Description
This 144 page, Official Kawasaki KG4000A KG4000AS KG5000A KG5000AS Portable Generator Service Manual provides repair and maintenance information for anyone who needs to repair Kawasaki KG4000A KG4000AS KG5000A KG5000AS Portable Generators.
This Kawasaki KG4000A KG4000AS KG5000A KG5000AS Portable Generator Service Manual includes the following chapters and topics:
GENERAL INFORMATION
Before Servicing
Mechanical Systems
Electrical Systems
Electrical connectors
Model Identification
General Specifications
Periodic Maintenance Chart
Wiring Diagrams
FUEL SYSTEM
Exploded View
Specifications
Tools and Equipment
Carburetor
Carburetor Theory
Starter system
Pilot system
Main system
Float system
Carburetor Adjustments
Running speed adjustment
Pilot Screw Adjustment
Idle Speed Adjustment
Float Level Adjustment
Idle Control Cable Adjustment
Choke Cable Adjustment
Carburetor Service
Carburetor Removal
Carburetor Installation
Carburetor Disassembly
Carburetor Assembly
Carburetor Cleaning
Carburetor Inspection
Air Cleaner
Air Cleaner Element
Air Cleaner Element Removal
Air Cleaner Element Installation
Air Cleaner Element Cleaning
Air Cleaner Element Inspection
Air Cleaner Housing
Air Cleaner Housing Removal
Air Cleaner Housing Installation
Air Cleaner Housing Inspection
Fuel Tank
Fuel Tank Removal
Fuel Tank Installation
Fuel Tank Draining
Fuel Tank Cleaning
Fuel Tank Inspection
Fuel Gauge
Fuel Gauge Removal
Fuel Gauge Installation
Fuel Gauge Inspection
Fuel Valve
Fuel Valve Removal
Fuel Valve Installation
Fuel Valve Disassembly
Fuel Valve Assembly
Fuel Valve Cleaning
Fuel Valve Inspection
Fuel Valve Sediment Bowl
Fuel Valve Sediment Bowl
Removal
Fuel Valve Sediment Bowl
Installation
Fuel Valve Sediment Bowl
Inspection
CONTROLS
Exploded View
Specifications
Tools and Equipment
Control Panel
Control Panel Face Plate
Removal
Control Panel Face Plate
Installation
Control Panel Removal
Control Panel Installation
Control Panel Disassembly
Control Panel Assembly
Fuses
Fuse Replacement
Control Panel Components
General Information
Choke Cable
Choke Cable Adjustment
Choke Cable Removal
Choke Cable Installation
Choke Cable Inspection
Idle Control Cable
Idle Control Cable Adjustment
Idle Control Cable Removal
Idle Control Cable Installation
Idle Control Cable Inspection
Idle Control Circuit
Idle control unit
Idle Control Unit Removal
Idle Control Unit Installation
Idle Control Unit Test
Idle control actuator solenoid
Idle Control Actuator Solenoid
Removal
Idle Control Actuator Solenoid
Installation
Idle Control Actuator Solenoid
Test
Idle control switch
Idle Control Switch Removal
Idle Control Switch Installation
Idle Control Switch Test
AC power supply
AC Power Supply to Idle Control
Unit Test
DC power supply
DC Power Supply to Idle
Control Unit Test
Idle control circuit wiring
Idle Control Circuit Wiring and
Fuse Test
Pilot Lamp Socket
Pilot Lamp Socket Removal
Pilot Lamp Socket Installation
Pilot Lamp Test
Low Oil Level Warning Circuit
Low oil level warning circuit
control unit
Low Oil Level Warning Circuit
Control Unit Removal
Low Oil Level Warning Circuit
Control Unit Installation
Low Oil Level Warning Circuit
Control Unit Test
Low oil level sensor
Low Oil Level Sensor Removal
Low Oil Level Sensor
Installation
Low Oil Level Sensor Test
Low oil level warning light (LED)
Low Oil Level Warning Light
(LED) Removal
Low Oil Level Warning Light
(LED) Installation
Low Oil Level Warning Light
(LED) Test
Engine Switch
Engine Switch Removal
Engine Switch Installation
Engine Switch Test
(Electric Start Models)
Engine Switch Test
(Manual Start Models)
