Kawasaki FD791D (DFI) 4-Stroke Liquid-Cooled V-Twin Gasoline Engine Service Repair Manual

4–strokeliquid-cooledv-twingasolineengine

ServiceManual

Allrightsreserved.Nopartsofthispublicationmaybereproduced,storedinaretrievalsystem,ortransmittedinany formorbyanymeans,electronicmechanicalphotocopying,recordingorotherwise,withoutthepriorwrittenpermissionof QualityAssuranceDepartment/ConsumerProducts&MachineryCompany/KawasakiHeavyIndustries,Ltd.,Japan.

Noliabilitycanbeacceptedforanyinaccuraciesoromissionsinthispublication,althougheverypossiblecarehasbeen takentomakeitascompleteandaccurateaspossible.

Therightisreservedtomakechangesatanytimewithoutpriornoticeandwithoutincurringanobligationtomakesuch changestoproductsmanufacturedpreviously.

Allinformationcontainedinthispublicationisbasedonthelatestproductinformationavailableatthetimeofpublication. Illustrationsandphotographsinthispublicationareintendedforreferenceuseonlyandmaynotdepictactualmodel componentparts. ©KawasakiHeavyIndustries,Ltd.,2000,2001

LISTOFABBREVIATIONS

A ampere(s) lb pound(s)

ABDC afterbottomdeadcenter m meter(s)

AC alternatingcurrent min minute(s)

ATDC aftertopdeadcenter

newton(s)

BBDC beforebottomdeadcenter Pa pascal(s)

BDC bottomdeadcenter PS horsepower

BTDC beforetopdeadcenter psi pound(s)persquareinch

C degree(s)Celsius

revolution

DC directcurrent rpm revolution(s)perminute

F farad(s)

topdeadcenter

totalindicatorreading ft foot,feet

F degree(s)Fahrenheit

g gram(s)

volt(s)

watt(s)

h hour(s) ohm(s)

L liter(s)

ReadOWNER’SMANUALbeforeoperating.

EMISSIONCONTROLINFORMATION

Toprotecttheenvironmentinwhichwelive,Kawasakihasincorporatedcrankcaseemission(1)andexhaustemission (2)controlsystemsincompliancewithapplicableregulationsoftheUnitedStatesEnvironmentalProtectionAgencyand theCaliforniaAirResourcesBoard.

Asealed-typecrankcaseemissioncontrolsystemisusedtoeliminateblow-bygasses.Theblow-by gassesareledtoabreatherchamberthroughthecrankcaseandfromtheretotheaircleaner.

Oilisseparatedfromthegasseswhilepassingthroughtheinsideofthebreatherchamberfromthe crankcase,andthenreturnedtothebottomofthecrankcase.

2. ExhaustEmissionControlSystem

Theexhaustemissioncontrolsystemappliedtothisengineconsistsofacarburetorandanignition systemhavingoptimumignitiontimingcharacteristics.

Thecarburetorhasbeencalibratedtoprovideleanair/fuelmixturecharacteristicsandoptimumfuel economywithasuitableaircleanerandexhaustsystem.

TAMPERINGWITHEMISSIONCONTROLSYSTEMPROHIBITED

FederallawandCaliforniaStatelawprohibitsthefollowingactsorthecausingthereof:(1)theremovalorrendering inoperativebyanypersonotherthanforpurposesofmaintenance,repair,orreplacement,ofanydeviceorelementof designincorporatedintoanynewengineforthepurposeofemissioncontrolpriortoitssaleordeliverytotheultimate purchaserorwhileitisinuse,or(2)theuseoftheengineaftersuchdeviceorelementofdesignhasbeenremovedor renderedinoperativebyanyperson.

Amongthoseactspresumedtoconstitutetamperingaretheactslistedbelow: Donottamperwiththeoriginalemissionrelatedpart.

• Carburetorandinternalparts

• Sparkplugs

• Magnetoorelectronicignitionsystem

• Fuelfilterelement

• Aircleanerelements

• Crankcase

• Cylinderheads

• Breatherchamberandinternalparts

• Intakepipeandtube

1. CrankcaseEmissionControlSystem

Foreword

Thismanualisdesignedprimarilyforusebytrained mechanicsinaproperlyequippedshop.However,it containsenoughdetailandbasicinformationtomake itusefultotheownerwhodesirestoperformhisown basicmaintenanceandrepairwork.Abasicknowledge ofmechanics,theproperuseoftools,andworkshop proceduresmustbeunderstoodinordertocarryout maintenanceandrepairsatisfactorily.Wheneverthe ownerhasinsufficientexperienceordoubtsastohis abilitytodothework,alladjustments,maintenance,and repairshouldbecarriedoutonlybyqualifiedmechanics.

