)
• Starter: Recoil starter with safety cover as standard. (Optional parts available.)
• Direction of rotation: Counterclockwise, viewed from power take-off side.
• Finish: Anti-rust, painted.

FA210D

• Air cooling: Large capacity, curved vane blower casting integrated with flywheel. Air passes through deep fins to maintain optimum operating temperature.
• Ignition: Magneto with waterproof molded ignition coil and dustproof breaker point enclosure. Breaker system standard. Electronic ignition system available as optional.
• Lubrication: Splash type.
• Carburetor: Pulse pump type with idle mixture adjustment.
• Air cleaner: Semi-dry type, washable polyurethane element with nylon brush.
• Fuel tank: Sheet metal.
• Governor: Mechanical fly-weight type, running in crankcase oil.
• Governor control: Adjustable speed control. Remote speed control joint optional.
• Cylinder and crank case: One-piece hypereutectic aluminum-silicon alloy die-casting with plateau honing.
• Piston: Hard-chrome plated aluminum alloy.
• Piston rings: Two compression rings (including silicon carbide on iron base) plated top ring. One oil control ring.
• Connecting rod: I-beam cross section, heat-treated aluminum alloy with large bearings.
• Crankshaft: Heat-treated ductile iron integrated with counter-balance weights and camshaft drive gear. Induction hardened crankpin, main journals and output shaft.
• Main bearings: PTO side, ball bearing. Magneto side, lead bronze sintered alloy plain bearing with steel back metal.
• Valves: Forged 21-4N austenitic stainless steel exhaust valve. Forged heat-resisting steel intake valve.
• Valve seats: Exhaust: Sintered alloy insert (Co-W-Ni-Cr-Mo) on an iron base. Intake: Sintered alloy insert (Cu-Mo) on an iron base.
• Valve guides: Exhaust: Sintered alloy insert (Cu-P-Sn) on an iron base. Intake: Directly borne by cylinder/crankcase. Die-casted hypereutectic aluminum-silicon alloy, machined.
• Valve tappets: Wear-resisting stamp-forged steel, hardened and ground.
• Breather: Vacuum type, vented through air cleaner to prevent oil spill.
• Muffler: Sheet metal painted with heat-resisting paint for noise suppression. (Optional parts available.)
• Starter: Recoil starter with safety cover as standard. (Optional parts available.)
• Direction of rotation: Counterclockwise, viewed from power take-off side.
• Finish: Anti-rust, painted.

B. Performance Curves

This section presents performance curves for the engines, illustrating output versus RPM. The curves are based on SAE test procedures and corrected for standard atmospheric conditions (sea level, 60°F). Production engines may show up to 5% less than maximum B.H.P. after run-in and cleaning.

FA76D Performance Curves

Graphs show Torque, Maximum Output, Recommended Maximum Output (with STD Governor Set-up), and Specific Fuel Consumption Ratio against RPM at Power Take-Off Shaft.

FA130D Performance Curves

Graphs show Torque, Maximum Output, Recommended Maximum Output (with STD Governor Set-up), and Specific Fuel Consumption Ratio against RPM at Power Take-Off Shaft.

FA210D Performance Curves

Graphs show Torque, Maximum Output, Recommended Maximum Output (with STD Governor Set-up), and Specific Fuel Consumption Ratio against RPM at Power Take-Off Shaft.

Engine power decreases by 3.5% for every 1,000 ft above sea level and 1% for every 10°F above 60°F.

C. Dimensional Specifications

This section provides detailed dimensional drawings and measurements for the engine models.

FA76D

Pulse pump model: Includes front, side, and top views with dimensions for length, height, width, and mounting points. Key dimensions include overall length (294 mm), height (289 mm), and width (205 mm).

Float model: Includes front, side, and top views with dimensions. Key dimensions include overall length (381 mm), height (289 mm), and width (205 mm).

FA130D

Pulse pump model: Includes front, side, and top views with dimensions. Key dimensions include overall length (324 mm), height (279 mm), and width (257 mm).

