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Kawasaki FD611V Troubleshooting

Engine Model: Kawasaki FD611V
Engine Type: 4-cycle 2-cylinder liquid cooled gasoline engine
Total Displacement: 35.7 (585 cc)
Rated Engine Power: 20 Hp (14.9 kW)
Carburetor Type: Horizontal draft, fixed main jet


Engine won't start or difficult to start

No gasoline in tank - Fill gasoline up.
Incorrect fuel grade - Use quality fuel.
Air in the fuel lines - Bleed the fuel lines.
Disconnected or loose spark plug wire - Check spark plug wiring connection, repair or change.
Spark plug is damaged - Spark plug need to be replaced.
Clogged fuel filter - Replace fuel filter.
Brake pedal not pushed down - Push the brake pedal down.
Carburetor is not adjusted - Check carburetor float adjustment.
Weak cylinder compression - Inspect cylinder block and change worn parts.
Throttle cable is damaged or adjusted incorrectly - Adjust correctly or change the cable.

Engine runs intermittently

Air intake screen is blocked - Need to wash or clean.
Defective ignition - Test ignition and replace failed parts.
Defective or stuck choke cable - Change or clean the cable.
Clogged air filter - Replace or service air filter.
Fuel pump is faulty or clogged - Service or change fuel pump.

Engine starts and stops

Spark plug is defective - Change spark plug as required.
Carburetor is dirty or defective - Clean or replace carburetor.
Ignition coil is defective - Ignition coil must be replaced.
Valve springs are damaged or weak - Change valve springs.
Valves sticking - Service the valves.

Engine overheating

Engine oil level is insufficient - Fill up the engine oil.
Engine is overloaded - Reduce engine load.
Clogged cooling fins - Clean and wash as required.
Too lean carburetor mixture - Set the carburetor correctly.
Improper ignition timing - Set the ignition timing correctly.
Valve setting is improper - Adjust valves as required.

Engine knocks or noises

Stale gasoline - Change fuel.
Engine overloaded - Reduce the load.
Engine oil level is insufficient - Checking oil level and add if necessary.
Improperly adjusted low idle speed - Correct the settings.
Dirty or defective fuel pump - Clean or install new fuel pump.
Main bearings or crankshaft failure - Need to install new components.
Improper valve clearance - Adjust valve clearance according to specifications.
Piston rings or cylinder bore are damaged - Change defective components.

Engine power loss

Carburetor is improperly adjusted or clogged - Clean or properly adjust carburetor.
Dirty air filter element - Change or clean air filter.
Fuel pump is dirty or defective - Service or replace fuel pump.
Ignition system malfunction - Test ignition and replace failed parts.
Damaged cylinder-head gasket - Replace cylinder head gasket.
Burned or stuck valves - Clean or change valves.
Bent or worn push rod - Push rod should be replaced.
Cylinder block parts are damaged - Replace defective components as required.
Oil filter element is plugged (if equipped) - Replace or service oil filter.

Excessive fuel consumption

Throttle is not fully open - Change or adjust throttle cable.
Improper adjustment of carburetor main jet - Adjust the carburetor main jet correctly.
Spark plug is defective or loose - Tighten or change the spark plug.
Burned, worn, or stuck valves - Replace or service valves.
Rings, sleeve, or piston are damaged - Change defective parts.
Excessive valve clearance - Adjust valve clearance according to specifications.

Engine consuming too much oil

Damaged seals or gaskets - Worn parts need to be replaced.
Damaged valve stems or valve guides - Install new valves.
Piston rings are defective or worn - Piston rings need to be replaced.
Scuffed cylinder liner or piston - Inspect liner and piston, fit new parts as necessary.
Breather hose or pipe is plugged - Change or clean.