Kawasaki FR651V 4 Stroke Air Cooled V Twin Gasoline Engine Owner’s Manual

Kawasaki FR651V 4 Stroke Air Cooled V Twin Gasoline Engine

SAFETY AWARENESS

• Whenever you see the symbols shown below, heed their instructions! Always follow safe operat- ing 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 that, if not strictly observed, could result in damage to, or destruction of equipment.

NOTE

• This note symbol indicates points of particular interest for more efficient and convenient operation.

READ THE OPERATING INSTRUCTIONS OF THE EQUIPMENT THIS ENGINE POWERS. 2008 Kawasaki Heavy Industries, Ltd. (1): Dec. 2010. (M)

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 conditions.
• Stop the engine and allow the engine to cool before refueling.
• DO NOT smoke. Make sure the area is well-ventilated and free from any source of flame or sparks including the pilot lamp of any appliance while refueling, servicing fuel system, draining gasoline, and/or adjusting the carburetor.
• DO NOT fill the tank so the fuel level rises into the filler neck or level surface of the level gauge. If the tank is overfilled, heat may cause the fuel to expand and overflow through the vents in the tank cap.
• Wipe off any spilled gasoline immediately.

To prevent fire hazard:

• Keep the engine at least 1 m (3.3 ft) away from buildings, obstructions, and other burnable objects.
• DO NOT place flammable 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 a spark arrester is installed on the muffler.
• 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 muffler. The engine becomes hot during operation. Before you service or remove parts, stop the engine and allow the engine to cool.
• DO NOT place hands or feet near moving or rotating parts. Place a protective cover over the pulley, V belt or coupling
• DO NOT run the 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 that 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

• FUHIS 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 sys-
• tem 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 en- gine.

Engine Emissions Compliance Period California

• Engines Greater Than or Equal To 225 cc
• Model Year – 2008 and later
• Durability Period – 250 hours

All Other States Engines Greater Than or Equal To 225 cc

• Model Year – 2011 and later
• Durability Period – 250 hours (Category C)

If your engine has an assigned emissions durability period it will be located on the certification label attached to the engine (IMPORTANT ENGINE INFORMATION).

High Altitude Performance Adjustment Information
To improve the EMISSIONS CONTROL PERFORMANCE of engines operated above 1,000 meters (3,300 feet), Kawasaki recommends the following Environmental Protection Agency (EPA) and the California Air Re- sources Board (CARB) approved modifications. However, the model with DFI (Digital Fuel Injection system) does not require high altitude performance ad- justment.
NOTE
When properly performed, these specified modifications only are not considered to be emissions system “tampering” and engine performance is generally unchanged as a result.
Maintenance and Warranty
Proper maintenance is necessary to ensure that your engine will continue to have low emission levels. This Owner’s Manual contains maintenance recommendations for your engine. Those items identified 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 dealer for a 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 prohibit 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 emission control before 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 filter element
• Air cleaner elements
• Crankcase
• Cylinder heads
• Breather chamber and internal parts
• Intake pipe and tube
• A muffler or any internal portion of the muffler

FOREWORD

• This Owner’s Manual is 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 following this Owner’s Manual.
• Please note that the photographs and illustrations shown in this manual are made based on Model FR730V as a typical example among other similar models.
• All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise, without the prior written permission of Kawasaki Heavy Industries, Ltd.,
• Motorcycle & Engine Company. Although every possible care has been taken to make this manual as complete and accurate as possible, Kawasaki cannot guarantee against errors and omissions.
• Due to improvements in design and performance during production, procedures and specifications are subject to change without prior notice. Illustrations are provided for general reference purposes, and may differ from actual product aspects and components.

GENERAL INFORMATION

Label Location

1. Warning Label
2. Important Engine Information Label
3. Engine Maintenance Label
4. 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.

Parts Location

• 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. Carburetor
• G. Fuel Pump
• H. Fuel Filter
• I. Electric Starter

Specifications

Tune-up Specifications

NOTE

• High and low idle speeds may vary depending on the equipment on which the engine is used. Refer to the equipment specification.