Float model: Includes front, side, and top views with dimensions. Key dimensions include overall length (425 mm), height (333 mm), and width (251 mm).

FA210D

Pulse pump model: Includes front, side, and top views with dimensions. Key dimensions include overall length (354 mm), height (318 mm), and width (257 mm).

Float model: Includes front, side, and top views with dimensions. Key dimensions include overall length (458 mm), height (347 mm), and width (251 mm).

D. Construction

This section illustrates the internal construction and components of the engines.

Main Parts

Diagrams show the overall engine assembly, highlighting the pulse pump carburetor and the camshaft/tappets/valves mechanism.

Carburetor Construction

Pulse Pump Type (FA76, FA130, FA210): Detailed diagrams illustrate the pulse pump model carburetor, showing components like the pilot needle, pilot outlet, bypass, slow jet, slow air-jet, inlet check valve, outlet check valve, pulse port, pump diaphragm, intake pipe, fuel tank, screen, main nozzle, throttle valve, choke valve, main air-jet, main air-bleed, fuel level, and overflow.

Float Type (FA76, FA210): Diagrams show the float type carburetor, including throttle valve, pilot outlet, bypass ports, main air jet, choke valve, pilot air jet, main nozzle, air vent, main air bleed, fuel level, overflow chamber, fuel tank, and float valve.

Float Type (FA130): Similar to the FA76/FA210 float type, with components like fuel cock, float valve, bleed pipe, main jet, float, pilot outlet, throttle valve, bypass, main nozzle, choke valve, and air vent.

E. Disassembly

This section outlines the step-by-step procedure for disassembling the engine components.

1. Draining engine oil: Remove drain plug, drain warm oil. Check for foreign matter in oil and inspect related parts (piston, rings, cylinder, con-rod, bearings, crankshaft).
2. Oil-gauge: Remove oil gauges from both sides.
3. Output-shaft pulley: Remove if present on the output shaft.
4. Air-cleaner: Remove air cleaner. Inspect and replace gasket if damaged.
5. Fuel-tank: Remove fuel tank from carburetor and crankcase. Inspect and replace gasket if damaged. (Tools: Screwdriver, 10mm/13mm spanner). For float models, specific steps for fuel pipe removal and tank bracket removal are detailed.
6. Governor arm: Loosen nut, remove arm from shaft, then remove link, link spring, and governor spring. Remove other ends of link and spring from carburetor and speed control lever.
7. Carburetor: Remove carburetor nuts, two gaskets, and insulator (pulse pump model). Inspect and replace gaskets if damaged.
8. Speed control plate assembly and breather cover: Remove assembly from crankcase. Replace gasket if damaged.
9. Fan housing: Remove fan housing from crankcase and cylinder head. Disconnect stop-switch wire.
10. Flywheel: Loosen nut counter-clockwise. Wedge wood to stop flywheel. Use appropriate spanner (17mm for FA76, 19mm for FA130/FA210). Use pulley puller to remove flywheel. Remove spark plug cap. Remove contact breaker cover, ignition coil, contact breaker, and condenser.
11. Cylinder head and cylinder head cover: Remove spark plug, check gap, clean/replace if necessary. Loosen cylinder head bolts evenly in specified order and remove head and cover. Inspect for gas leakage and gasket damage. Inspect combustion chamber for carbon build-up.
12. Muffler: Loosen nuts and remove muffler. (Tools: 10mm spanner for FA76, 13mm for FA130/FA210).
13. Valves: Use screwdrivers to remove retainers. Remove valves from cylinder. Check valve seating, reface seats if necessary. Inspect valves and stems for damage. Remove carbon build-up.
14. Crankcase cover: Loosen crankcase cover bolts evenly in specified order. Use wooden hammer to gently tap and remove cover. Do not pry. Check oil seal for damage. Inspect governor assembly for wear/malfunction. Remove governor gear assembly if necessary. Check governor tip for wear.

F. Assembly

This section details the procedures for reassembling the engine components.

