WARNING Part No. 99920-2289-01 ADVERTENCIA The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. El escape del motor de este producto contiene productos químicos que, según el Estado de California, provocan cáncer, defectos de nacimiento o afectan a la fecundidad.
ENGLISH General-purpose Engine Owner’s Manual Original instructions j
SAFETY AWARENESS Whenever you see the symbols shown below, heed their instructions! Always follow safe operating and maintenance practices. WARNING This warning symbol identifies special instructions or procedures which, if not correctly followed, could result in personal injury, or loss of life. CAUTION This caution symbol identifies special instructions or procedures which, if not strictly observed, could result in damage to, or destruction of equipment.
READ THIS FIRST For your safety, read this Owner’s Manual and understand it thoroughly before operating this ENGINE. WARNING DO NOT run the engine in a closed area. Exhaust gas contains carbon monoxide, an odorless and deadly poison. Gasoline is extremely flammable and can be explosive under certain condition. Stop engine and allow the engine to cool before refueling. DO NOT smoke.
EMISSION CONTROL INFORMATION Fuel Information THIS ENGINE IS CERTIFIED TO OPERATE ON UNLEADED REGULAR GRADE GASOLINE ONLY. A minimum of 87 octane of the antiknock index is recommended. The antiknock index is posted on service station pumps in the U.S.A.
High Altitude Performance Adjustment Information To improve the EMISSIONS CONTROL PERFORMANCE of engines operated above 1000 meters (3300 feet), Kawasaki requires the following Environmental Protection Agency (EPA) and California Air Resources Board (CARB) approved modifications. High altitude adjustment requires replacement of carburetor main jets.
Among those acts presumed to constitute tampering are the acts listed below: Do not tamper with the original emission related parts: or DFI system, and their internal parts • Carburetor Spark Plug • Magneto or electronic ignition system • Fuel filter element • Air cleaner elements • Crankcase • Cylinder heads • Breather chamber and internal parts • Intake pipe and tube • Muffler or any internal portion of the muffler •
FOREWORD This Owner’s Manual provided to aid you in the safe and reliable operation of your Engine. READ AND UNDERSTAND IT THOROUGHLY BEFORE OPERATING YOUR ENGINE. READ THE OPERATING INSTRUCTIONS OF THE EQUIPMENT THIS ENGINE POWERS. To ensure a long, trouble-free life for your Engine, give it proper care and maintenance in accordance with this Owner’s Manual.
TABLE OF CONTENTS GENERAL INFORMATION.............................. Label Location ............................................... Parts Location ............................................... Tune-up Specifications .................................. Engine Oil Capacity....................................... FUEL AND OIL RECOMMENDATIONS .......... Fuel ............................................................... Engine Oil...................................................... PREPARATION ...............
10 8 GENERAL GENERALINFORMATION INFORMATION GENERAL INFORMATION Label Location 1. 2. 3. 4. Warning Label Important Engine Information Label Engine Maintenance Label Engine Serial Number Label The engine serial number is your only means of identifying your particular engine from others of the same model type. This engine serial number is needed by your dealer when ordering parts.
GENERALINFORMATION INFORMATION11 9 GENERAL Parts Location G. Fuel Pump H. Fuel Filter I. Electric Starter A. Air Cleaner B. Air Inlet Guard C. Oil Drain Plug D. Oil Filter E. Spark Plugs/Spark Plug Caps F. Oil Gauge J. Control Panel K.
12 10 GENERAL INFORMATION Tune-up Specifications ITEM Specifications Ignition Timing Unadjustable Spark Plugs: Gap NGK BPR4ES 0.75 mm (0.030 in) Low Idle Speed 1 550 r/min (rpm) High Idle Speed 3 600 r/min (rpm) Valve Clearance In 0.10 ∼ 0.15 mm (0.004 ∼ 0.006 in) Ex 0.10 ∼ 0.15 mm (0.004 ∼ 0.006 in) Other Specifications No other adjustment needed NOTE ○High and low idle speeds may vary depending on the equipment on which the engine is used. Refer to the equipment specification.
FUEL 11 FUEL AND OIL RECOMMENDATIONS 13 FUEL AND OIL RECOMMENDATIONS Fuel Use only clean, fresh, unleaded regular grade gasoline. CAUTION Do not mix oil with gasoline. Octane Rating The octane rating of a gasoline is a measure of its resistance to “knocking”. Using a minimum of 87 octane by the antiknock index is recommended. The antiknock index is posted on service station pumps in the U.S.A.
14 12 FUEL AND AND OIL OIL RECOMMENDATIONS RECOMMENDATIONS Engine Oil Engine Oil NOTE The following engine oils are recommended. The followingClassification: engine oils are API Service SF,recommended. SG, SH, SJ or SL. API Service Classification : SF, SG, SH, SJ or SL.
