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Kawasaki FD620D Troubleshooting

Engine Model: Kawasaki FD620D
Engine Type: 4-cycle 2-cylinder liquid cooled gasoline engine
Total Displacement: 37.7 (617 cc)
Rated Engine Power: 18.7 Hp (14 kW)
Carburetor Type: Down draft, fixed main jet


Engine hard to start or won't start

No fuel in fuel tank - Fill it up.
Wrong grade of gasoline - Change fuel.
Dirt and debris in fuel system - Remove debris and dirt.
Loose or disconnected spark plug wire - Check the spark plug wire connection, repair or replace.
Defective spark plug - Spark plug need to be replaced.
Fuel filter is clogged - Fuel filter needs changing.
Brake pedal not depressed - Press the brake pedal.
Carburetor components worn out - Repair or replace parts.
Low cylinder compression - Check cylinder block and replace worn parts.
Improperly adjusted or worn throttle cable - Adjust correctly or change the cable.

Unstable engine running

Cooling fins are plugged - Clean and wash as required.
Defective ignition - Check ignition system and replace faulty parts.
Faulty or stuck throttle cable - Service or change the cable.
Air filter is blocked - Clean or change air filter.
Clogged or defective fuel pump - Clean or install new fuel pump.

Engine starts but stalls suddenly

Spark plug is damaged - Change spark plug.
Carburetor is faulty or dirty - Clean or install new carburetor.
Defective ignition coil - Ignition coil should be replaced.
Loose or broken valve springs - Install new valve springs.
Valves sticking - Service the valves.

Engine overheated

Engine oil level is low - Fill up the engine oil.
Engine is overloaded - Load reducing required.
Air intake screen is blocked - Wash or clean as required.
Carburetor is running lean - Adjust carburetor properly.
Bad ignition timing - Adjust ignition timing as required.
Incorrect valve setting - Set the valves correctly.

Engine noise or knocking

Low octane gasoline - Change fuel.
Engine overloaded - Load reducing is recommended.
Low engine oil level - Fill up the oil to required level.
Low idle speed adjustment is incorrect - Adjust as required.
Clogged or damaged fuel pump - Clean or install new fuel pump.
Main bearings or crankshaft failure - Install new parts as as required.
Valve clearance is not correct - Check and adjust.
Damaged piston rings or cylinder bore - Replace defective parts.

Low engine power

Incorrectly adjusted or clogged carburetor - Service or correctly adjust carburetor.
Air filter is dirty - Service or replace air filter.
Dirty or defective fuel pump - Clean or install new fuel pump.
Ignition system problems - Check ignition and replace faulty components.
Cylinder head gasket is worn - Replace the head gasket.
Stuck or burned valves - Change or clean valves.
Push rod is worn or bent - Push rod needs to be changed.
Damaged cylinder block parts - Replace defective parts as required.
Oil filter is blocked (if equipped) - Clean or replace oil filter.

Engine uses too much fuel

Insufficient throttle opening - Adjust or replace throttle cable.
Improper adjustment of carburetor main jet - Adjust the carburetor main jet correctly.
Spark plug is defective or loose - Tighten or replace spark plug.
Valves are stuck, worn, or burned - Clean or change valves.
Worn piston, rings, or sleeve - Replace faulty parts.
Excessive valve clearance - Check and adjust.

Excessive oil consumption

Gaskets or seals may be damaged - Defective components must be replaced.
Valve stems or guides are damaged - Need to replace the valves.
Seized or wear piston rings - Change the piston rings as required.
Cylinder liner or piston is scored - Check liner and piston, replace as required.
Blocked breather hose or pipe - Clean or change.