1. Crankshaft bearing (when bearing is replaced): Insert plain bearing into crankcase, aligning oil groove. Press bearing in 1mm. Insert ball bearing and plain bearing into crankcase cover. Press bearings in 1mm. Fit crankcase and crankcase cover oil seals, ensuring correct orientation.
2. Governor gear assembly: Fit governor weight onto gear with pin. If gear was removed, use a new one. Push pins against projection. Fit governor sleeve by pressing tongued parts into gear groove. Place thrust washer on governor gear shaft and press assembly onto shaft.
3. Governor tip: Place washer on governor tip. Insert tip into crankcase from inside and clip snap-pin firmly.
4. Crankshaft: Coat crankshaft journals, bearings, and oil seal sections with fresh oil. Take care not to damage oil seals. For pump shaft models, no shim adjustment is needed for FA76. Measure axial play and select shim if crankshaft or crankcase replaced. Axial play should not exceed 0.3 mm. Use specified shims (1.0, 1.2, 1.4, or 1.6 mm).
5. Piston and con-rod: Fit piston rings (oil, second, top) in correct grooves. Ensure ring marks face upwards. Fit snap-ring on one side of piston. Position con-rod small-end on piston, aligning 'M' mark on piston and 'Made In Japan' mark on con-rod on the same side. Insert piston pin and fit snap-ring on other end. Coat con-rod small-end and bearing with oil before inserting pin. Insert piston/con-rod assembly into cylinder with 'Made In Japan' mark on con-rod on magneto side. Arrange piston ring openings as shown. Align con-rod cap, lock washer, and splasher with crankpin. Insert and finger-tighten con-rod bolts. Use new lock washer. Ensure splasher is correctly oriented. Tighten con-rod bolts evenly using a torque wrench (FA76: 0.7 kg-m; FA130/FA210: 1.2 kg-m). Bend con-rod lock washer against bolt heads.
6. Tappets and camshaft: Insert tappets into guide holes from inside crankcase, maintaining intake/exhaust side. Coat tappets with oil. Insert camshaft into crankcase, aligning marks on crank gear and cam gear. Coat camshaft journals, cams, and bearings with oil.
7. Crankcase cover: For FA76 float type, fasten cover with fuel pipe clamp. Position gasket on crankcase. Fit cover, ensuring governor gear meshes with cam gear. Tighten bolts evenly. Tightening torque: 0.6 kg-m.
8. Valves (checking tappet clearances): Insert valve springs and retainers. Insert valves into guides after coating stems with oil. Lever spring up and slot retainer into valve stem groove. Check tappet clearances when cold (Intake: 0.10-0.20 mm for FA76, 0.12-0.18 mm for FA130/FA210; Exhaust: 0.10-0.30 mm for FA76, 0.10-0.34 mm for FA130/FA210).
9. Muffler: Fit muffler onto exhaust port with gasket and tighten flange nuts evenly.
10. Breather cover and control panel assembly: Fit breather cover with gasket and control panel assembly. Plug breather tube into cover.
11. Cylinder head: Arrange gasket correctly, position cylinder head, then place cylinder cover on cylinder head. (Tools: 10mm/13mm box wrench, torque wrench). For float models, position fuel tank upper stay, hand-tighten head bolts, then tighten evenly. Final tightening with torque wrench (FA76: 0.7 kg-m; FA130/FA210: 2 kg-m).
12. Flywheel (adjusting ignition timing): Tighten ignition coil slightly. Position contact breaker and fasten plate screw lightly. Fit condenser. Locate flywheel key in crankshaft keyway. Position flywheel on crankshaft and finger-tighten nut. Adjust ignition coil core gap to 0.5 mm using a thickness gauge. Turn flywheel clockwise until rim aligns with coil core edge. Use tester to confirm points are about to open. Repeat steps if timing is off. Remove flywheel, fit points cover. Fit flywheel, starter pulley, and washer. Tighten flywheel nut (FA76: 3-3.5 kg-m; FA130/FA210: 6-6.5 kg-m). Brace flywheel to prevent turning. Screw spark plug into cylinder head and attach plug cap.
13. Carburetor and governor (governor adjustment): Hook governor spring between speed control lever and governor arm. Lightly fix governor arm on governor tip shaft. For pulse pump models, position gasket, insulator, and another gasket on cylinder intake port. For float models, fit gasket, insulator, and another gasket for FA76/FA130, or gasket for FA130, then fit inlet pipe. Use governor link and spring to connect governor arm to carburetor (throttle valve). Do not reverse steps 13-7 and 13-8. For float models, fit gasket on inlet pipe flange, then carburetor. Fit gasket on carburetor and air cleaner case. Tighten flange nuts evenly. Pull up speed control lever to fully open throttle valve. Poke rod into governor tip shaft hole, turn shaft clockwise, and fix governor arm to shaft.
14. Fan housing (with recoil starter): Fix fan housing on cylinder. Ensure high tension cable is not caught and wire outlet has a grommet. Connect stop switch wire. For float models, screw fuel tank lower stay to crankcase, fit fuel tank between stays, tighten bolts, and connect fuel pipe to carburetor.
15. Fuel tank: Position gasket on fuel tank and screw to carburetor. Screw fuel tank stay to crankcase. Evenly tighten fuel tank screws and stay screw.
16. Air cleaner: Fit air cleaner onto carburetor. Replace gasket if damaged. Clean foam elements by washing in kerosene, wringing, and drying. Soak foam element in engine oil, squeeze out excess. Do not soak paper element in oil. Clean paper elements every 100 hours, foam elements every 25 hours, or more often in dusty conditions. Insert breather tube into back of air cleaner.

