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Old 01-24-2020, 01:58 PM   #51
jclark138
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Default Re: FE290 engine rebuild

Thanks CP241
what engine you doin’ next ?
How ‘ bout a G2 !
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Old 01-24-2020, 05:23 PM   #52
CP241
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Default Re: FE290 engine rebuild

Quote:
Originally Posted by jclark138 View Post
Thanks CP241
what engine you doin’ next ?
How ‘ bout a G2 !
Thanks

This will be the last one for me for a while. About to change careers and move somewhere else in the country so gotta sell all my carts and pack up my shop :) to be continued in a different universe
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Old 01-24-2020, 08:26 PM   #53
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Default Re: FE290 engine rebuild

Ok, heres kawasaki part numbers for FE290 that I used.

Head gasket 11004-2138
Crankcase cover gasket 11060-2122
Std. Size piston rings 13008-6007
Valve stem seals (qty 2) 92049-2100
Crank seal 92049-2199
Intake valve 12004-2084
Exhaust valve 12005-2077
Crank seal 92049-2220
Valve cover gasket 11009-2829
Counterbalance weight link rods (with bushing) 46102-6004 (note you will need to press the gear off to remove the link in the front)
Counterbalance weight link rod (bushing only) 92141-2090
Connecting rod 13251-6033
Counterbalance weight shaft 13107-2088


I didn't need or use ALL of these parts on this motor, just putting them here for reference. For example, I didnt touch the counterbalance weight link rods, they were tight on this one. I've had others where they are worn (and make a TON of noise, I've posted videos here previously showing the noise).


And I havent compared these specs to the repair manual, but going off of memory they look right to me. I'm just being lazy and cutting and pasting from another website lol

Standard Bore:*2.9949 in. (76.070mm)*
Piston to Cylinder Clearance: .010 in.*
Bore Taper (top to bottom): .006 in.*
Bore Out of Round: .0022 in. max
Ring end Gap*(top & second): .047 in. max
Piston Pin to Piston Clearance: .0023 in. max
Connecting Rod Big End Side Play: .013 in. max

Standard Crank Pin: 1.3954 in.*(35.444mm)*
Crank Pin Wear: .002 in.

Valve Clearance: .12mm (.0047")
Plug Gap: .028"-.031"
Ignition Coil Air Gap Standard.: .3mm (.012")
Air Gap Adjustment Range: .25mm-.4mm (.010"-.016")

FE290 Torque Specs*

Cylinder Head Bolts: 18 ft lbs
Connecting Rod Bolts: 15 ft. lbs.
Flywheel Nut: 63*ft lbs
Spark Plug: 17*ft lbs
Crankcase Bolts: 23*ft lbs
Fan Retaining Plate: 7.2*ft lbs
Fan Housing: 7.2*ft lbs
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Old 01-24-2020, 09:27 PM   #54
LukeL
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Default Re: FE290 engine rebuild

Very nice job [emoji1303]
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Old 01-25-2020, 12:39 PM   #55
jakesnake27
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Default Re: FE290 engine rebuild

Nice work, this thread will be a great resource for many in the future!
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Old 01-25-2020, 01:09 PM   #56
CP241
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Default Re: FE290 engine rebuild

Quote:
Originally Posted by jakesnake27 View Post
Nice work, this thread will be a great resource for many in the future!
Thanks, that's my hope

Even if it's just referencing someone where the ignitor or rev limiter is, or how to loosen the engine to replace the ignition coil. I tried to capture as much as I could

I will say this 93 was a LOT easier to work on than the newer ones like my 02 DS when I rebuilt that motor. All the bolts are much more accessible than the newer ones.
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Old 01-27-2020, 10:44 AM   #57
Fairtax4me
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Default Re: FE290 engine rebuild

Quote:
Originally Posted by CP241 View Post

Fairtax must have gotten ahold of this one, it was set to top out around 8mph

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Old 01-27-2020, 03:20 PM   #58
oldphart
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Default Re: FE290 engine rebuild

Jeez. That took me back to when I had hair and saw 'em live a few times....

Ok....I just dated myself.....and yes, I usta' have one of the hats with "FOG" on the front...

Jim
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Old 07-29-2021, 08:26 AM   #59
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Default Re: FE290 engine rebuild

Found this link for the "avid reader", a MUST HAVE for CC enthusiasts, and appended to this thread (seemed logical):

FE290 Maintenance / Service Supplement (free download in PDF format)
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