Engine Oil Capacity

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.

• Antiknock Index: (RON + MON)/2
• RON = Research Octane Number
• MON = Motor Octane Number
• NOTE: Olf “knocking or pinging” occurs, use a different brand of gasoline or higher octane rating.

Oxygenated Fuel

• Oxygenates (either ethanol or MTBE) are added to the gasoline.
• If you use the oxygenated fuel be sure it is unleaded and meets the minimum octane rating requirement.
• The following 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) 5% by volume 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 the metal, rubber, and plastic parts of your fuel system.

Engine Oil

• The following engine oils are recommended.
• API Service Classification: SF, SG, SH, SJ or SL.

Oil Viscosity

• Choose the viscosity according to the temperature as follows:

NOTE

• Using multi-grade oils (5W-20, 10W-30, and 10W-40) will increase oil consumption. Check oil levels more frequently when using them.

PREPARATION

Fuel WARNING

• Gasoline is extremely flammable and can be explosive under certain conditions.
• Before refueling, turn the engine switch to the “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 the 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 the tank cap.
• After refueling make sure the tank cap is se- curely closed.
• If gasoline is spilled, wipe it up immediately.

Engine Oil
Check the engine oil daily before starting the engine otherwise shortage of engine oil may cause serious damage to the engine such as seizure.

• Place the engine on level surface. Clean the area around the oil gauge before removing it.
• Remove the oil gauge (A) and wipe it with a clean cloth.
• Pour the oil slowly to the “FULL” mark on the oil gauge.
• Insert the oil gauge into tube (B) WITHOUT SCREWING IT IN.
• Remove the oil gauge (A) to check the oil level. The level should be between “ADD” and “FULL” marks. Do not overfill.
• Install and tighten the oil gauge (A).

CAUTION

• Do not fill above the “FULL” mark. Excess oil will cause a smoking condition and may cause the engine to overheat.

Engine Oil Capacity

CAUTION: The engine is shipped without engine oil.

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.
• NOTE
  • Be aware of the following to start the engine easily in cold weather.
  • Use proper oil for expected temperature (See “FUEL AND OIL RECOMMENDATIONS” chapter). Use fresh gasoline.
  • Protect the engine or the equipment from direct exposure to weather when not in operation.
• NOTE
  • Follow the operating instructions of the equipment this engine powers.
  • Before starting the engine, disconnect all possible external loads.
  • Open the fuel valve (A) on the equipment.
  • Move the throttle lever on the dash to the half-throttle position.
  • Use full choke when the engine is cold, but in hot weather or when the engine is already warm, use half choke or leave the choke fully open.
  • Put the switch key into the engine switch.
  • Turn the switch key to the START position on the equipment. Usually, the engine will start within 3 seconds.
• CAUTION
  • Do not run the electric starter continuously for more than 5 seconds, otherwise the battery may discharge quickly.
  • If the engine does not start right away, wait 15 seconds and try again.

OPERATING

Warming Up

• 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.

CAUTION

• Allow the engine to warm up sufficiently (3 to 5 minutes at idle) before applying a load.
• This will allow oil to reach all engine parts, and allow piston clearance to reach design specifications.

CAUTION

• While warming up the engine, make sure the warning lamp (oil pressure) on the dash is not on.
• The warning lamp must not be illuminated during engine operation (if equipped).

Engine Inclination

• This engine will operate continuously at angles up to 25° in any direction.
• Refer to the operating instructions of the equipment this engine powers. Because of equipment design or application, there may be more stringent restrictions regarding the angle of operation.

CAUTION

• Do not operate this engine continuously at angles exceeding 25° in any direction. En- gine damage could result from insufficient lubrication.

