Kawasaki FD620D FD661D 4-Stroke Liquid-Cooled V-Twin Gasoline Engine Service Repair Manual INSTANT

Kawasaki FD620D FD661D 4-stroke liquid-cooled v-twin gasoline engine Service Manual

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This quick reference guide will assist you in locating a desired topic or procedure. • Bend the pages back to match the black tab of the desired chapter number with the black tab on the edge at each table of contents page. e Refer to the sectional table of contents for the exact pages to locate the specific topic required. Quick Reference Guide General Information Fuel System Cooling System Engine Top End Lubrication m Camshaft I Crankshaft Electric System Trouble Shooting

Kawasaki FD620D FD661D 4-stroke liquid cooled v-twin gasoline engine Service Manual All rights reserved. No parts 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 Quality Assurance Department/Consumer Products & Machinery Group/Kawasaki Heavy Industries, Ltd., Japan. No liability can be accepted for any inaccuracies or omissions in this publication, although every possible care has been taken to make it as complete and accurate as possible. The right is reserved to make changes at any time without prior notice and without incurring an obligation to make such changes to products manufactured previously. All information contained in this publication is based on the latest product information available at the time of publication. Illustrations and photographs in this publication are intended for reference use only and may not depict actual model component parts. © Kawasaki Heavy Industries, Ltd. 1996, 1999 Third Edition (1): Dec.7,1999 (K)

A ABDC AC ATDC BBDC BDC BTDC ·c DC F ·F ft g h L WARNING CONTAINS ASBESTOS Breathing asbestos dust is dangerous to health Follow safety instructions This warning may apply to any of the following components or any assembly containing one or more of these components:- Brake Shoes or Pads Clutch Friction Material Gaskets Insulators SAFETY INSTRUCTIONS eOperate if possible out of doors or in a well ventilated place. • Preferably use hand tools or low speed tools equipped, if necessary, with an appropriate dust extraction facility. If high speed tools are used, they should always be so equipped. elf possible, dampen before cutting or drilling. • Dampen dust and place it in properly closed receptacle and dispose of it safely. LIST OF ABBREVIATIONS ampere(s) lb pound(s) after bottom dead center m meter(s) alternating current min minute(s) after top dead center N newton(s) before bottom dead center Pa pascal(s) bottom dead center PS horsepower before top dead center psi pound(s) per square inch degree(s) Celsius r revolution direct current rpm revolution(s) per minute farad (s) TDC top dead center degree(s) Fahrenheit TIR total indicator reading foot, feet v volt(s) gram(s) w watt(s) hour(s) n ohm(s) liter(s) Read OWNER'S MANUAL before operating.

Foreword This manual is designed primarily for use by trained mechanics in a properly equipped shop. However, it contains enough detail and basic information to make it useful to the owner who desires to perform his own basic maintenance and repair work. A basic knowledge of mechanics, the proper use of tools, and workshop procedures must be understood in order to carry out maintenance and ·repair satisfactorily. Whenever the owner has insufficient experience or has doubts as to his ability to do the work, all adjustments, maintenance, and repair should be carried out only by qualified mechanics. In order to perform the work efficiently and to avoid costly mistakes, read the text. thoroughly familiarize yourself with the procedures before starting work, and then do the work carefully in a clean area. Whenever special tools or equipment are specified, do not use makeshift tools or equipment. Precision measurements can only be made if the proper instruments are used, and the use of substi- tute tools may adversely affect safe operation. To get the longest life out of your engine: • Follow the Periodic Maintenance Chart in the Service Manual. • Be alert for problems and non-scheduled maintenance. eUse proper tools and genuine Kawasaki engine parts. Genuine parts provided as spare parts are listed in the Parts Catalog. eFollow the procedures in this manual carefully. Don't take shortcuts. • Remember to keep complete records of maintenance and repair with dates and any new parts installed. How to Use this Manual In preparing this manual, we divided the product into its major systems. These systems became the manual's chapters. All information for a particular system from adjustment through disassembly and inspection is located in a single chapter. The Quick Reference Guide shows you all of the product's system and assists in locating their chapters. Each chapter in turn has its own compre- hensive Table of Contents. The Periodic Maintenance Chart is located in the General Information chapter. The chart gives a time schedule for required maintenance operations. If you want spark plug information, for example, go to the Periodic Maintenance Chart first. The chart tells you how frequently to clean and gap the plug. Next, use the Quick Reference Guide to locate the electric System chapter. Then, use the Table of Contents on the first page of the chapter to find the Spark Plug section. Whenever you see these WARNING and CAUTION symbols, heed their instructions! Always follow safe operating and maintenance practices. A 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 o.r destruction of equipment.

