KAWASAKI FH680V (01) PDF Document

Before starting to service your KAWASAKI FH680V engine, please follow these recommendations:

(1) Dirt: Before removal and disassembly, clean the engine. Any dirt entering the engine, carburetor, or other parts will act as an abrasive and shorten the life of the engine. For the same reason, before installing a new part, clean off any dust or metal filings.

(2) Battery Ground: Remove the ground (–) lead from the battery before performing any disassembly operations. This prevents accidental engine turnover, sparks at connections, and damage to electrical parts.

(3) Tightening Sequence: When installing a part with several bolts, nuts, or screws, start them all in their holes and tighten them to a snug fit. Then tighten them evenly in a staggered sequence to avoid distortion and leakage. When loosening, first loosen all of them by about a quarter of a turn and then remove them. If a specific tightening sequence is indicated, it must be followed.

(4) Torque: Use the torque values specified in the Service Manual. Using too little or too much torque can lead to serious damage. Use a good quality, reliable torque wrench.

(5) Force: Use common sense to determine the necessary force for assembly and disassembly. If a part is difficult to remove or install, stop and investigate the cause. For tapping, use a wooden or plastic-faced mallet. Use an impact driver for screws held by a locking agent.

(6) Edges: Be cautious of sharp edges, especially during major engine disassembly and assembly. Protect your hands with gloves or a thick cloth.

(7) High-Flash Point Solvent: Use a high-flash point solvent to reduce fire danger. Always follow manufacturer directions.

(8) Gasket, O-Ring: Do not reuse a gasket or O-ring once it has been in service. Ensure mating surfaces are clean and smooth.

(9) Liquid Gasket, Non-Permanent Locking Agent: Follow the manufacturer’s directions. Apply sparingly to avoid blocking oil passages.

(10) Press: A part installed with a press or driver should be coated with oil on its circumference for smooth installation.

(11) Ball Bearing: When installing a ball bearing, push on the race that is affected by friction to prevent stress on the balls and races.

(12) Oil Seal and Grease Seal: Replace any removed oil or grease seals with new ones. Press them in with manufacturer’s marks facing out, using a suitable driver until the seal face is even with the end of the hole.

(13) Seal Guide: Use a seal guide for certain seals to avoid damaging the lips. Apply a little oil or grease to the lips before a shaft passes through.

(14) Circlip, Retaining Ring: Replace any removed circlips and retaining rings with new ones. When installing, compress or expand them only enough to install them.

(15) Cotter Pin: Replace any removed cotter pins with new ones.

(16) Lubrication: During assembly, apply oil or grease to any rubbing surface that has lost its lubricative film. Clean off old grease and dirty oil. Use only the recommended types of oil or grease for specific applications.

(17) Replacement Parts: When instructed, replace parts with new ones every time they are removed.

(18) Inspection: After disassembly, visually inspect parts for conditions like abrasion, cracks, dents, wear, etc. If in doubt, replace the part.

The general specifications for the KAWASAKI FH680V engine are as follows:

Item	FH601V, FH641V, FH680V	FH721V
Type of engine	Forced air-cooled, vertical shaft, OHV, 4-stroke gasoline engine.
Cylinder layout	90 V-Twin
Bore x Stroke	75.2 mm x 76 mm (2.96 in x 2.99 in)
Piston displacement	675 mL (41.19 cu.in)
Direction of rotation	Counterclockwise facing the PTO shaft
Compression release	Automatic compression release
Low idle speed	1550 rpm
Fast idle speed	3600 rpm
Ignition system	Transistorized-fly wheel magneto
RFI	Per Canada and U.S.A. requirements
Starting system	Electric starter and/or recoil starter
Charging system	12 V – 13 amps with regulator
Spark plug	NGK BPR4ES
Carburetor	Float type, fixed main jet, two barrel
Fuel pump	Diaphragm type pulse pump
Air cleaner	Dual stage element, dry type
Governor	Flyweight all speed governor
Lubrication system	Pressure feed by positive displacement pump
Oil filter	Cartridge type full flow filter
Oil pressure switch	ON-OFF switch
Oil capacity (when engine is completely dry)	1.8 L (1.9 US-qt)	1.9 L (2.0 US-qt)
Cooling system	Forced air cooling by fan
Dimensions (L x W x H) Electric starter model	458 mm x 430 mm x 381mm (18.0 in x 16.9 in x 15.0 in)
Dry weight Electric starter model	40.5 kg (89.3 lbs)	41.2 kg (90.8 lbs)

The following table shows the recommended maintenance intervals for your KAWASAKI FH680V engine to ensure satisfactory operation.