G. Setting Table

This table summarizes key settings and specifications for the engines.

Abbreviations: B.T.D.C. : Before Top Dead Center, A.B.D.C. : After Bottom Dead Center, B.B.D.C. : Before Bottom Dead Center, A.T.D.C. : After Top Dead Center.

H. Torque Settings

This table lists the specified torque values for various engine components.

I. Standard Tolerances

This section provides standard tolerances for engine parts to ensure proper fit and function.

J. Troubleshooting

This section provides guidance for diagnosing and resolving engine malfunctions.

Low Power Output

• Is the engine overheated?
  • YES: Oil level too low or high (Reduce or top up), Overload (Reduce load), Cooling system clogged (Clean), Carbon deposit in combustion chamber (Clean).
  • NO: Check ignition timing.
• Is ignition timing normal?
  • NO: Wrong timing (Adjust), Faulty condenser (Replace), Faulty ignition coil (Replace), Faulty high tension cord (Replace), Malfunction of contact breaker arm (Disassemble and clean or replace), Demagnetized flywheel (Replace).
  • YES: Check lubricating system.
• Is lubricating system normal?
  • NO: Oil level too low or high (Adjust level or add), Excessively dirty lubricating oil (Change oil).
  • YES: Check if smoke is coming out of the muffler.
• Is smoke coming out of the muffler?
  • YES: Fouled air cleaner element (Clean), Carbon deposit in exhaust and muffler (Clean).

Starting Difficulties

Procedure: Remove spark plug, fit plug cap, turn crankshaft using starter, check for sparks. If no sparks, check plug cap, ignition timing, condenser, ignition coil, high tension cord, contact breaker arm, and flywheel.

