Kawasaki FX801V User Manual

FX801V, FX751V

4 stroke air-cooled V-twin gasoline engine

OWNER’S MANUAL

SAFETY AWARENESS

Whenever you see the symbols shown below, heed their instructions! Always follow safe operating and maintenance practices.

DANGER

DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

NOTICE

NOTICE is used to address practices not related to personal injury.

NOTE

○NOTE indicates information that may help or

guide you in the operation or service of the vehicle.

READ THIS FIRST

For your safety, read this Owner’s Manual and understand it thoroughly before operating this ENGINE.

DANGER

Exhaust gas contains carbon monoxide, a colorless, odorless poisonous gas. Inhaling carbon monoxide can cause serious brain injury or death.

DO NOT run the engine in enclosed areas. Operate only in a well-ventilated area. Gasoline is extremely ammable

and can be explosive under certain conditions, creating the potential for serious burns. When refueling, servicing fuel system, draining gasoline and/or adjusting the carburetor: Stop engine and allow it to cool before refueling. DO NOT smoke.

Make sure the area is well-ventilated and free from any source of ame or sparks, including the pilot light of any

appliance.

DO NOT ll the tank so the fuel level rises into the ller neck or level surface of level gauge. If the tank is overlled, heat may cause the fuel to expand and overow through the vents in the tank cap.

Wipe off any spilled gasoline immediately.

Engines can become extremely hot during normal operation.

To prevent re hazard:

Keep the engine at least 1 m (3.3 ft) away from buildings, obstructions and other burnable objects.

DO NOT place ammable objects close to the engine.

DO NOT expose combustible materials to the engine exhaust. DO NOT use the engine on any forest covered, brush covered or grass covered unimproved land unless spark

arrester is installed on the mufer.

To avoid getting an electric shock, DO NOT touch spark plugs, plug caps or spark plug leads during engine running.

To avoid a serious burn, DO NOT touch a hot engine or mufer. The engine becomes hot during operation. Before you

service or remove parts, stop engine and allow the engine to cool. DO NOT place hands or feet near moving or rotating parts. Place a protective cover over pulley, V belt or coupling. DO NOT run engine at excessive speeds. This may result in injury. Always remove the spark plug caps from spark plugs when servicing the engine to prevent accidental starting.

Read warning labels which are on the engine and understand them. If any label is missing, damaged, or worn get a

replacement from your Kawasaki engine dealer and install it in the correct position.

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.

Emission Control Information

To protect the environment in which we all live, Kawasaki has incorporated an exhaust emission control system in compliance with applicable regulations of the United States Environmental Protection Agency and the California Air Resources Board. Also, depending on when your engine was produced, it may have an assigned emissions durability period. *See below for the engine emissions durability period that may apply to your engine.

Exhaust Emission Control System

The exhaust emission control system applied to this engine consists of a carburetor and an ignition system

having optimum ignition timing characteristics. The carburetor has been calibrated to provide specic air/fuel

mixture characteristics and optimum fuel economy with a suitable air cleaner and exhaust system.

A sealed-type crankcase emission control system is also used to eliminate blow-by gasses. The blow-by gasses are led to a breather chamber through the crankcase and from there to the air cleaner.

Engine Emission Compliance Period California

Engines Greater Than or Equal To 225 cc

Model Year - 2015 and later Durability period - 1 000 hours

* If your engine has an assigned emissions durability period it will be located on the certication label

attached to the engine (IMPORTANT ENGINE INFORMATION).

All Other States

Engines Greater Than or Equal To 225 cc

Model Year - 2015 and later Durability Period - 1 000 hours (Category 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 modications. High altitude adjustment requires replacement of carburetor main jets. Installation of these optional parts may be performed by an authorized Kawasaki engine dealer or equally qualied service facility, or the consumer, following repair recommendations specied in the appropriate

Kawasaki Service document or parts catalog.

Operating with the wrong conguration at a given altitude may increase its emissions and decrease fuel

efciency and performance.

NOTE

○When properly performed, these specied modications only are not considered to be emissions system

“tampering” and engine performance is generally unchanged as a result.

○Engine models with fuel injection do not require high altitude performance adjustment.

Maintenance and Warranty

Proper maintenance is necessary to ensure that your engine will continue to have low emission levels. This

Owner’s Manual contains those maintenance recommendations for your engine. Those items identied by the

Periodic Maintenance Chart are necessary to ensure compliance with the applicable standards.

As the owner of the engine, you have the responsibility to make sure that the recommended maintenance is

carried out according to the instructions in this Owner’s Manual at your own expense.

The Kawasaki Limited Emission Control System Warranty requires that you return your engine to an

authorized Kawasaki engine dealer for remedy under warranty. Please read the warranty carefully, and keep it

valid by complying with the owner’s obligations it contains.

Tampering with Emission Control System Prohibited

Federal law and California State law prohibits the following acts or the causing thereof: (1) the removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement, of any device or element of design incorporated into any new engine for the purposes of emission control prior to its sale or delivery to the ultimate purchaser or while it is in use, or (2) the use of the engine after such device or element of design has been removed or rendered inoperative by any person.

Among those acts presumed to constitute tampering are the acts listed below:

Do not tamper with the original emission related parts:

●Carburetor or DFI system, and their internal parts

●Spark Plug

●Magneto or electronic ignition system

●Fuel lter element

●Air cleaner elements

●Crankcase

●Cylinder heads

●Breather chamber and internal parts

●Intake pipe and tube

FOREWORD

We wish to thank you for purchasing this Kawasaki engine. Please read this Owner’s Manual carefully before starting your new engine so that you will be thoroughly

familiar with the proper operation of your engine’s control, its features, capabilities and limitations.

