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Kawasaki FC540V Carburetor

Kawasaki FC540V carburetor is float type with adjustable pilot screw (idle mixture), fixed main jet, and float chamber drain screw.

Kawasaki FC540V carburetor parts: 1 - Choke shaft, 2 - Collar, 3 - Spring, 4 - Choke valve, 5 - Screw, 6 - Ring, 7 - Pilot jet, 8 - Screw, 9 - Pilot screw, 10 - Spring, 11 - Throttle shaft, 12 - Seal, 13 - Throttle valve, 14 - Screw, 15 - Main air jet, 16 - Pilot air jet, 17 - Needle valve, 18 - Clip, 19 - Main nozzle, 20 - Bleed pipe, 21 - Main jet, 22 - Float, 23 - Float pin, 24 - Gasket, 25 - Float chamber, 26 - Drain screw, 27 - Spring, 28 - Bolt, 29 - Washer, 30 - Collar, 31 - Spring, 32 - Screw, 33 - O-ring, 34 - Plate, 35 - Seal, 36 - Collar, 37 - Carburetor body

Kawasaki FC540V carburetor removing

Before removing carburetor from engine, drain fuel in float chamber to suitable container loosening drain screw (A).

Float chamber removal

Before removing float chamber, rotate float chamber clockwise and counterclockwise for 1/6 turns 2 or 3 times, pushing float chamber to carburetor body to release sticking of float chamber and rubber gasket.

Kawasaki FC540V carburetor - Cleaning and checking

Do not clean jet orifices with hard object. Dip carb components except non-metaric parts such as gasket into carburetor cleaner until dirt is removed and rinse them with solvent. Rinse carb aluminum components in hot water to neutralize corrosive action of cleaner, if so instructed by the manufacturer.

Dry components with compressed air. Make sure all orifices and passages are free from dirt or foreign object. Do not use rags or paper to dry components to avoid plugging orifices by lint. Check diaphragm for crack, tear, or pin hole. If defect is found, replace it.

Kawasaki FC540V carburetor adjustment

Float adjustment

Do not strike float pin to remove or install it, to avoid breakage of pin holder. To remove float pin, pull the transformed end with pliers. To install float pin, push float pin transformed end until the other end flushes with pin holder outer surface.

Do not push down float or needle valve when checking parallelism. Check float angle and correct it as follows. Place carburetor upside down and check whether float surface (A) is parallel with carb. body (B) when float tang (C) just begins to come in contact with point of needle valve (F). If not parallel, adjust float surface angle bending tang (C) with needle-nose pliers.

Slow idle speed adjustment

Turn Kawasaki FC540V carburetor pilot screw (B) in until it just seats and then back out 1-1/2 turns. Start and warm up engine without load. Move throttle lever on dash to "SLOW" position. Adjust slow idle speed to specified rpm by moving throttle stop screw (A). Adjust pilot screw (B) until engine idles at maximum speed and then turn pilot screw out additional 1/4 turn. Readjust slow idle speed, to specified rpm.

Fast idle speed adjustment

Air cleaner must be installed to engine before starting. Start and warm up engine without load. Loosen two control plate bolts (I). Align hole (B) of speed control lever (C) with hole (D) of control plate (E) and insert 6 mm (0.24 in.) diameter pin or 6 mm bolt through two holes.

Make sure choke valve is fully opened. Adjust fast idle speed for specified rpm by moving control plate (E). Tighten two bolts (I) securely in a manner to avoid changing specified speed. Stop engine, remove 6 mm pin, and set throttle lever on dash in "CHOKE" position. Make sure carburetor choke valve is closed completely.