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Kawasaki FC540V Engine

General Technical Data

Kawasaki FC540V Engine Specifications

Engine Model .......... Kawasaki FC540V
Engine Type .......... Forced Air-cooled, Vertical Shaft, OHV, 4-Stroke Gasoline Engine
Number of Cylinder .......... Single
Piston Displacement, cc (cu.in) .......... 535 (32.6)
Engine Bore, mm (in) .......... 89.0 (3.50)
Engine Stroke, mm (in) .......... 86.0 (3.39)
Engine Power, Hp (kW) .......... 17.0 (12.7)
Maximum Torque, Nm (ft-lb) .......... 36.7 (27.1)
Direction of Rotation .......... Counterclockwise facing the PTO Shaft
Fast Idle Speed, rpm .......... 3275-3425
Low Idle Speed, rpm .......... 1450-1650
Lubricating Method .......... Pressurized
Oil Pan Capacity, L (qt) .......... 1.6 (1.7)
Choke Control .......... Automatic (with Throttle Control)
Air Cleaner .......... Semi-cyclone Type with Dual Element
Cooling Air Inlet .......... Rotating Screen with Periphery Blade Protector

Fuel System

Fuel System Type .......... Carburetor
Carburetor Type .......... Float Fixed Main Jet
Fuel Pump .......... Diaphragm Type Pulse Pump
Governor .......... Mechanical Flyweight
Fuel Capacity, L (qt) .......... 8.0 (8.2)

Ignition System

Ignition System Type .......... Transistorized Flywheel Magneto
Charging Coil .......... 12V-15A with Regulator
Spark Plug .......... Champion RN11YC
Spark Plug Gap, mm (in) .......... 0.7-0.8 (0.028-0.031)
Ignition Coil Air Gap, mm (in) .......... 0.3 (0.012)
Spark Plug Torque, Nm .......... 15

Electrical System

Electrical System Rating, Volts .......... 12
Alternator Charging Capacity, Amp .......... 15
Electric Starter .......... 12V, 0.8 kW Shift Type
Recommended Battery .......... 12V, 280 CCA

Dimensions

Length, mm (in) .......... 490 (19.3)
Width, mm (in) .......... 447 (17.6)
Height, mm (in) .......... 438 (17.3)
Dry weight, kg (lbs) .......... 45.5 (100.0)

Kawasaki FC420V Maintenance Data

Fuel Type (min. octane) .......... 86 Octane Unleaded
Engine oil type .......... SAE 10W-30/10W-40
Engine oil capacity, L (qts) .......... 1.6 (1.7)
Oil filter change interval .......... Every 100 hours
Oil change interval .......... Every 100 hours
Fuel filter change interval .......... Every 100 hours

Kawasaki FC540V Service Specifications

Cylinder Block

Cylinder Bore Inside Diameter (Maximum), mm (in) .......... 89.076 (3.5069)
Cylinder Bore Out Of Round (Maximum), mm (in) .......... 0.063 (0.0025)
Cylinder Boring Size (0.25 mm Oversize), mm (in) .......... 89.230 - 89.210 (3.5130 - 3.5122)
Cylinder Boring Size (0.50 mm Oversize), mm (in) .......... 89.480 - 89.460 (3.5228 - 3.5220)
Cylinder Boring Size (0.75 mm Oversize), mm (in) .......... 89.730 - 89.710 (3.5327 - 3.5319)
Camshaft Bearing Inside Diameter (Maximum), mm (in) .......... 21.076 (0.8298)
Camshaft Bearing Inside Diameter (Maximum), mm (in) .......... 21.076 (0.8298)
Camshaft Bearing Journal Diameter (Camshaft Side, Minimum), mm (in) .......... 20.912 (0.8233)
Camshaft Bearing Journal Diameter (Gear Side, Minimum), mm (in) .......... 20.912 (0.8233)
Lobe Height (Minimum), mm (in) .......... 37.10 (1.461)
Camshaft End Play, mm (in) .......... 0.07 - 0.19 (0.0028 - 0.0075)
Rocker Arm Diameter, mm (in) .......... 12.936 - 13.068 (0.5093 - 0.5145)
PTO Bearing Inside Diameter (Maximum), mm (in) .......... 38.056 (1.4983)
Connecting Rod Small End Diameter (Maximum), mm (in) .......... 22.059 (0.8685)
Connecting Rod Big End Diameter (Maximum), mm (in) .......... 41.068 (1.6169)
Crankshaft Bearing Journal Diameter (PTO Side, Minimum), mm (in) .......... 37.904 (1.4923)
Crankshaft Bearing Journal Diameter (Magneto Side, Minimum), mm (in) .......... 34.945 (1.3757)
Crank Pin Outside Diameter (Minimum), mm (in) .......... 40.928 (1.6113)
Balancer Link Rod Journal Outside Diameter (Minimum), mm (in) .......... 57.941 (2.2811)
Crankshaft End Play, mm (in) .......... 0.09 - 0.22 (0.0035 - 0.0087)
Balancer Link Rod Big End Inside Diameter (Maximum), mm (in) .......... 58.153 (2.2895)

Cylinder Head

Clearance Between Valve Stem And Rocker Arm, mm (in) .......... 0.15 (0.006)
Intake Valve Stem Diameter (Minimum), mm (in) .......... 0.2728 (6.930)
Exhaust Valve Stem Diameter (Minimum), mm (in) .......... 0.2722 (6.915)
Valve Spring Free Length, mm (in) .......... 37.5 (1.47)
Intake/Exhaust Valve Seat Width, mm (in) .......... 1.1 - 1.46 (0.043 - 0.057)
Valve Guide Inside Diameter, mm (in) .......... 7.00 - 7.015 (0.2756 - 0.2762)

Piston and Piston Rings

Top Ring Groove Clearance (Maximum), mm (in) .......... 0.17 (0.0067)
Second Ring Groove Clearance (Maximum), mm (in) .......... 0.15 (0.0059)
Oil Ring Groove Clearance (Maximum), mm (in) .......... 0.20 (0.0079)
Piston Pin Hole Diameter (Maximum), mm (in) .......... 22.037 (0.8676)
Piston Pin Diameter (Minimum), mm (in) .......... 21.977 (0.8652)
Top and Second Piston Ring Thickness (Minimum), mm (in) .......... 1.94 (0.076)
Top and Second Piston Ring End Gap (Maximum), mm (in) .......... 0.9 (0.035)

Tightening Torque Specs

Connecting rod bolt, Nm (lbf-in) .......... 20 (180)
Crankcase cover bolt, Nm (lbf-in) .......... 26 (230)
Valve clearance adjust nut, Nm (lbf-in) .......... 20 (180)
Cylinder head bolt and nut, Nm (lbf-in) .......... 52 (380)
Flywheel nut, Nm (lbf-in) .......... 172 (127)
Electric starter to block bolt and nut, Nm (lbf-in) .......... 16 (140)
Electric starter terminal nut, Nm (lbf-in) .......... 11 (100)
Oil drain extension joint to block, Nm (lbf-in) .......... Tighten firmly
Oil drain plug, Nm (lbf-in) .......... 23 (200)
PTO side crankshaft end bolt (with plane washer), Nm (lbf-in) .......... 38 (340)
Engine mounting flange bolt (M8) (if equipped), Nm (lbf-in) .......... 20 (180)