Stopping the Engine

• WARNING
  • Always remove the Engine Key from the switch when leaving equipment unattended or when equipment is not in use.
• Ordinary Stop
  • Move the throttle lever (A) to the “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 the engine is stopped suddenly from highspeed loaded operation. Reduce engine speed to idle for one minute before shutting the engine off.
  • Turn the engine switch or the switch key to the “OFF” position.
  • For Control Panel Switch Type, move the throttle lever against its low-speed end to turn the ignition off.
• Emergency Stop
  • Immediately turn the engine switch or the switch key to the “OFF” position.
  • Close the fuel valve on the equipment.
  • For Control Panel Switch Type, move the throttle lever on the equipment to its low-speed end. Moving the lever to its low-speed end turns the ignition off.
• Emergency Stop
  • Immediately turn the engine switch or the switch key to the “OFF” position.
  • Close the fuel valve on the equipment.
  • For Control Panel Switch Type, move the throttle lever on the equipment to its low-speed end.
  • Moving the lever to its low-speed end turns the ignition off.

ADJUSTMENT

Throttle Cable Installation, Adjustment

• Link the throttle cable (G) to the speed control lever (C) and loosely clamp the throttle cable outer housing (F) with the cable clamp bolt (A).
• Move the throttle lever to the “FAST” position.
• Pull up the outer housing (F) of the throttle cable until the inner wire (G) has almost no slack, and tighten the cable clamp bolt (A).
• Move the throttle lever to the “SLOW” position. Make sure that the carburetor throttle valve (H) is moved smoothly.
• Choke Cable Installation, Adjustment
• Link the choke cable (K) to the choke control lever (D), and loosely clamp the choke cable outer housing (L) with the cable clamp bolt (B).
• Move the equipment choke control to the “OPEN” position. Make sure that the carburetor choke valve (1) is fully opened.
• Pull up the outer housing (L) of the choke cable until the inner wire (K) has almost no slack, and tighten the cable clamp bolt (B).
• Move the equipment choke control to the “CHOKE” position. Make sure that the carburetor choke valve (1) is completely closed.
• Make sure that the choke valve turns from a fully closed position to a fully opened position when operating the equipment choke control.

Engine Speed Adjustment

• NOTE
  • Do not tamper with the governor setting or the carburetor setting to increase the engine speed.
  • Ev-ery carburetor is adjusted at the factory and a cap or stop plate is installed on each mixture screw.
  • Olf any adjustment is necessary, it must be performed by your authorized Kawasaki Engine dealer.

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.
  • K: Service to be performed by an authorized Kawasaki dealer.

Oil Level Check

• Check oil level daily and before each time of operation. Be sure the oil level is maintained. See the “PREPARATION” chapter.

Engine Oil Capacity

Oil Change

• Change oil after the first 8 hours of operation. Thereafter changing oil every 100 hours.
• Run the engine to warm the oil.
• Be sure the engine (equipment) is level. Stop the engine.
• Remove the oil drain plugs (A) and drain the oil into a suitable container while the engine is warm.

WARNING

• Hot engine oil can cause severe burns.
• Allow engine temperature to drop from hot to warm level before draining and handling oil.
• Install the oil drain plugs.
• Remove oil gauge and refill with fresh oil (See “FUEL AND OIL RECOMMENDATIONS” chapter).
• Check the oil level (See “PREPARATION” chapter for oil level check).

WARNING

• Engine oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods or possible recycling.

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 the oil filter.
• Drain engine oil into a suitable container (C).

CAUTION

• Before removing the oil filter, place a suitable pan under the filter connection.
• Rotate the oil filter (A) counterclockwise to remove it.
• Coat a film of clean engine oil on the seal of a new filter. Install new filter rotating it clockwise until seal contacts mounting surface (B). Then rotate the filter 3/4 turn more by hand.
• Supply engine oil as specified.
• Run the engine for about 3 minutes, stop the engine, and check the oil leakage around the filter.
• Add oil to compensate for oil level drop due to oil filter capacity (See “PREPARATION” chapter for oil level check).

WARNING

Engine oil is a toxic substance. Dispose of used oil properly. Contact your local authorities for approved disposal methods or possible recycling.