This manual contains four more symbols (in addition to WARNING and CAUTION) which will help you distinguish different types of information. NOTE o This note symbol indicates points of particular interest for more efficient and convenient operation. elndicates a procedural step or work to be done. o Indicates a procedural sub-step or how to do the work of the procedural step it follows. It also precedes the text of a WARNING, CAUTION, or NOTE. *Indicates a conditional step or what action to take based on the results of the test or inspection in the procedural step or sub-step it follows. In most chapters an exploded view illustration of the system components follows the Table of Contents. In these illustrations you will find the instructions indicating which parts require specified tightening torque, oil, grease or a locking agent during assembly.

GENERAL INFORMATION 1-1 General Information Table of Contents· Before Servicing .......................................................................................................... 1-2 Model Identification .................................................................................................... 1-5 General Specifications ................................................................................................1 -6 Periodic Maintenance Chart except U.S ...................................................................... 1 -7 Periodic Maintenance Chart for U.S ........................................................................... 1-8 Torque and Locking Agent ......................................................................................... 1-9

1-2 GENERALINFORMATION Before Servicing Before starting to service the engine, carefully read the applicable section to eliminate unnecessary work. Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been included wherever necessary. Nevertheless, even a detailed account has limitations, a certain amount of basic knowledge is required for successful work. Especially note the following: (1) Dirt Before removal and disassembly, clean the engine. Any dirt entering the engine, carburetor, or other parts, will work as an abrasive and shorten the life of engine. For the same reason, before installing a new part, clean off any dust or metal filings. (2) Battery Ground Remove the ground (-) lead from the battery before performing any disassembly operations on the equipment. This prevents: (a) the possibility of accidentally turning the engine over while partially disassembled. (b) sparks at electrical connections which will occur when they are disconnected. (c) damage to electrical parts. (3) Tightening Sequence Generally, when installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them evenly, in a staggered sequence. This is to avoid distortion of the part and/or causing gas or oil leakage. Conversely, when loosening the bolts, nuts, or screws, first loosen all of them by about a quarter of a turn and then remove them. Where there is a tightening sequence indication in this Service Manual, the bolts, nuts, or screws must be tightened in the order and method indicated. (4) Torque When torque values are given in this Service Manual, use them. Either too little or too much torque may lead to serious damage. Use a good quality, reliable torque wrench. (5) Force Common sense should dictate how much force is necessary in assembly and disassembly. If a part seems especially difficult to remove or install, stop and examine what may be causing the problem. Whenever tapping is necessary, tap lightly using a wooden or plastic-faced mallet. Use an impact driver for screws (particularly for the removal of screws held by a locking agent) in order to avoid damaging the heads. (6) Edges Watch for sharp edges, especially during major engine disassembly and assembly. Protect your hands with gloves or a piece of thick cloth when lifting the engine or turning it over. (7) High-Flash Point Solvent A high-flash point solvent is recommended to reduce fire danger. A commercial solvent commonly available in North America is Stoddard solvent (generic name). Always follow manufacturer and container directions regarding the use of any solvent. (8) Gasket, 0- Ring Do not reuse a gasket or 0-ring once it has been in service. The mating surfaces around the gasket should be free of foreign matter and perfectly smooth to avoid oil or compression leaks. (9) Liquid Gasket, Non-Permanent Locking Agent Follow manufacturer's directions for cleaning and preparing surfaces where these compounds will be used. Apply sparingly. Excessive amounts may block engine oil passages and cause serious damage. An example of a non-permanent locking agent commonly available in North America is Loctite Lock'n Seal (Blue). (1 0) Press A part installed using a press or driver, such as a journal, should first be coated with oil on its outer or inner circumference so that it will go into place smoothly. (11) Ball Bearing When installing a ball bearing , the bearing race which is affected by friction should be pushed by a suitable driver. This prevents severe stress on the balls and races, and prevents races and balls from being dented. Press a ball bearing until it stops at the stop in the hole or on the shaft.

Kawasaki FD620D FD661D 4-Stroke Liquid-Cooled V-Twin Gasoline Engine Service Repair Manual INSTANT

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