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Kawasaki FH680V - Owner's Manual

Other manuals for FH680V -: Service Manual, Service Manual, Service Manual, Datasheet
Manual is about: 4-Stroke Air-Cooled V-Twin Gasoline Engine

Summary of FH680V -

  • Page 1

    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 in- structions or procedures which, if not cor- rectly followed, could result in personal injury, or loss of li...

  • Page 2

    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...

  • Page 3

    Emission control information fuel information this engine is certified to operate on unleaded regular grade gasoline only. A min- imum 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 ...

  • Page 4

    * 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 30...

  • Page 5

    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 incorpo...

  • Page 6

    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...

  • Page 7

    Table of contents general information.............................. 8 location of safety related labels................. 8 location of parts ........................................... 9 engine serial number ................................... 10 tune-up specifications .................................

  • Page 8

    8 general information general information location of safety related labels a. Warning label b. Engine maintenance.

  • Page 9

    General information 9 location of parts a. Oil gauge/filler b. Oil filter c. Oil drain plugs d. Air cleaner/carburetor e. Control panel f. Spark plug caps/spark plugs g. Air inlet screen h. Fan housing k. Fuel pump l. Fuel tube m. Fuel filter i. Electric starter j. Voltage regulator.

  • Page 10

    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 specifications item specifications...

  • Page 11

    General information 11 engine oil capacity engine oil capacity 1.5 l (1.6 us·qt) [when oil filter is not removed] fh601v fh641v fh661v fh680v 1.7 l (1.8 us·qt) [when oil filter is removed] 1.5 l (1.6 us·qt) [when oil filter is not removed] fh721v 1.8 l (1.9 us·qt) [when oil filter is removed].

  • Page 12

    12 fuel and oil recommendations 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 in...

  • Page 13

    Fuel and oil recommendations 13 engine oil the following engine oils are recommended. Api service classification : sf, sg, sh, or sj. 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 14

    14 preparation 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 ap- plia...

  • Page 15

    Preparation 15 engine oil check the engine oil daily before starting the en- gine otherwise shortage of the engine oil may cause serious damage to the engine such as seizure. • place the engine on level surface. Clean area around the oil gauge before removing it. • remove the oil gauge (a) and wipe ...

  • Page 16

    16 starting starting start 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 ma- terials and cause a fire. Keep the area aroun...

  • Page 17

    Starting 17 a. Fuel valve a. Throttle lever a. Throttle lever.

  • Page 18

    18 starting • put the switch key (a) into the engine switch. • turn the switch key to the start position on the equipment. Normally the engine will start within 3 seconds. Caution do not run the electric starter continuously for more than 5 seconds, otherwise the bat- tery may discharge quickly. If ...

  • Page 19

    Operating 19 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, mo...

  • Page 20

    20 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...

  • Page 21

    Stopping 21 stopping stopping the engine ordinary stop • move 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 spe...

  • Page 22

    22 adjustment adjustment two types of choke control are used for fh601v, fh641v, fh661v, fh661v, fh680v, fh721v model engines. Associated choke type throttle cable installation, adjustment make sure that the throttle lever on the equipment links to the engine with the throttle cable. • leave the cab...

  • Page 23

    Adjustment 23.

  • Page 24

    24 adjustment separate choke type 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 “fast” position. • pull up the outer housing (f) o...

  • Page 25

    Adjustment 25.

  • Page 26

    26 adjustment engine speed adjustment note ○ do not tamper with the governor setting or the car- buretor setting or the carburetor setting to increase the engine speed. Every carburetor is adjusted at the factory and a cap or a stop plate is installed on each mixture screw. ○ if any adjustment is ne...

  • Page 27

    Maintenance 27 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 pre...