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 conditions may require more frequent maintenance than above.

CAUTION

• Do not wash paper elements.
• Do not oil paper element.
• Do not use pressurized air to clean paper elements.

Spark Plug Service

• WARNING
  • Hot engine components can cause severe burns.
  • Stop the engine and allow it to cool before checking the 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 them with a wire brush to remove carbon deposits.
  • Inspect for cracked porcelain or other wear and damage. Replace the spark plug with a new one if necessary.
  • Check the spark plug gap and reset it if necessary.
  • The gap must be 0.75 mm (0.030 in). To change the gap, bend only the side-electrode, using a spark plug tool.
  • Install and tighten the spark plugs to 22 N•m (2.2 kgf•m, 16 ft-lb). Connect the spark plug caps.
• RECOMMENDED SPARK PLUG
  • NGK BPR4ES
  • 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.

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).

CAUTION

• Do not run the engine before all cooling system parts are reinstalled to keep cooling and carburetion as intended.

CAUTION

• Bend the engine shroud (regulator side) [A] only within the shown range [B] (70°).

[Bolts Size, Tightening Torque]

Fuel System Draining

• Engines to be stored over 30 days should be completely drained of fuel to prevent gum deposits from forming on essential carburetor parts, fuel filters, and fuel tanks.

WARNING

• Gasoline is extremely flammable and can be explosive under certain conditions.
• Drain fuel before storing the equipment for extended periods.
• Drain fuel in a well-ventilated area away from any source of flame or sparks, including any appliances with a pilot lamp. Store fuel in an approved container in a safe location.
• Clean every part of the engine.
• Be sure that the engine switch or switch key is positioned at “OFF”
• Close the fuel valve and remove the sediment bowl.
• Put a pan under the fuel valve to receive the drained fuel, and open the fuel valve to drain the fuel from the fuel tank completely.
• Install the sediment bowl and open the fuel valve.
• To remove the fuel from the carburetor, run the engine to use up the fuel in the carburetor.
• Remove the spark plugs and pour approx. 1 ~ 2 mL (0.06 ~ 0.1 cu. in.) of engine oil through the spark plug holes (A) and then screw the spark plugs in after turning the engine a few times.
• Slowly turn the engine until you feel compression and then leave it there. This blocks the air inside the cylinder and prevents rust inside the engine. Wipe the body with oily cloth.
• Wrap the engine with plastic sheeting and store it in a dry place.
• Change engine oil for next use after a period of storage (refer to the “Oil Change” section in the “MAINTE- NANCE” chapter).

WARNING

• Gasoline is a toxic substance. Dispose of gasoline properly. Contact your local authorities for approved disposal methods.

TROUBLESHOOTING GUIDE

If the engine malfunctions, carefully examine the symptoms and the operating conditions and use the table below as a guide to troubleshooting.

• K: Service to be performed by an authorized Kawasaki dealer.
• M: For the Control Panel Switch Type, move the throttle lever on the equipment away from its low-speed end to turn the engine switch to the “START” position.

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 disposal procedure.

SPECIFICATIONS

NOTE

• Specifications are subject to change without notice.
• Dry weight excludes that of the fuel tank and muffler.

WIRING DIAGRAM

NOTE

• Portion Surrounded by Hatching Shows Kawasaki Procurement Parts.

WARNING

• For electrical safety, always remove the cable from the negative (-) side of the battery before attempting any repair or maintenance.

Battery Capacity Recommended

• Battery Capacity
• 12 V 550 CCA Class

WARNING:
The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

• For repair/warranty assistance please contact your local Kawasaki Authorized Dealer,
• email kawpower-website@kmc-usa.com
• or call toll-free 1-877-364-6404
• Engine oil is a toxic substance.
• Dispose of used oil properly.
• Contact your local authorities for approved disposal methods or possible recycling.
• Gasoline is a toxic substance. Dispose of gasoline properly.
• Contact your local authorities for approved disposal methods.
• Part No. 99920-2249-04

References

• USA Location information - USA.com
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