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Kawasaki FX801V Owner's Manual

4-stroke air-cooled v-twin gasoline engine.
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4-Stroke Air-Cooled V-Twin Gasoline Engine
Part No. 99920-2231-05


Table of Contents

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  • Page 1 FX801V FX751V 4-Stroke Air-Cooled V-Twin Gasoline Engine OWNER’S MANUAL Part No. 99920-2231-05...
  • Page 2 SAFETY AWARENESS Whenever you see the symbols shown below, heed CAUTION their instructions! Always follow safe operating and maintenance practices. CAUTION indicates a hazardous situation which, if not avoided, could result in minor or DANGER moderate injury. DANGER indicates a hazardous situation which, if not avoided, will result in death or serious NOTICE injury.
  • Page 3 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.
  • Page 4: Emission Control Information

    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.
  • Page 5 The Kawasaki Limited Emission Control System Warranty requires that you return your engine to an autho- rized Kawasaki dealer for remedy under warranty. Please read the warranty carefully, and keep it valid by complying with the owner’s obligations it contains.
  • Page 6 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...
  • Page 7 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.
  • Page 8: Table Of Contents

    TABLE OF CONTENTS GENERAL INFORMATION......Choke Cable Installation, Adjustment ..Location of Safety Related Labels....Engine Speed Adjustment......MAINTENANCE ..........Location of Parts ........... Engine Serial Number ........Periodic Maintenance Chart ......Tune-up Specifications ........Oil Level Check ..........Engine Oil Capacity ........Oil Cooler Service .........
  • Page 9: General Information

    GENERAL INFORMATION GENERAL INFORMATION Location of Safety Related Labels A. Warning Label B. Engine Maintenance...
  • Page 10: Location Of Parts

    GENERAL INFORMATION Location of Parts 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.
  • Page 11: Engine Serial Number

    GENERAL INFORMATION Engine Serial Number Tune-up Specifications The engine serial number is your only means of ITEM Specifications identifying your particular engine from others of the Ignition Timing Unadjustable same model type. This engine serial number is needed by your Spark Plugs: NGK BPR4ES dealer when ordering parts.
  • Page 12: Engine Oil Capacity

    GENERAL INFORMATION Engine Oil Capacity Engine Oil Capacity 2.1 L (2.2 US qt) [when oil filter is not removed] FX801V FX751V 2.3 L (2.4 US qt) [when oil filter is removed]...
  • Page 13: Fuel And Oil Recommendations

    FUEL AND OIL RECOMMENDATIONS FUEL AND OIL RECOMMENDATIONS ETHANOL: (Ethyl or Grain Alcohol) Fuel You may use gasoline containing up to 10% ethanol by volume. Use only clean, fresh, unleaded regular grade MTBE: (Methyl Tertiary Butyl Ether) gasoline. You may use gasoline containing up to 15% MTBE by volume.
  • Page 14: Engine Oil

    FUEL AND OIL RECOMMENDATIONS 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.
  • Page 15: Preparation

    PREPARATION PREPARATION Place the engine on level surface before fueling. Fuel Remove the fuel tank cap. Slowly pour fuel into the tank through the fuel strainer. WARNING Close the tank cap securely. Gasoline is extremely flammable and can be explosive under certain conditions, creating the potential for serious burns.
  • Page 16: Engine Oil

    Install and tighten the oil gauge. B. Tube Engine Oil Capacity NOTICE 2.1 L (2.2 US qt) [when oil filter is not removed] FX801V The engine is shipped without engine oil. FX751V 2.3 L (2.4 US qt) [when oil filter is removed]...
  • Page 17: Starting

    STARTING STARTING Use proper oil for expected temperature (See Start Engine FUEL AND OIL RECOMMENDATIONS chapter). Use fresh gasoline. Protect the engine or the equipment from direct DANGER exposure to weather when not in operation. Before starting the engine, disconnect all possible Exhaust gas contains carbon monoxide, a external loads.
  • Page 18 STARTING A. Throttle Lever A. Fuel Valve A. Throttle Lever...
  • Page 19 STARTING NOTICE NOTICE Put the switch key into the engine switch. Turn the switch key to the START position on the Do not run the electric starter continuously equipment. Normally the engine will start within 3 for more than 5 seconds, otherwise the bat- seconds.
  • Page 20: Operating

    OPERATING OPERATING NOTICE NOTICE Warming Up Allow engine to warm up sufficiently (3 to 5 minutes at idle) before applying a load. This After the engine starts, move the throttle lever will allow oil to reach all engine parts, and on the equipment to halfway between "FAST"...
  • Page 21: Engine Inclination

    OPERATING Engine Inclination This engine will operate continuously at angles up to 25 in any direction. Refer to the operating instructions of the equip- ment this engine powers. Because of equipment design or application, there may be more stringent restrictions regarding the angle of operation. NOTICE NOTICE Do not operate this engine continuously at...
  • Page 22: Stopping

    STOPPING STOPPING Close the fuel valve on the equipment. Stopping the Engine 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 ignition off. Ordinary Stop Move throttle lever to "SLOW"...
  • Page 23: Adjustment

    ADJUSTMENT ADJUSTMENT Move the equipment choke control to "CHOKE" Separate Choke Type position. Make sure that the carburetor choke valve (pivot arm) is completely closed. Make sure that the choke valve turns from fully Throttle Cable Installation, Adjustment close position to fully open position when actuating Link the throttle cable to the speed control lever the equipment choke control.
  • Page 24: Engine Speed Adjustment