Also read the manual of the equipment to which this engine is attached.

To ensure a long, trouble-free life for your engine, give it the proper care and maintenance described in this

manual. Always keep this manual at your ngertip so that you can refer to it whenever you need information.

This manual should be considered a permanent part of the engine and should remain with the engine when it is sold.

All rights reserved. No part of this publication may be reproduced without our prior written permission. This publication includes the latest information available at the time of printing. However, there may be minor

differences between the actual product and illustrations and text in this manual.

All products are subject to change without prior notice or obligation.

KAWASAKI HEAVY INDUSTRIES, LTD.

Motorcycle & Engine Company

TABLE OF CONTENTS

GENERAL INFORMATION ............................... 8

Location of Safety Related Labels ................... 8

Location of Parts ............................................. 9

Engine Serial Number ..................................... 10

Tune-up Specications .................................... 10

Engine Oil Capacity ......................................... 11

FUEL AND OIL RECOMMENDATIONS ............ 12

Fuel ................................................................. 12

Engine Oil ........................................................ 13

PREPARATION ................................................. 14

Fuel ................................................................. 14

Engine Oil ........................................................ 15

STARTING ......................................................... 16

Start Engine ..................................................... 16

OPERATING ...................................................... 19

Warming Up ..................................................... 19

Engine Inclination ............................................ 20

STOPPING ........................................................ 21

Stopping the Engine ........................................ 21

Ordinary Stop ............................................... 21

Emergency Stop ........................................... 21

ADJUSTMENT .................................................. 22

Separate Choke Type ...................................... 22

Throttle Cable Installation, Adjustment ......... 22

Choke Cable Installation, Adjustment ........... 22

Engine Speed Adjustment ............................... 23

MAINTENANCE ................................................ 24

Periodic Maintenance Chart ............................ 24

Oil Level Check ............................................... 26

Oil Cooler Service ........................................... 26

Oil Change ...................................................... 27

Oil Filter Change ............................................. 28

Air Cleaner Service ......................................... 29

Air Cleaner ................................................... 29

Primary Element ........................................... 29

Secondary Element ...................................... 29

Cap (Dust Ejector Valve) .............................. 29

Fuel Filter and Fuel Pump Service .................. 31

Spark Plug Service .......................................... 32

Cooling System Cleaning ................................ 33

STORAGE ......................................................... 34

Engine Storage Procedure .............................. 34

TROUBLESHOOTING GUIDE .......................... 36

ENVIRONMENTAL PROTECTION ................... 37

SPECIFICATIONS ............................................. 38

WIRING DIAGRAM ........................................... 39

Wiring Diagram

(With 12 V - 15 A Charging Coil) ..................... 39

8 GENERAL INFORMATION

GENERAL INFORMATION

Location of Safety Related Labels

A. Warning Label B. Engine Maintenance

Location of Parts

GENERAL INFORMATION 9

A. Oil Gauge Filler B. Oil Filter C. Oil Drain Plug D. Air Cleaner E. Carburetor F. Spark Plug Cap/

Spark Plug G. Guard H. Fan Housing

I. Electric Starter J. Voltage Regulator K. Fuel Tube L. Fuel Filter M. Oil Cooler N. Control Panel O. Cleanout Cover

(if equipped)

10 GENERAL INFORMATION

Engine Serial Number

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.

A. Engine Serial Number

Tune-up Specications

ITEM Specications

Ignition Timing Unadjustable

Spark Plugs: Gap

Low Idle Speed 1 550 r/min (rpm)

High Idle Speed 3 600 r/min (rpm)

Valve Clearance

Other Specications

NGK BPR4ES

0.75 mm (0.030 in)

IN 0.10 - 0.15 mm (0.004 - 0.006 in) EX 0.10 - 0.15 mm (0.004 - 0.006 in)

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 specication.

Engine Oil Capacity

2.1 L (2.2 US·qt)

FX801V FX751V

[when oil lter is not removed]

2.3 L (2.4 US·qt)

[when oil lter is removed]

GENERAL INFORMATION 11

12 FUEL AND OIL RECOMMENDATIONS

FUEL AND OIL RECOMMENDATIONS

Fuel

Use only clean, fresh, unleaded regular grade gasoline.

NOTICE

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.

NOTE

○If “knocking” or “pinging” occurs, use a different

brand of gasoline or higher octane rating.

○When not operating your kawasaki engine more

than once per month, you can mix a fuel stabilizer

with gasoline in the fuel tank. Fuel stabilizer

additive could inhibit oxidation of fuel.

Oxygenated Fuel

Oxygenates (either ethanol or MTBE) are added to the gasoline. If you use the oxygenates, be sure it is unleaded and meets the minimum octane rating requirement.

The followings are the EPA approved percentages of fuel oxygenates.

ETHANOL: (Ethyl or Grain Alcohol)

You may use gasoline containing up to 10%

ethanol by volume.

MTBE: (Methyl Tertiary Butyl Ether)

You may use gasoline containing up to 15% MTBE

by volume.

METHANOL: (Methyl or Wood Alcohol)

You may use gasoline containing up to 5%

methanol by volume, as long as it also contains

cosolvents and corrosion inhibitors to protect the

fuel system. Gasoline containing more than 5%

methanol by volume may cause starting and/or

performance problems. It may also damage metal,

rubber, and plastic parts of your fuel system.

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