Battery Charging Circuit Rectifier
(Electric Start Models Only)
Battery Charging Circuit
Rectifier Removal
Battery Charging Circuit
Rectifier Installation
Battery Charging Circuit
Rectifier Test
CDI Unit Diode
CDI Unit Diode Removal
CDI Unit Diode Installation
CDI Unit Diode Test
Generator Ground Terminal
Generator Ground Terminal
Removal
Generator Ground Terminal
Installation
240 VAC Receptacle
240 VAC Receptacle Removal
240 VAC Receptacle
Installation
240 VAC Receptacle
Inspection
120 VAC, 30 A Receptacle
120 VAC, 30 A Receptacle
Removal
120 VAC, 30 A Receptacle
Installation
120 VAC, 30 A Receptacle
Inspection
120 VAC Receptacle
120 VAC Receptacle Removal
120 VAC Receptacle
Installation
120 VAC Receptacle
Inspection
DC Terminals
DC Terminals Removal
DC Terminals Installation
120 VAC and 240 VAC Circuit
Breakers
120 VAC and 240 VAC Circuit
Breaker Removal
120 VAC and 240 VAC Circuit
Breaker Installation
120 VAC and 240 VAC Circuit
Breaker Test
12 VDC Circuit Breaker
12 VDC Circuit Breaker
Removal
12 VDC Circuit Breaker
Installation
12 VDC Circuit Breaker Test
RECOIL STARTER
Exploded View
Recoil Starter
Recoil Starter Removal
Recoil Starter Installation
Recoil Starter Disassembly
Recoil Starter Assembly
Recoil Starter Cleaning
Recoil Starter Inspection
ELECTRIC STARTING SYSTEM
Exploded View
Specifications
Tools and Equipment
Electric Starter System
Starter Motor Circuit
Starter Relay Test
(KG5000AS Only)
Starter Solenoid Test
(KG4000AS Only)
Starter Motor
Starter Motor Removal
Starter Motor Installation
Starter Motor Disassembly
(KG5000AS Only)
Starter Motor Disassembly
(KG4000AS Only)
Starter Motor Assembly
(KG5000AS Only)
Starter Motor Assembly
(KG4000AS Only)
Starter Motor Brush Length
Starter Motor Brush Spring
Tension
Starter Motor Brush Assembly
Inspection
Starter Motor Armature
Inspection
Starter Motor Yoke Assembly
Inspection
Battery
Battery Removal
Battery Installation
Electrolyte
Electrolyte Level Inspection
Battery Charging
Battery Condition
Battery Initial Charging
Battery Ordinary Charging
Battery Test Charging
Charging System
Charging Coil
Charging Coil Removal
Charging Coil Installation
Charging Circuit Rectifier
Charging Circuit Rectifier Removal
Charging Circuit Rectifier
Installation
Charging Circuit Rectifier Test
Charging System Inspection
Initial Inspection
Operational Inspection
IGNITION SYSTEM
Exploded View
Specifications
Tools and Equipment
CDI Ignition System
Ignition Coil and CDI Unit
Ignition Coil and CDI Unit
Removal
Ignition Coil and CDI Unit
Installation
Ignition Coil and CDI Unit Test
Exciter Coil
Exciter Coil Removal
Exciter Coil Installation
Exciter Coil Test
PulserCoil
Pulser Coil Removal
Pulser Coil Installation
PulserCoil Test
Spark Plug
Spark Plug Removal
Spark Plug Installation
Spark Plug Cleaning and
Inspection
Spark Plug Gap
ENGINE TOP END
Exploded View
Specifications
Tools and Equipment
Cylinder Head
Cylinder Head Removal
Cylinder Head Installation
Cylinder Head Cleaning
Cylinder Head Warp
Cylinder, Piston, and Rings
Cylinder Removal/Installation
Cylinder Removal
Cylinder Ins tallation
Piston and Ring Removal/ Installation
Piston and Ring Removal
Piston and Ring Installation
Cylinder, Piston, and Ring
Maintenance
Compression Measurement
Cylinder/Piston Wear
Piston/Cylinder Clearance
Cylinder Boring and Honing
Piston/Cylinder Seizure
Piston Cleaning
Piston Ring and Ring Groove
Wear
Piston Ring End Gap
Piston Ring Free Gap
Piston Pin, Piston Pin Hole, and
Connecting Rod Wear
Valves, Guides, Seats, and Springs
Valves
Valve Clearance Check
Valve Clearance Adjustment
Valve Removal
Valve Installation
Valve Visual Inspection