    If any adjustment is necessary, see your autho- rized Kawasaki Engine dealer to perform the ad- justment. E. Throttle Valve Pivot Arm...
  • Page 25: Maintenance

    The service intervals indicated are to 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. INTERVAL MAINTENANCE First 8...
  • Page 26 MAINTENANCE INTERVAL MAINTENANCE First 8 Every Every Every Every Every Daily 100 hr. 200 hr. 250 hr. 300 hr. 500 hr. Tighten nuts and screws. Change engine oil. Check and clean oil cooler fins. Clean and regap spark plugs. Change oil filter. Replace air cleaner primary element.
  • Page 27: Oil Level Check

    Clean dirt off the outside fins with a brush or com- PREPARATION chapter. pressed air. Engine Oil Capacity 2.1 L (2.2 US qt) [when oil filter is not removed] FX801V FX751V 2.3 L (2.4 US qt) [when oil filter is removed] Oil Cooler Fins A. Oil Gauge...
  • Page 28: Oil Change

    MAINTENANCE Install the oil drain plug. Oil Change Remove the oil gauge and refill with fresh oil (See FUEL AND OIL RECOMMENDATIONS chapter). Change oil after first 8 hours of operation. There- Check the oil level (see PREPARATION chapter). after change oil every 100 hours. WARNING Run the engine to warm oil.
  • Page 29: Oil Filter Change

    MAINTENANCE 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 the engine oil into a suitable container. NOTICE A.
  • Page 30: Air Cleaner Service

    MAINTENANCE NOTE Air Cleaner Service Operating in dusty condition may require more fre- quent maintenance. NOTICE Primary Element Do not run the engine with the air cleaner Replace the primary element every 250 hrs. removed. Secondary Element Replace the secondary element with a new one, Air Cleaner if the secondary element is dirty when the primary This air cleaner elements are not recommended to...
  • Page 31 MAINTENANCE Install the new air cleaner elements into the air cleaner body. Reinstall the case and the cap then securely fasten the two retaining clamps. D. Primary Element E. Secondary Element A. Retaining Clamps B. Case C. Air Cleaner Body F.
  • Page 32: Fuel Filter And Fuel Pump Service

    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 sol- vents 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 ap- pliances with a pilot light.
  • Page 33: Spark Plug Service

    MAINTENANCE RECOMMENDED SPARK PLUG Spark Plug Service NGK ........BPR4ES WARNING Engines can become extremely hot during normal operation. Hot engine components can cause severe burns. Stop the engine and allow it to cool before checking spark plugs. Clean or replace the spark plugs and reset the gap every 100 hours of operation.
  • Page 34: Cooling System Cleaning

    MAINTENANCE Cooling System Cleaning Before each operation, check that the air inlet (ro- tary) screen is free from grass and debris. Clean the screen if necessary. Every 100 hours of opera- tion, check and clean the cooling fins and the inside of engine shrouds to remove grass, chaff or dirt clogging the cooling system and causing overheating.
  • Page 35: Storage

    STORAGE STORAGE Install the sediment bowl. Fuel System Draining Put a pan under the carburetor and loosen the drain screw of the carburetor to drain the gasoline Engine to be stored over 30 days should be com- completely. pletely drained of fuel to prevent gum deposits form- Tighten the drain screw.
  • Page 36 STORAGE Remove the spark plugs and pour approx 1 - 2 mL (0.06 - 0.1 cu in.) of engine oil through the spark plug holes then screw the spark plugs in after turning the engine a few times. Slowly turn the engine until you feel the compression then leave it there.
  • Page 37: Troubleshooting Guide

    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. Symptom Probable Cause Remedy Engine won’t Insufficient Faulty pistons, cylinders, piston rings, start or output is compression and head gaskets Faulty valves...
  • Page 38 Faulty governor won t increase K : Service to be performed by an authorized Kawasaki dealer. M : For Control Panel Switch Type, move the throttle lever on the equipment away from its low speed end to turn the engine switch to "START" position.
  • Page 39: Environmental Protection

    To help preserve the environment, properly discard used batteries, oils and fluids, or other engine components that you might dispose of in the future. Consult your authorized Kawasaki dealer or local environmental waste agency for their proper disposal procedure. This also applies to disposal of the entire engine at the end of its life.
  • Page 40: Specifications

    SPECIFICATIONS SPECIFICATIONS FX801V, FX751V Type Air- cooled, 4-stroke OHV 4Valves, V-twin cylinder, gasoline engine Bore x Stroke 84.5 x 76 mm (3.33 x 2.99 in.) Displacement 852 mL (52 Ignition System Solid-state ignition Direction of rotation Counterclockwise facing the PTO Shaft...
  • Page 41: Wiring Diagram

    Model Battery Capacity Lawn Mower 12 V 550 CCA Class Snow Thrower 12 V 550 CCA Class NOTE Portion surrounded by hatching shows Kawasaki procurement parts. A. Flywheel F. Key Switch B. Ignition Coils G. Fuse C. Charging Coil H. Voltage Regulator D.
  • Page 42 For repair/warranty assistance please contact Gasoline is a toxic substance. your local Kawasaki Authorized Dealer, email Dispose of gasoline properly. or call Contact your local authorities for toll-free 1-877-364-6404...

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