OPERATION	Daily	First 8 hr.	Every 25 hr.	Every 50 hr.	Every 100 hr.	Every 200 hr.	Every 300 hr.
Check or clean air intake screen	•
Check and add engine oil	•
Check for fuel and oil leakage	•
Check for loose or lost nut and screw	•
Check battery electrolyte level	•
Clean air cleaner foam element (1)			•
Clean air cleaner paper element (1)				•
Clean dust and dirt from cylinder and cylinder head fins (1)					•
Tighten nut and screws		•
Change engine oil					•
Clean and re-gap spark plugs					•
Check and clean oil cooler fins (FH721V engines)					•
Change Oil filter						•
Change air cleaner paper element (1)						•
★Check and adjust valve clearance							•
★Clean and lap valve seating surface							•
★Clean combustion chamber							•

Note:

(1): Service more frequently under dusty conditions.

★: These items must be performed with the proper tools. See your authorized Kawasaki Engine Dealer for service, unless you have the proper equipment and mechanical proficiency.

Low Idle Speed Adjustment

1. Disconnect all possible external loads from the engine.

2. Start the engine and warm it up thoroughly. Always keep your hands clear of the moving parts.

3. Adjust the low idle speed screw (C) with a Phillips screwdriver (D) until the engine idles at the specified speed.

Idle Speed (Carburetor idle rpm): 1450 rpm

4. Release the throttle lever and adjust the low idle speed set screw (B) on the control plate to obtain the specified governed low idle speed.

Low Idle Speed (Governed idle rpm): 1550 rpm

High Idle Speed Adjustment

Note: High idle speed adjustment should be made after the idle speed adjustment is performed. Do not adjust high idle speed with the air cleaner removed.

1. Start and warm up the engine thoroughly. Always keep your hands clear of the moving parts.

2. Move the throttle lever at a dash to the high idle position and match the lever hole position with the panel hole by inserting a 6 mm dia. pin or bolt (A).

3. Loosen two M6 control panel mounting bolts (B) enough to move the control panel assembly.

4. Carefully move the control panel assembly right side (C) up or down to obtain the specified high idle speed.

High Idle Speed: 3600 rpm

5. Tighten the M6 Mounting bolts.

Torque – Control Panel Mounting Bolts: 5.9 N·m (0.60 kg·m, 52 in·lb)

6. Remove the 6 mm dia. pin or bolt.

7. Check the idle speed, and readjust the idle speed if necessary.

CAUTION: Be sure to make the idle and high idle speeds respectively correspond to those of the equipment.

To test the fuel flow of your KAWASAKI FH680V engine, follow these steps:

WARNING: Gasoline is extremely flammable and can be explosive under certain conditions. Turn the ignition switch OFF. Do not smoke. Make sure the area is well-ventilated and free from any source of flame or sparks; this includes any appliance with a pilot light.

1. Disconnect the fuel pump outlet nozzle from the tube.

2. Connect a suitable hose to the outlet nozzle.

3. Run the lower end of the hose into a container.

4. Start the engine and check the fuel flow.

5. If there is no or little fuel flow, replace the fuel pump.

6. Check for clogged or damaged tubes and fuel filter. Replace any faulty parts.

Element Removal

1. Remove the Air Cleaner Case Nut and Air Cleaner Case.

2. Remove the Wing Nut (A), Foam Element (B), and Paper Element (C).

Element Cleaning and Inspection

Note: In dusty areas, the elements should be cleaned more frequently than the recommended intervals.

WARNING: Because of the danger of highly flammable liquids, do not use gasoline or a low flash-point solvent to clean the element.

1. Remove the foam element and the paper element.

2. Clean the foam element in a bath of detergent and water, and let it air-dry thoroughly before installation.

3. Clean the paper element by tapping it gently on a flat surface to remove dust. If the element is very dirty, replace it with a new one.

CAUTION: Do not use compressed air to clean the paper element. Do not oil the paper or foam element.

Element Installation

1. Install the element correctly on the air cleaner body.

2. Be sure the paper element is in-place in the air cleaner body.

3. Be sure the foam element is in-place on the paper element body.

To measure the compression of your KAWASAKI FH680V engine, follow these steps:

1. Ensure the battery is fully charged.

2. Thoroughly warm up the engine to normal operating temperature.

3. Stop the engine.

4. Disconnect the spark plug caps of each cylinder and remove the spark plugs.

5. Ground the spark plugs to the engine. To avoid fire, do not ground the spark plugs in proximity to the plug holes. Keep them as far away as possible.