Inordertoperformtheworkefficientlyandtoavoid costlymistakes,readthetext,thoroughlyfamiliarize yourselfwiththeproceduresbeforestartingwork,and thendotheworkcarefullyinacleanarea.Whenever specialtoolsorequipmentarespecified,donotuse makeshifttoolsorequipment.Precisionmeasurements canonlybemadeiftheproperinstrumentsareused, andtheuseofsubstitutetoolsmayadverselyaffectsafe operation.

Togetthelongestlifeoutofyourengine:

• FollowthePeriodicMaintenanceChartintheService Manual.

• Bealertforproblemsandnon-scheduledmaintenance.

• UsepropertoolsandgenuineKawasakiengineparts. Genuinepartsprovidedassparepartsarelistedinthe PartsCatalog.

• Followtheproceduresinthismanualcarefully.Don’t takeshortcuts.

• Remembertokeepcompleterecordsofmaintenance andrepairwithdatesandanynewpartsinstalled.

HowtoUseThisManual

Inpreparingthismanual,wedividedtheproductinto itsmajorsystems.Thesesystemsbecamethemanual’s chapters.Allinformationforaparticularsystemfrom adjustmentthroughdisassemblyandinspectionislocated inasinglechapter.

TheQuickReferenceGuideshowsyouallofthe product’ssystemandassistsinlocatingtheirchapters. EachchapterinturnhasitsowncomprehensiveTableof Contents.

ThePeriodicMaintenanceChartislocatedinthe GeneralInformationchapter.Thechartgivesatime scheduleforrequiredmaintenanceoperations.

Ifyouwantsparkpluginformation,forexample,goto thePeriodicMaintenanceChartfirst.Thecharttellsyou howfrequentlytocleanandgaptheplug.Next,usethe QuickReferenceGuidetolocatetheElectricalSystem chapter.Then,usetheTableofContentsonthefirstpage ofthechaptertofindtheSparkPlugsection.

WheneveryouseetheseWARNINGandCAUTION symbols,heedtheirinstructions!Alwaysfollowsafe operatingandmaintenancepractices.

Thiswarningsymbolidentifiesspecialinstructionsorprocedureswhich,ifnotcorrectlyfollowed,couldresultinpersonalinjury,orlossof life.

CAUTION

Thiscautionsymbolidentifiesspecialinstructionsorprocedureswhich,ifnotstrictlyobserved,couldresultindamagetoordestruction ofequipment.

Thismanualcontainsfourmoresymbols(inadditionto WARNINGandCAUTION)whichwillhelpyoudistinguish differenttypesofinformation.

NOTE

Thisnotesymbolindicatespointsofparticularinterestformoreefficientandconvenientoperation.

• Indicatesaproceduralsteporworktobedone.

Indicatesaproceduralsub-steporhowtodothework oftheproceduralstepitfollows.Italsoprecedesthe textofaWARNING,CAUTION,orNOTE.

Indicatesaconditionalsteporwhatactiontotakebased ontheresultsofthetestorinspectionintheprocedural steporsub-stepitfollows.

Inmostchaptersanexplodedviewillustrationofthe systemcomponentsfollowstheTableofContents.In theseillustrationsyouwillfindtheinstructionsindicating whichpartsrequirespecifiedtighteningtorque,oil,grease oralockingagentduringassembly.

1-2GENERALINFORMATION

BeforeServicing

Beforestartingtoservicetheengine,carefullyreadtheapplicablesectiontoeliminateunnecessarywork.Photographs, diagrams,notes,cautions,warnings,anddetaileddescriptionshavebeenincludedwherevernecessary.Nevertheless, evenadetailedaccounthaslimitations,acertainamountofbasicknowledgeisrequiredforsuccessfulwork.

Especiallynotethefollowing:

(1)Dirt

Beforeremovalanddisassembly,cleantheengine.Anydirtenteringtheengine,carburetor,orotherparts,will workasanabrasiveandshortenthelifeofengine.Forthesamereason,beforeinstallinganewpart,cleanoffany dustormetalfilings.

(2)BatteryGround

Removetheground(—)leadfromthebatterybeforeperforminganydisassemblyoperationsontheequipment. Thisprevents:

(a)thepossibilityofaccidentallyturningtheengineoverwhilepartiallydisassembled.

(b)sparksatelectricalconnectionswhichwilloccurwhentheyaredisconnected.

(c)damagetoelectricalparts.

