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Kawasaki FS481V Troubleshooting

Engine Model: Kawasaki FS481V
Engine Type: 4-cycle V-twin cylinder OHV gasoline engine
Total Displacement: 36.8 (603 cc)
Rated Engine Power: 13.5 Hp (10 kW)
Carburetor Type: Internally vented, fuel shut-off solenoid


Engine difficult to start or will not start

Empty gas tank - Fill it up.
Wrong grade of gasoline - Use quality gasoline.
Dirty fuel lines - Inspect and clean.
Defective spark plug wire connection - Inspect spark plug wiring connection, change or repair.
Damaged spark plug - Change spark plug.
Fuel filter is dirty - Change fuel filter.
Safety contact for brake pedal defective - Install new part.
Carburetor problems - Carburetor diagnostics required.
Poor engine compression - Check cylinder block and replace damaged components.
Unadjusted or worn throttle cable - Change cable or adjust properly.

Engine runs intermittently

Air intake screen is plugged - Wash or clean as required.
Defective ignition - Test ignition and replace failed parts.
Choke cable is faulty or stuck - Replace or service the cable.
Plugged air filter - Service or change air filter.
Dirty or damaged fuel pump - Clean or change fuel pump.

Engine starts but then stalls

Spark plug is damaged - Change spark plug.
Carburetor is defective or clogged - Clean or change carburetor.
Faulty ignition coil - Ignition coil should be replaced.
Valve springs are broken or bad - New valve springs need to be installed.
Stuck valves - Clean the valves.

Engine keeps overheating

Low engine oil level - Fill the crankcase with engine oil.
Excessive engine load - Reduce load.
Cooling fins are clogged - Wash or clean as required.
Too lean fuel mixture in carburetor - Adjust carburetor properly.
Ignition timing is improper - Adjust ignition timing correctly.
Valve setting is wrong - Valves needs to be set correctly.

Engine knocking or noise

Stale or low octane fuel - Change gasoline.
Engine is running overloaded - Reduce load.
Engine oil insufficient - Need to add engine oil.
Too low idle RPM - Need to adjust idle speed.
Fuel pump is damaged or dirty - Clean or replace fuel pump.
Crankshaft or main bearings wear - Repair or replace defective parts.
Improper valve clearance - Need to adjust valve clearance.
Damaged cylinder bore or piston rings - Replace defective components.

Loss of engine power

Improperly adjusted or dirty carburetor - Service or correctly adjust carburetor.
Air filter is blocked - Service or replace air filter.
Dirty or defective fuel pump - Check fuel pump and change if required.
Defective ignition - Test ignition and replace failed parts.
Worn cylinder head gasket - Cylinder-head gasket replacement required.
Stuck or burned valves - Service or change valves.
Push rod is bent or worn - Install a new push rod.
Worn cylinder block components - Replace defective components.
Oil filter element is clogged (if equipped) - Change or clean oil filter.

Excessive fuel consumption

Choke did not open fully - Change or adjust choke cable.
Carburetor main jet adjustment is incorrect - Adjust it correctly.
Spark plug is loose or faulty - Tighten or replace spark plug.
Valves are worn, stuck, or burned - Clean or change valves.
Sleeve, piston, or rings are damaged - Replace defective components.
Improper valve clearance - Adjust to proper valve clearance.

High oil consumption

Defective seals or gaskets - Replace to repair leaks.
Worn valve stems and valve guides - Change the valves.
Piston rings are seized or worn - Piston rings replacement required.
Scored cylinder liner or piston - Inspect piston and liner, replace as required.
Breather hose or pipe is clogged - Service or change.