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Kawasaki FH500V Carburetor

Kawasaki FH500V Carburetor Adjustment

Low Idle Speed Adjustment

Disconnect all possible external loads from the engine. Start the engine and warm it up thoroughly. Move the throttle lever on dash to the idle position, and hold the throttle lever on the carburetor in closed position (turn the governor arm clockwise all the way) and adjust the low idle speed screw until the engine idles at specified speed.

Idle Speed (Carburetor idle rpm) - 1450 rpm. Release the throttle lever and adjust the low idle speed set screw on the control plate to obtain the specified governed low idle speed. Low Idle Speed (Governed idle rpm) - 1550 rpm.

High Idle Speed Adjustment

High idle speed adjustment should be made after the idle speed adjustment is performed. Do not adjust high idle speed with the air cleaner removed. Start and warm up the engine thoroughly. Move the throttle lever at a dash to the high idle position and match the lever hole position with the panel hole by inserting 6 mm dia., pin or bolt.

Loosen two M6 control panel mounting bolts enough to move the control panel assembly. Carefully move the control panel assembly right side up or down to obtain the specified high idle speed. High Idle Speed 3600 rpm.

Tighten the M6 Mounting bolts. Torque - Control Panel Mounting Bolts: 5.9 Nm (52 in-lb). Remove the 6 mm dia., pin or bolt. Check the idle speed, and readjust the idle speed if necessary.

High Altitude Operation

At high altitude, the standard carburetor air-fuel mixture will be excessively rich. Performance will decrease, and fuel consumption will increase.

High altitude performance can be improved by installing a smaller diameter main-jet in the carburetor and correct idle speed. The main jet high altitude kits are available if the equipment is to be used in the high altitudes. The main jet numbers are stamped on ends of the main jets.

High Altitude Main Jet

Altitude 0-1000 m (0-3000 ft): Main Jet #125
Altitude 1000-2000 m (3000-6000 ft): Main Jet #122.5
Altitude 2000 m (6000 ft): Main Jet #120

Kawasaki FH500V Carburetor Removal

Remove: air cleaner and related parts. Turn the fuel shut off valve to the OFF position. Drain the carburetor. Disconnect the fuel tube at the fuel inlet joint A of the carburetor. Disconnect the solenoid valve lead terminal and remove the earth terminal (Electric Starter Model).

Unhook the throttle link spring B at the throttle shaft lever C top end with a long nose plier. Unhook the throttle D and choke link rods E at the top ends of their arms while pull off the carburetor.

Main Jet Replacement

Place the engine (equipment) on a level surface. Close the fuel shut off valve in the equipment. Drain the fuel in the carburetor completely by unscrewing the drain screw at the bottom of the float chamber. Remove the carburetor.

Unscrew the float chamber bolt and take off the float chamber. Unscrew the solenoid valve, and take off the valve and gasket (Electric Starter Model). Using a proper blade screw driver, carefully replace the main jet with a new one for altitude expected. Tighten the main jet to the specification. Install the float chamber, gasket and solenoid valve.

Kawasaki FH500V Carburetor Disassembly and Assembly

1. Limiter, 2. Pilot Screw, 3. Spring, 4. Low Idle Speed Screw, 5. Spring, 6. Seal, 7. Ring, 8. Throttle Shaft (Electric Starter Model), 9. Throttle Valve, 10. Screws, 11. Pilot Jet, 12. Screw, 13. Choke Valve, 14. Choke Shaft, 15. Spring, 16. Coller, 17. Main jet, 18. Float, 19. Main Nozzle, 20. Valve Seat, 21. Float Chamber, 22. Gasket, 23. Bolt, 24. Gasket, 25. Solenoid Valve, 26. Drain Screw, 27. Gasket, 28. Pin, 29. Snap Ring, 30. Float Valve, 31. Main Air Jet, 32. Air Jet, 33. Washer, 34. E-Type Circlip, 35. Cap, 36. Earth Lead (Electric Starter Model)

Before disassembly, mark the out side of choke valve and throttle valves for assembling them. Replace the pilot screw in accordance with the following procedure if necessary. Carefully mark the position of the pilot screw limiter on the carburetor body so that it can be installed and set to its original position later. Remove the limiter. Be careful not to turn pilot screw at this point.

Turn the pilot screw clockwise and count the number of turns until screw is gently seated in the pilot passage. Record the number of turns needed to closed the screw. Turn out the pilot screw to replace it with anew one. Install the new pilot screw until the screw is gently seated. Then open the screw the same number of turns as recorded prior to removal.

Align the limiter with the mark on the carburetor body to install, taking care not to turn the pilot screw. Install the choke valve and throttle valve on the shaft as the out side mark of them facing out side. Drive the float pin so that it’s big diameter side faces the engine flange side. The fuel inlet valve seat is pressed into the carburetor body and is not replaceable. Assemble carburetor parts which recommended tightening torque.