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Kawasaki FH500V Engine

General Technical Data

Kawasaki FH500V Engine Specifications

Engine Model .......... Kawasaki FH500V
Engine Type .......... Forced Air-cooled, Vertical Shaft, OHV, 4-Stroke Gasoline Engine
Number of Cylinder .......... 2
Cylinder Layout .......... 90 V-Twin
Piston Displacement, cc (cu.in) .......... 494 (30.1)
Engine Bore, mm (in) .......... 68.0 (2.68)
Engine Stroke, mm (in) .......... 68.0 (2.68)
Engine Power, Hp (kW) .......... 17.0 (12.7)
Maximum Torque, Nm (ft-lb) .......... 37 (27.3)
Fast Idle Speed, rpm .......... 3600
Low Idle Speed, rpm .......... 1550
Compression Release .......... Automatic compression release
Direction of Rotation .......... Counterclockwise facing the PTO Shaft
Choke Control .......... Automatic (with Throttle Control)
Cooling System .......... Forced air cooling by fan
Air Cleaner .......... Dual stage element, dry type

Lubricating System

Lubricating System Type - Pressure feed by positive displacement pump
Oil Filter - Cartridge type full flow filter
Oil Pressuer Switch - ON-OFF switch
Engine oil capacity, L (qts) .......... 1.8 (1.9)

Fuel System

Fuel System Type .......... Carburetor
Carburetor Type .......... Float type, fixed main jet
Fuel Pump .......... Diaphragm Type Pulse Pump
Governor .......... Flyweight all speed governor
Fuel Capacity, L (qt) .......... 11.0 (11.2)

Ignition System

Ignition System Type .......... Transistorized Flywheel Magneto
Charging Coil .......... 12V-13 amps with regulator
Spark Plug .......... Champion RCJ8Y
Spark Plug Gap, mm (in) .......... 0.75 (0.029)
Spark Plug Torque, Nm .......... 22 (16.2)

Electrical System

Electrical System Rating, Volts .......... 12
Alternator Charging Capacity, Amp .......... 13
Electric Starter .......... 12V-0.6 kW
Recommended Battery .......... 12V-200CCA

Dimensions

Length, mm (in) .......... 425 (16.7)
Width, mm (in) .......... 359 (14.1)
Height, mm (in) .......... 361 (14.2)
Dry weight, kg (lbs) .......... 33.0 (72)

Kawasaki FH500V Maintenance Data

Fuel Type (min. octane) .......... 86 Octane Unleaded
Engine oil type .......... SAE 10W-40, 10W-30, 5W-20
Engine oil capacity, L (qts) .......... 1.8 (1.9)
Oil filter change interval .......... Every 150 hours
Oil change interval .......... Every 100 hours
Fuel filter change interval .......... Every 100 hours

Kawasaki FH500V Service Specifications

Cylinder Head and Valves

Cylinder head warp .......... 0.05 mm (0.002 in.)
Valve clearance (Intake, Exhaust) .......... 0.075-0.125 mm (0.003-0.005 in.)
Valve seating surface angle (Intake, Exhaust) .......... 45 deg
Valve seating surface width (Intake, Exhaust) .......... 0.6-0.9 mm (0.024-0.035 in.)
Valve guide inside diameter (Intake, Exhaust) .......... 6.00-6.012 mm (0.2362-0.2367 in.)
Valve head thickness (Intake, Exhaust) .......... 0.35 mm (0.014 in.)
Valve stem runout (Intake, Exhaust) .......... 0.05 mm (0.002 in.)
Valve stem diameter (Intake) .......... 5.95 mm (0.0234 in.)
Valve stem diameter (Exhaust) .......... 5.93 mm (0.0233 in.)
Valve guide inside diameter (Intake, Exhaust) .......... 6.08 mm (0.239 in.)
Valve spring free length (Intake, Exhaust) .......... 31.0 mm (1.22 in.)
Rocker arm push rod run out (Intake, Exhaust) .......... 0.5 mm (0.02 in.)