PREPARATION 15 13 PREPARATION Fuel Engine Oil WARNING Gasoline is extremely flammable and can be explosive under certain conditions. Before refueling, turn the engine switch to “OFF” position. Do not smoke. Make sure the area is well ventilated and free from any source of flame or sparks, including any appliances with a pilot lamp. Never fill tank so that fuel level rises into the filler neck. If tank is overfilled, heat may cause fuel to expand and overflow through vents in tank cap.
16 14 PREPARATION CAUTION The engine is shipped without engine oil. A. Oil Gauge B.
STARTING 17 15 STARTING Starting the Engine WARNING Exhaust gases contain carbon monoxide, a colorless, odorless, poisonous gas. Do not operate the unit in enclosed areas. Provide adequate ventilation at all times. WARNING Engine exhaust may ignite combustible materials and cause a fire. Keep the area around the exhaust outlet clear. Locate the unit so that the exhaust outlet points toward an open area and is located at least one meter (3.3 feet) from any obstructions.
18 16 STARTING CAUTION Whenever you start engine, make sure warning lamp is not illuminated after engine starts. If warning lamp comes on, stop engine immediately and check oil level (If equipped). starting the engine, gradually • After choke lever to the fully open position.
OPERATING 19 17 OPERATING Warming Up Engine Inclination After the engine starts, move the throttle lever (A) on the equipment to halfway between “FAST” and “SLOW”. To warm up the engine, run it for 3 to 5 minutes with the throttle lever in the same load position (halfway) before putting the equipment under load. Then, move the throttle lever (A) on the equipment to its “FAST” position. This engine will operate continuously at angles up to 25° in any direction.
20 18 STOPPING STOPPING Stopping the Engine WARNING Always remove Engine Key from switch when leaving equipment unattended or when equipment is not in use. Ordinary Stop Move the throttle lever (A) to “slow” position. Lower the engine speed to the idle speed. Keep running at the idle speed for about one minute. • • CAUTION Engine damage can occur from run-on or after-burning if engine is stopped suddenly from high speed loaded operation.
ADJUSTMENT 21 19 ADJUSTMENT Throttle Cable Installation, Adjustment Choke Cable Installation, Adjustment the throttle cable (G) to the speed control • Link lever (C) and loosely clamp the throttle cable outer the choke cable (K) to the choke control lever • Link (D), and loosely clamp the choke cable outer housing (F) with the cable clamp bolt (A). Move the throttle lever to “FAST” position.
22 20 ADJUSTMENT Engine Speed Adjustment NOTE ○Do not tamper with the governor setting or the car- buretor setting to increase the engine speed. Every carburetor is adjusted at the factory and a cap or stop plate is installed on each mixture screw. adjustment is necessary, necessary, it must be per○If any adjustment formed by your authorized Kawasaki Engine engine dealer.or equally qualified service facility.
MAINTENANCE 23 21 MAINTENANCE Maintenance, replacement, or repair of the emission control devices and systems may be performed by any nonroad engine repair establishment or individual. Periodic Maintenance Chart WARNING Always remove the spark plug caps from spark plugs when servicing the engine to prevent accidental starting. NOTE ○The service intervals can be used as a guide. Service more frequently as necessary by operating conditions. ♦ : Service more frequently under dusty conditions.
24 MAINTENANCE INTERVAL MAINTENANCE Daily Every 100 hr. ◆ Clean air cleaner paper element. ● ◆ Clean dust and dirt from cylinder and cylinder head fins. ● Tighten nuts and screws. ● ● ● Change engine oil. Clean and regap spark plugs. ◆ Every 200 hr. Change oil filter. ● Replace air cleaner paper element. ● Every 250 hr. Every 300 hr. Check and adjust valve clearance. ● ● Clean and lap valve seating surface. ● Clean combustion chamber. Every 500 hr.
MAINTENANCE 25 23 Oil Level Check Check oil level daily and before each time of operation. Be sure oil level is maintained. See “PREPARATION” chapter. Engine Oil Capacity 1.8 L (1.9 US·qt) FR651V [when oil filter is not removed] FR691V 2.1 L (2.
24 MAINTENANCE 26 24 MAINTENANCE Oil Change Oil Change Change oil after first 8 hours of operation.ThereChange after first 8hours. hours of operation.Thereoil oil every 100100 after change every hours. after oil every 100 hours. Runchange the engine to warm oil. Runsure the the engine to warm oil. Be engine (equipment) is level. Be sure engine (equipment) is level. Stop thethe engine. Stop the engine.