  • Page 28

    28 maintenance interval maintenance daily first 8 hr. Every 25 hr. Every 50 hr. Every 100 hr. Every 200 hr. Every 250 hr. Every 300 hr. Every 500 hr. ♦clean air cleaner paper element • ♦check or clean air inlet screen. • ♦ k clean dust and dirt from cylinder and cylinder head fins. • tighten nuts an...

  • Page 29

    Maintenance 29 oil level check check the oil level daily and before each time of operation. Be sure the oil level is maintained. See preparation chapter. Engine oil capacity 1.5 l (1.6 us·qt) [when oil filter is not removed] fh601v fh641v fh661v fh680v 1.7 l (1.8 us·qt) [when oil filter is removed] ...

  • Page 30

    30 maintenance oil change change oil after first 8 hours of operation. There- after change oil every 100 hours. • run the engine to warm oil. • be sure the engine (equipment) is on level sur- face. • stop the engine. • remove the oil drain plug and drain the oil into a suitable container while engin...

  • Page 31

    Maintenance 31 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. Caution before remov...

  • Page 32

    32 maintenance warning engine oil is a toxic substance. Dispose of used oil properly. Contact your local author- ities for approved disposal methods or pos- sible recycling. Air cleaner service caution do not run the engine with the air cleaner removed. Foam element clean the foam element (a) every ...

  • Page 33

    Maintenance 33 paper element clean the paper element (b) every 100 hours. • clean the element by tapping gently to remove dust. If very dirty, replace the element with a new one. • replace with a new paper element yearly or 200 hours, whichever comes first. Note ○ operating in a dusty condition may ...

  • Page 34

    34 maintenance a. Retaining clamps b. Case c. Air cleaner body f. Cap (dust ejector valve) d. Primary element e. Secondary element • install the new air cleaner elements into the air cleaner body. • reinstall the case and the cap (f) then securely fasten the two retaining clamps..

  • Page 35

    Maintenance 35 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 ...

  • Page 36

    36 maintenance a. Spark plug gap b. Electrodes cooling system cleaning before each operation, check that the air inlet (ro- tary) screen (a) is free from grass and debris. Clean the screen if necessary. Every 100 hours of oper- ation, check and clean the cooling fins and the in- side of engine shrou...

  • Page 37

    Maintenance 37.

  • Page 38

    38 storage storage fuel system draining engine to be stored over 30 days should be com- pletely drained of fuel to prevent gum deposits form- ing on essential carburetor parts, the fuel filter and the tank. Warning gasoline is extremely flammable and can be explosive under certain conditions. Drain ...

  • Page 39

    Storage 39 • 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 turn- ing the engine a few times. Slowly turn the engine until you feel the compression then leave it there. This traps the air inside the c...

  • Page 40

    40 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 insufficient compression faulty pistons, cylinders, piston rings, and head gask...

  • Page 41

    Troubleshooting guide 41 symptom probable cause remedy faulty spark plugs replace spark plugs faulty ignition coils k no spark or weak spark engine switch is in "off" position turn engine switch to "start" position (see m) clogged air cleaner clean air inlet screen or cooling air path clogged with d...

  • Page 42

    42 environmental protection environmental protection to protect our environment, properly dispose of used batteries, engine oil, gasoline, coolant, or other com- ponents that you might discard. Consult your authorized kawasaki dealer or local environmental waste agency for the proper disposal pro- c...

  • Page 43

    Specifications 43 specifications fh601v, fh641v, fh661v, fh680v fh721v type air- cooled, 4-stroke ohv, v-twin cylinder, gasoline engine bore x stroke 75.2 x 76 mm (2.96 x 2.99 in.) displacement 675 ml (41.19 cu.In) ignition system solid-state ignition direction of rotation counterclockwise facing th...

  • Page 44

    44 wiring diagram wiring diagram wiring diagram (with 12 v - 13 a charging coil) warning for electrical safety, always remove cable from negative (–) side of battery before at- tempting any repair or maintenance. Battery capacity recommended model battery capacity lawn mower 12 v 200 cca class snow ...