Valve Head Thickness
Valve Stem Bend
Valve Stem Diameter
Valve Guides
Valve Guide Inside Diameter
Valve Guide Wear by Wobble
Method
Valve Seats
Valve Seat Inspection
Valve Seat Repair
Valve Springs
Valve Spring Removal
Valve Spring Installation
Valve Spring Tension
Valve Spring Squareness
Exhaust System
Spark Arrester
Spark Arrester Removal
Spark Arrester Installation
Spark Arrester Cleaning
Muffler
Muffler Removal
Muffler Installation
Spiral Case
Spiral Case Removal
Spiral Case Installation
Flywheel
Flywheel Removal
Flywheel Installation
ENGINE BOTTOM END
Exploded View
Specifications
Tools and Equipment
Engine Oil
Engine Oil Change
Engine Oil Draining
Engine Oil Filling
Crankcase
Crankcase Removal/Installation
Crankcase Removal
Crankcase Installation
Crankcase Splitting
Crankcase Disassembly
Crankcase Assembly
Crankcase Bearings and Seals
Crankcase oil seals
Crankcase Oil Seal Removal
Crankcase OH Seal Installation
Crankcase bearings
Crankcase Bearing Removal
Crankcase Bearing Installation
Crankcase Bearing Inspection
Dynamic Balancer Shaft
Dynamic Balancer Shaft Removal
Dynamic Balancer Shaft
Installation
Dynamic Balancer Shaft
Inspection
Crankshaft and Connecting Rod
Crankshaft and Connecting Rod
Removal/Installation
Crankshaft and Connecting Rod
Removal
Crankshaft and Connecting Rod
Installation
Crankshaft and Connecting Rod
Inspection/Maintenance
Crankshaft Inspection
Connecting Rod Bend/Twist
Connecting Rod to Crankshaft
Clearance
Connecting Rod Big End Side
Clearance
Crankshaft Alignment
Crankshaft End Play
Measurement
Crankshaft End Play Adjustment
Camshaft
Camshaft Removal
Camshaft Installation
Cam Wear Inspection
Camshaft Inspection
Camshaft End Play Measurement
Camshaft End Play Adjustment
Compression Release Mechanism
Compression Release Mechanism
Operation
Compression Release Mechanism
Inspection
Governor
Governor Operation
Governor Adjustment
Governor External Components
Governor External Components
Removal
Governor External Components
Installation
Governor Internal Components
Governor Internal Components
Removal
Governor Internal Components
Installation
Governor Internal Components
Inspection
Low Oil Level Sensor
Low Oil Level Sensor Removal
Low Oil Level Sensor Installation
Low Oil Level Sensor Switch Test
GENERATOR
Exploded View
Specifications
Tools and Equipment
Generator Components
Stator
Main coil (Me)
Sub coil (Sc)
Rotor
Field coil (Fc)
Voltage Regulator
Voltage regulator sampling circuit
Capacitor
Diodes
Brushes
Generator Theory
Types of Generators
Generator Operation
Frequency
Changing Frequency
Fine Tuning Frequency
Generator End Case
Generator End Case Removal
Generator End Case Installation
Stator
Stator Removal’
Stator Installation
Rotor
Rotor Removal
Rotor Installation
AC Output
Inspections and Tests
120 VAC Output Voltage
Measurement
120 VAC, 30 A Output Voltage
Measurement
240 VAC Output Voltage
Measurement
Initial Inspection
Main Coil Resistance
Measurement
Voltage Regulator Resistor Test
Voltage Regulator Operation Test
Field Coil Resistance
Measurement
Voltage Regulator Sampling Circuit
Resistance Measurement
Sub Coil Resistance
Measurement
DC Output’
Inspections and Tests
DC Output Voltage Measurement
AC Voltage to Diodes Test
Diode Test
Engine Power Output Tests
Inspection and Tests
AC voltage
AC Unloaded Voltage
Measurement
AC Rated Output Measurement
AC Voltage Variation
DC voltage
DC Unloaded Voltage
Measurement
DC Rated Output Measurement
Troubleshooting Guide
This Official Kawasaki KG4000A KG4000AS KG5000A KG5000AS Portable Generator Service Manual is a Reproduction of original out of print book.
