Home / Small Engines / Kawasaki Engines / Kawasaki FX541V

Kawasaki FX541V Troubleshooting

Engine Model: Kawasaki FX541V
Engine Type: 4-cycle 2-cylinder air-cooled gasoline engine
Total Displacement: 36.8 (603 cc)
Rated Engine Power: 16.5 Hp (12.3 kW)
Carburetor Type: 1-barrel, fixed main jet


Engine starts up hard or will not start

Empty gas tank - Add fuel.
Wrong fuel grade - Use quality fuel.
There is air in the fuel system - Bleed the system.
Defective wiring connection of spark plug - Check the spark plug wire connection, repair or replace.
Faulty spark plug - Spark plug need to be replaced.
Clogged fuel filter - Replace fuel filter.
Faulty safety switch - Change damaged switch.
Carburetor is clogged - Clean the carburetor.
Engine has bad compression - Check cylinder block and change wear parts.
Worn or unadjusted choke cable - Adjust properly or change the cable.

Rough engine running

Air intake grill is clogged - Need to clean or wash.
Ignition failure - Inspect ignition system and change failed components.
Defective or stuck throttle cable - Clean or replace the cable.
Dirty air filter element - Clean or change air filter.
Dirty or defective fuel pump - Service or replace fuel pump.

Engine starts and immediately shuts off

Faulty spark plug - Install new spark plug.
Defective or dirty carburetor - Service or replace carburetor.
Ignition coil is not working - Change ignition coil as required.
Damaged or weak valve springs - Install new valve springs.
Valves sticking - Service the valves.

Engine is overheated

Lack of engine oil - Checking oil level and add if necessary.
Engine overloaded - Load reducing required.
Plugged cooling fins - Need to wash or clean.
Too lean fuel mixture in carburetor - Adjust carburetor correctly.
Ignition timing is wrong - Set the ignition timing correctly.
Valve setting is incorrect - Valves needs to be adjusted properly.

Abnormal engine noise or knocking

Low octane fuel - Use correct fuel.
Engine is overloaded - Load reducing is recommended.
Engine oil level low - Fill the crankcase with engine oil.
Wrong adjustment of low idle speed - Correct idle settings.
Clogged or defective fuel pump - Inspect fuel pump and change as required.
Crankshaft or main bearings failure - Have bearings or crankshaft replaced.
Excessive valve clearance - Adjust valve clearance.
Cylinder bore or piston rings are damaged - Change faulty components.

Engine power is insufficient

Carburetor is dirty or improperly adjusted - Adjust carburetor properly or service it.
Dirty air filter element - Replace or clean air filter.
Dirty or damaged fuel pump - Inspect fuel pump and change as required.
Ignition system malfunction - Inspect ignition system and change faulty parts.
Cylinder head gasket is worn - Replace cylinder head gasket.
Valves are stuck or burned - Service or replace valves.
Bent or worn push rod - Change push rod.
Faulty cylinder block parts - Defective components need to be replaced.
Oil filter is dirty (if equipped) - Clean or replace oil filter.

High fuel consumption

Throttle does not open well - Inspect throttle cable and adjust it.
Carburetor main jet is incorrectly adjusted - Adjust it correctly.
Loose or defective spark plug - Spark plug need to be replaced or tightened.
Stuck, burned, or worn valves - Replace or clean valves.
Worn sleeve, rings, or piston - Replace defective parts.
Valve clearance is incorrect - Adjustment procedure required.

Excessive engine oil consumption

Worn seals or gaskets - Replace defective parts.
Valve stems and guides are worn - Valves need to be changed.
Piston rings are stuck or broken - Change piston rings.
Worn cylinder liner or piston - Check liner and piston, change as required.
Clogged breather pipe or hose - Service or replace.