Cylinder and Piston

Cylinder compression .......... 390 kPa (57 psi)
Cylinder inside diameter (Standard) .......... 68.10 mm (2.681 in.)
Cylinder inside diameter (0.50 mm Oversize) .......... 68.60 mm (2.701 in.)
Cylinder bore diameter (Standard) .......... 68.00-67.98 mm (2.677-2.676 in.)
Cylinder bore diameter (0.50 mm Oversize) .......... 68.50-68.48 mm (2.697-2.696 in.)
Cylinder bore out round .......... 0.056 mm (0.0022 in.)
Piston diameter .......... 67.79 mm (2.669 in.)
Piston top ring/groove clearance .......... 0.15 mm (0.006 in.)
Piston second ring/groove clearance .......... 0.12 mm (0.005 in.)
Piston ring thickness .......... 1.40 mm (0.055 in.)
Piston top ring end gap .......... 0.70 mm (0.028 in.)
Piston second ring end gap .......... 0.78 mm (0.031 in.)
Piston oil ring end gap .......... 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.)
Cam lobe height .......... 29.131 mm (1.1469 in.)
Camshaft journal diameter .......... 15.985 mm (0.6293 in.)
Camshaft bearing inside diameter .......... 16.136 mm (0.6352 in.)

Crankshaft and Connecting Rod

Connecting rod bend .......... 0.15/100 mm (0.006/3.94 in.)
Connecting rod twist .......... 0.15/100 mm (0.006/3.94 in.)
Connecting rod big end width .......... 18.80 mm (0.74 in.)
Crankpin width .......... 39.50 mm (1.56 in.)
Connecting rod big end inside diameter .......... 35.055 mm (1.3801 in.)
Crankpin outside diameter .......... 34.94 mm (1.3756 in.)
Crankshaft run out .......... 0.05 mm (0.002 in.)
Crankshaft journal diameter (PTO side) .......... 34.90 mm (1.374 in.)
Crankshaft journal diameter (Flywheel side) .......... 34.93 mm (1.375 in.)
Crankshaft journal bearing inside diameter .......... 35.15 mm (1.384 in.)

Caburetor Specifications

Model - Mikuni B24T1
Throttle bore diameter - 24 mm
Venturi diameter - 16 mm (0.63 in.)
Main Jet (MJ) - #125
Pilot jet (PJ) - #48.8
Main air jet (MAJ) - 1.7 mm
Pilot air jet (PAJ) - 1.2 mm
Pilot air screw turns out - 2-1/4

Lubricating System

Oil pressure .......... 241-310 kPa (35-45 psi)
Oil pressure switch .......... 98 kPa (14.2 psi)
Oil filter by-pass valve openning pressure .......... 78.5-117.5 kPa (11.4-17.1 psi)
Oil pump inner and outer rotor clearance .......... 0.2 mm (0.008 in.)
Oil pump outer rotor outside diameter .......... 40.470 mm (1.5933 in.)
Oil pump housing inside diameter .......... 40.801 mm (1.6063 in.)
Oil pump housing depth .......... 10.230 mm (0.4028 in.)
Oil pump shaft outside diameter .......... 10.923 mm (0.4300 in.)
Oil pump shaft bearing inside diameter .......... 11.072 mm (0.4359 in.)
Relief valve spring free length .......... 19.50 mm (0.77 in.)

Tightening Torque Specs

Cylinder Head Bolts .......... 25 Nm (19 ft-lb)
Valve Clearance Lock Screws .......... 6.9 Nm (61 in-lb)
Connecting Rod Big End .......... 5.9 Nm (52 in-lb)
Rocker Arm Bolts .......... 28 Nm (20 ft-lb)
Rocker Cover Mounting Bolts .......... 5.9 Nm (52 in-lb)
Exhaust Pipe Flange Nuts .......... 15 Nm (11 ft-lb)
Spark Plugs .......... 22 Nm (16 ft-lb)
Drain Screw (Carburetor) .......... 1.3 Nm (11 in-lb)
Governor Arm Clamp Nut .......... 7.8 Nm (69 in-lb)
Intake Manifold Mounting Bolts .......... 5.9 Nm (52 in-lb)
Cleaner Body Mounting Screws .......... 3.4 Nm (30 in-lb)
Plug Bolt (Engine-shroud) .......... 5.9 Nm (52 in-lb)
Plug Screw (Engine-shroud) .......... 3.4 Nm (30 in-lb)
Choke Valve Screw .......... 0.7 Nm (6 in-lb)
Throttle Valve Screws .......... 1.0 Nm (9 in-lb)