MAINTENANCE 27 25 Oil Filter Change • Change the oil filter every 200 hours of operation. WARNING Hot engine oil can cause severe burns. Allow engine temperature to drop from hot to warm level before attempting to remove oil filter. • Drain engine oil into a suitable container (C). CAUTION Before removing the oil filter, place suitable pan under filter connection. the oil filter (A) counterclockwise to remove • Rotate it. Coat a film of clean engine oil on seal of new filter.
28 26 MAINTENANCE Air Cleaner Service CAUTION To prevent excessive engine wear, do not run the engine with the air cleaner removed. Paper Element Clean the paper element (A) every 100 hours. Clean the paper element by tapping gently to remove dust. If very dirty, replace the paper element with a new one. Replace with a new paper element yearly or 200 hours. Whichever comes first. • NOTE ○Operating in dusty condition may require more frequent maintenance than above. CAUTION Do not wash paper element.
MAINTENANCE 29 27 Spark Plug Service WARNING Hot engine components can cause severe burns. Stop engine and allow it to cool before checking spark plugs. Clean or replace the spark plugs and reset spark plug gap (A) every 100 hours of operation. Disconnect the spark plug caps from the spark plugs and remove the spark plugs. Clean the electrodes (B) by scraping with a wire brush to remove carbon deposits. Inspect for cracked porcelain or other wear and damage.
30 28 MAINTENANCE Fuel Filter and Fuel Pump Service WARNING Improper use of solvents can result in fire or an explosion. Do not use gasoline or low flash-point solvents to clean the fuel filter and/or the fuel pump. Clean only in a well ventilated area away from sources of sparks or flame, including any appliances with a pilot lamp. fuel filter can not be disassembled. If the fuel • The filter gets clogged, replace it with a new one. The fuel pump can not be disassembled.
31 MAINTENANCE 29 MAINTENANCE Cooling System Cleaning Before each use, check that the air inlet (rotary) screen (inside A) is free from grass and debris and clean if necessary. Every 100 hours of operation, check and clean the cooling fins and inside of engine shrouds to remove grass, chaff or dirt clogging the cooling system and causing overheating. When cleaning, remove the air cleaner (inside E) loosen the bolts (C), (D), and then, remove the fan housing (B).
32 30 STORAGE 34 STORAGE 30 STORAGE Engine Storage Procedure Fuel System Draining Fuel System Draining STORAGE STORAGE STORAGE When not your 30 Kawasaki engine more Engines to operating be stored over days should be completely drained of fuel to prevent gum deposits formthan 30 days, add fuel stabilizer to fuel tank and run Engines to be stored over 30 days should be coming on essential carburetor parts, fuel filter and fuel engine for 5 minutes then drain the fuel tank.
STORAGE 33 31 A.
34 32 TROUBLESHOOTING GUIDE TROUBLESHOOTING GUIDE If the engine malfunctions, carefully examine the symptoms and the operating conditions, and use the table below as a guide to troubleshooting.
TROUBLESHOOTING GUIDE 35 33 Symptom No spark or weak spark Low output Engine overheats Engine speed won’t increase Probably Cause Remedy Faulty spark plugs Replace spark plugs Faulty ignition coil K Engine switch left in “OFF” position Turn engine switch to “START” position (See M) Clogged air cleaner Clean Air inlet screen or cooling air path clogged with dirt Insufficient engine oil Replenish or change oil Carbon build-up in combustion chamber K Poor ventilation around engine Select a b
36 34 ENVIRONMENTAL PROTECTION ENVIRONMENTAL PROTECTION To protect our environment, properly discard used batteries, engine oil, gasoline, coolant, or other components that you might dispose of in the future. Consult your authorized Kawasaki engine dealer or local environmental waste agency for their proper disequally qualified service facility or local environmental posal waste procedure. agency for their proper disposal procedure.
SPECIFICATIONS 37 35 SPECIFICATIONS FR651V, FR691V, FR730V Type Air-cooled, 4-stroke OHV, V-twin cylinder, gasoline engine Bore × Stroke 78 × 76 mm (3.07 × 2.99 in.) Displacement 726 mL (44.3 cu.in) Ignition System Solid-state ignition Direction of Rotation Counterclockwise facing the PTO Shaft Electric starter Starting System Dry Weight : kg (lbs) 40 (88.2) NOTE ○Specifications are subject to change without notice. ○Dry weight excludes that of fuel tank and muffler.
38 36 WIRING DIAGRAM WIRING DIAGRAM Wiring Diagram NOTE ○Portion Surrounded by hatching Shows Kawasaki Procurement Parts. WARNING For electrical safety, always remove cable from negative (–) side of battery before attempting any repair or maintenance.
WARNING Part No. 99920-2289-01 ADVERTENCIA The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. El escape del motor de este producto contiene productos químicos que, según el Estado de California, provocan cáncer, defectos de nacimiento o afectan a la fecundidad.