(3)TighteningSequence

Generally,wheninstallingapartwithseveralbolts,nuts,orscrews,startthemallintheirholesandtightenthemto asnugfit.Thentightenthemevenly,inastaggeredsequence.Thisistoavoiddistortionofthepartand/orcausing gasoroilleakage.Conversely,whenlooseningthebolts,nuts,orscrews,firstloosenallofthembyaboutaquarter ofaturnandthenremovethem.WherethereisatighteningsequenceindicationinthisServiceManual,thebolts, nuts,orscrewsmustbetightenedintheorderandmethodindicated.

(4)Torque

WhentorquevaluesaregiveninthisServiceManual,usethem.Eithertoolittleortoomuchtorquemayleadto seriousdamage.Useagoodquality,reliabletorquewrench.

(5)Force

Commonsenseshoulddictatehowmuchforceisnecessaryinassemblyanddisassembly.Ifapartseemsespecially difficulttoremoveorinstall,stopandexaminewhatmaybecausingtheproblem.Whenevertappingisnecessary,tap lightlyusingawoodenorplastic-facedmallet.Useanimpactdriverforscrews(particularlyfortheremovalofscrews heldbyalockingagent)inordertoavoiddamagingtheheads.

(6)Edges

Watchforsharpedges,especiallyduringmajorenginedisassemblyandassembly.Protectyourhandswithgloves orapieceofthickclothwhenliftingtheengineorturningitover.

(7)High-FlashPointSolvent

Ahigh-flashpointsolventisrecommendedtoreducefiredanger.AcommercialsolventcommonlyavailableinNorth AmericaisStandardsolvent(genericname).Alwaysfollowmanufacturerandcontainerdirectionsregardingtheuse ofanysolvent.

(8)Gasket,O-Ring

DonotreuseagasketorO-ringonceithasbeeninservice.Thematingsurfacesaroundthegasketshouldbe freeofforeignmatterandperfectlysmoothtoavoidoilorcompressionleaks.

(9)LiquidGasket,Non-PermanentLockingAgent

Followmanufacturer’sdirectionsforcleaningandpreparingsurfaceswherethesecompoundswillbeused.Apply sparingly.Excessiveamountsmayblockengineoilpassagesandcauseseriousdamage.AnexampleofanonpermanentlockingagentcommonlyavailableinNorthAmericaisLoctiteLock’nSeal(Blue).

(10)Press

Apartinstalledusingapressordriver,suchasajournal,shouldfirstbecoatedwithoilonitsouterorinner circumferencesothatitwillgointoplacesmoothly.

(11)BallBearing

Wheninstallingaballbearing,thebearingracewhichisaffectedbyfrictionshouldbepushedbyasuitabledriver. Thispreventsseverestressontheballsandraces,andpreventsracesandballsfrombeingdented.Pressaball bearinguntilitstopsatthestopintheholeorontheshaft.

(12)OilSealandGreaseSeal

Replaceanyoilorgreasesealsthatwereremovedwithnewones,asremovalgenerallydamagesseals.

Whenpressinginasealwhichhasmanufacturer’smarks,pressitinwiththemarksfacingout.Sealsshouldbe pressedintoplaceusingasuitabledriver,whichcontactsevenlywiththesideofseal,untilthefaceofthesealiseven withtheendofthehole.

(13)SealGuide

Asealguideisrequiredforcertainoilorgreasesealsduringinstallationtoavoiddamagetotheseallips.Before ashaftpassesthroughaseal,applyalittleoil,preferablyhightemperaturegreaseonthelipstoreducerubberto metalfriction.

(14)Circlip,RetainingRing

Replaceanycirclipsandretainingringsthatwereremovedwithnewones,asremovalweakensanddeformsthem. Wheninstallingcirclipsandretainingrings,takecaretocompressorexpandthemonlyenoughtoinstallthemand nomore.

BeforeServicing

(15)CotterPin

Replaceanycotterpinsthatwereremovedwithnewones,asremovaldeformsandbreaksthem.

(16)Lubrication

Enginewearisgenerallyatitsmaximumwhiletheengineiswarmingupandbeforealltherubbingsurfaceshave anadequatelubricativefilm.Duringassembly,oilorgrease(whicheverismoresuitable)shouldbeappliedtoany rubbingsurfacewhichhaslostitslubricativefilm.Oldgreaseanddirtyoilshouldbecleanedoff.Deterioratedgrease haslostitslubricativequalityandmaycontainabrasiveforeignparticles.

Don’tusejustanyoilorgrease.Someoilsandgreasesinparticularshouldbeusedonlyincertainapplicationsand maybeharmfulifusedinanapplicationforwhichtheyarenotintended.Thismanualmakesreferencetomolybdenum disulfidegrease(MoS2)intheassemblyofcertainengineparts.Alwayscheckmanufacturerrecommendationsbefore usingsuchspeciallubricants.