• Are sparks produced when the spark plug is replaced with a spare?
  • YES: Faulty spark plug (Replace).
  • NO: Check sparks between high tension cord and engine block.
• Are sparks produced between the high tension cord and the engine block?
  • YES: Faulty contact in plug cap (Correct), Ignition timing normal? (If NO: Faulty ignition timing - Adjust).
  • NO: Check condenser.
• Are sparks produced when the condenser is replaced with a spare?
  • YES: Faulty condenser (Replace), Faulty ignition coil (Replace), Faulty high tension cord (Replace), Malfunction of contact breaker arm (Disassemble and clean or replace), Demagnetized flywheel (Replace).
  • NO: Check compression.
• Is compression sufficient?
  • NO: Check spark plug electrodes for wetness (indicates fuel issue). No fuel in tank (Add), Entry of dust or air into fuel pipe or filter (Clean), Air hole in tank cap plugged (Clean).
  • YES: Excessive choke (Remove plug and pull starter).
• If compression is sufficient, check for: Worn piston/piston rings (Replace), Piston rings stuck (Clean or replace), Worn cylinder bore (Rebore or replace), Loose cylinder head bolts (Tighten), Faulty contact of valve seat (Relap), Wrong valve clearance (Adjust valve clearance), Wrong valve timing (Adjust), Broken valve spring (Replace), Stuck valve (Clean valve and guide).

Engine Malfunctions at High Speed

• Does engine speed vary considerably when load is applied?
  • YES: Plugged air hole in tank cap (Clean), Plugged air vent on carburetor (Clean), Entry of dust and air into fuel filter or fuel pipe (Clean).
  • NO: Check for faulty plug insulation (Replace), dirty electrodes (Clean), contaminated or pitted breaker points (Clean, lap, or replace), wrong ignition timing (Adjust), damaged condenser (Replace).

Engine Malfunctions at Low Speed

• Remove spark plug, fit plug cap, turn crankshaft, check for strong sparks.
  • WEAK sparks: Faulty plug insulation (Replace), Dirty electrodes (Clean), Contaminated or pitted breaker points (Clean, lap, or replace), Wrong ignition timing (Adjust), Damaged condenser (Replace).
  • STRONG sparks: Check if smoke is coming out of the muffler.
• Is smoke coming out of the muffler?
  • YES: Overrich fuel in slow system (Turn off pilot air jet slightly).
  • NO: Gradually open throttle valve by hand. Does speed drop or engine stall?
• If speed drops/stalls: Clogged carburetor (Disassemble and clean).
• If speed does not drop/stall: Is air sucked in through carburetor flange?
• Air sucked in?
  • YES: Loose flange nuts (Retighten), Damaged gasket (Replace).
  • NO: Check valve clearances.
• Are valve clearances correct?
  • NO: Compression loss (Adjust valve clearances), Wrong valve timing (Adjust).
  • YES: Check alignment of timing gear marks.
• Is alignment of timing gear marks correct?
  • NO: Valve timing out (Correct alignment of timing gear marks).

Engine Hunts

• Problem in fuel system (lack of fuel): Entry of dust and air into fuel pipe or filter (Clean), Air hole in tank cap clogged with dust (Clean), Fuel and air passages in carburetor clogged (Disassemble carburetor and clean), Pilot air screw too far in (Adjust).
• Problem in governor system: Wrong governor setting (Adjust), Faulty governor spring (Replace), Worn governor fork and governor weight (Replace).

Excessive Fuel Consumption

• Is compression sufficient?
  • YES: Fuel level in carburetor float chamber too high (Adjust), Ignition timing retarded (Adjust), Idling too fast (Adjust), Incomplete opening of choke valve (Open choke), Pilot air screw too far out (Adjust).
  • NO: Worn piston/piston rings (Replace), Stuck piston (Clean or replace), Worn cylinder bore (Rebore or replace), Loose cylinder head bolts (Tighten), Faulty valve seat contact (Lap), Wrong valve clearance (Adjust valve clearance), Wrong valve timing (Adjust), Broken valve spring (Replace), Stuck valve (Clean valve and guide).

Excessive Oil Consumption

• Is compression sufficient?
  • YES: Plugged oil ring groove (Clean), Oil level too high (Adjust), Faulty valve seat contact (Lap), Worn valve stems and valve guides (Replace), Oil leakage along governor shaft (Replace), Oil leakage from oil seal (Replace), Oil leakage from side base mounting surface (Replace gasket), Oil leakage from drain plug (Retighten or replace gasket).
  • NO: Worn piston rings (Replace), Stuck piston rings (Clean or replace), Worn cylinder bore (Rebore or replace).