(17)ElectricalWires

Alltheelectricalwiresareeithersingle-colorortwo-colorand,withonlyafewexceptions,mustbeconnectedto wiresofthesamecolor.Onanyofthetwo-colorwiresthereisagreateramountofonecolorandalesseramountof asecondcolor,soatwo-colorwireisidentifiedbyfirsttheprimarycolorandthenthesecondarycolor.Forexample, ayellowwirewiththinredstripesisreferredtoasa"yellow/red"wire;itwouldbea"red/yellow"wireifthecolorswere reversedtomakeredthemaincolor.

(18)ReplacementParts

Whenthereisareplacementinstruction,replacethesepartswithnewoneseverytimetheyareremoved.There replacementpartswillbedamagedorlosetheiroriginalfunctiononceremoved.

(19)Inspection

Whenpartshavebeendisassembled,visuallyinspectthesepartsforthefollowingconditionsorotherdamage.If thereisanydoubtastotheconditionofthem,replacethemwithnewones.

(20)Specifications

Specificationtermsaredefinedasfollows:

"Standards"showdimensionsorperformanceswhichbrand-newpartsorsystemshave.

"ServiceLimits"indicatetheusablelimits.Ifthemeasurementshowsexcessivewearordeterioratedperformance, replacethedamagedparts.

1-4GENERALINFORMATION

ModelIdentification

CylinderNumberDesignation: No.1Cyl.isontheoilfilterside. No.2Cyl.isontheelectricstarterside.

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GeneralSpecifications

Items

FD671D,FD711D,FD750D

Typeofengine Liquid-cooled,Horizontalshaft,OHV,4-stroke,90 V-twin,Gasolineengine.

BorexStroke 2-78mmx78mm(3.07inx3.07in)

Pistondisplacement 745mL(45.5cu.in)

Directionofrotation CounterclockwisefacingthePTOshaftend

Lowidlespeed 1550rpm

Highidlespeed 3600rpm

Ignitionsystem Transistorized-flywheelmagneto

RFI PerCanadaandU.S.A.requirements

Startingsystem Shifttypeelectricstarter

Chargingsystem 12V-20ampswithregulator

Carburetor Floattype,fixedmainjet

Fuelpump Electromagneticpump(in-linetype)

Aircleaner Dualstageelement,drytype

Governor Allspeedmechanicalflyweights

Lubricationsystem Pressurefeedbypositivedisplacementpump

Oilfilter Cartridgetypefullflowfilter

Oilpressuerswitch ON-OFFswitch

Oilcapacity 2.0L(2.1USqt)[Whenoilfilterisremoved]

Coolingsystem Pressurizedforcedcirculationtype

Radiator 2-rowswithlouverlesscorrugatedfin(aluminum)

Dimensions(HxWxL) 520mmx458mmx580mm (20.5inx17.9inx22.8in)

Dryweight 58kg(128lb)

NOTE:Specificationsaresubjecttochangewithoutnotice.

1-6GENERALINFORMATION

GeneralSpecifications

Items

FD791D(DFI)

Typeofengine Liquid-cooled,Horizontalshaft,OHV,4-stroke,90 V-twin,Gasolineengine.

BorexStroke 2-78mmx78mm(3.07inx3.07in)

Pistondisplacement 745mL(45.5cu.in)

Directionofrotation CounterclockwisefacingthePTOshaftend

Lowidlespeed 1550rpm

Highidlespeed 3600rpm

Ignitionsystem Transistorized-flywheelmagneto

RFI PerCanadaandU.S.A.requirements

Startingsystem Shifttypeelectricstarter

Chargingsystem 12V-20ampswithregulator

FuelSystem DFI(DigitalFuelInjection)

Fuelpump Electromagneticpump(in-linetype)

Aircleaner Dualstageelement,drytype

Governor Allspeedmechanicalflyweights

Lubricationsystem Pressurefeedbypositivedisplacementpump

Oilfilter Cartridgetypefullflowfilter

Oilpressuerswitch ON-OFFswitch

Oilcapacity 2.0L(2.1USqt)[Whenoilfilterisremoved]

Coolingsystem Pressurizedforcedcirculationtype

Radiator 2-rowswithlouverlesscorrugatedfin(aluminum)

Dimensions(HxWxL) 520mmx458mmx580mm (20.5inx17.5inx22.8in)

Dryweight 59kg(130lb)

NOTE:Specificationsaresubjecttochangewithoutnotice.