6. Attach a compression gauge (Special Tool: 57001-221) with an adapter (Special Tool: 57001-1159) firmly into one spark plug hole.

7. With the throttle fully open, use the starter motor to turn the engine over until the compression gauge stops rising. The compression is the highest reading obtainable.

Cylinder Compression (MIN): 390 kPa (57 psi)

8. Repeat the measurement for the other cylinder.

If compression is too high, check for carbon build-up, incorrect cylinder head gasket, or worn valve guides/piston rings.

If cylinder compression is lower than the minimum, check for gas leakage around the cylinder head, the condition of the valve seating, valve clearance, piston/cylinder wear, or piston seizure.

Note: Valve clearance must be checked when the engine is cold (at room temperature).

Valve Clearance Inspection

1. Remove the rocker cover.

2. Turn the crankshaft clockwise (facing the flywheel) to place the piston at Top Dead Center (TDC) of the compression stroke. For No. 1 Cylinder, the left projection (A) on the flywheel should be aligned with the right leg (B) on the #1 ignition coil (C). Check that both intake and exhaust valves are closed.

3. Use a thickness gauge to measure the valve clearance between the rocker arm and the valve stem end.

Valve Clearance (when cold): 0.075 – 0.125 mm (0.003 – 0.005 in.)

4. If the clearance is incorrect, adjust it.

Valve Clearance Adjustment

1. Loosen the lock screw (A) and the valve clearance adjusting nut (B).

2. Insert a thickness gauge (C) between the rocker arm and valve stem. Tighten the adjusting nut until the gauge begins to bind. Use a sweeping motion with the gauge while adjusting.

3. Holding the adjusting nut with a spanner, tighten the lock screw to the specified torque. Do not overtighten.

Torque – Valve Clearance Lock screws: 6.9 N·m (0.70 kg·m, 61 in·lb)

4. Remeasure the clearance and readjust if necessary.

Oil Change

Change the oil after the first 8 hours of operation, and every 100 hours thereafter.

1. Start and warm up the engine so the oil will drain easily. Then stop the engine.

2. Place the engine on a level surface.

3. Place a suitable container under the engine.

4. Remove the drain plug (A) and drain the oil. Be careful of hot oil, as it may be hot enough to cause severe burns.

5. Check the O-ring (B) on the drain plug for damage. Replace if necessary.

6. Install the drain plug with the O-ring and tighten it.

Torque – Oil Drain Plug (Plastic): 6.9 N·m (0.7 kg·m, 61 in·lb)

Torque – Oil Drain Plug (Metal): 20 N·m (2.0 kg·m, 14.5 ft·lb)

7. Remove the oil filler cap and pour in the specified type and amount of oil.

Engine Oil Grade: SF, SG, SH or SJ class

Viscosity: SAE40, SAE30, SAE10W-30/SAE10W-40, or SAE5W-20

Capacity (when filter is removed): 1.7 L (1.8 US qt)

Oil Filter Removal & Installation

1. Using an oil filter wrench (Special Tool: 57001-1249), remove the old oil filter (B). Place a container underneath to catch any oil.

2. Apply a light film of engine oil to the seal (A) of the new filter.

3. Install the new filter. Turn it until the seal contacts the mounting surface (B), then turn it by hand an additional 3/4 turn.

4. After changing the oil and filter, run the engine at slow idle for 2 minutes and check for leaks around the filter.

5. Stop the engine and check the oil level, adding oil if necessary.

When servicing the electrical system of your KAWASAKI FH680V, please observe the following precautions:

• Do not reverse the battery lead connections. This will burn out the diodes in the electrical parts.

• Always check battery condition before condemning other parts of an electrical system. A fully charged battery is a must for conducting accurate electrical system tests.

• Electrical parts should never be struck sharply, as with a hammer, or allowed to fall on a hard surface. Such a shock can damage them.

• To prevent damage, do not disconnect the battery leads or any other electrical connections when the engine switch is on, or while the engine is running.

• Due to the large amount of current, never keep the engine switch in the start position if the starter motor won’t turn over, as this may burn out the starter motor windings.

• Be careful not to short the leads that are directly connected to the battery positive terminal to the chassis ground.

• Troubles may involve one or multiple items. Always determine the cause of a failure before replacing a part to prevent the replacement part from failing soon after.

• Ensure all connectors are clean and tight. Examine wires for signs of burning, fraying, etc. Poor wires and connections will affect system operation.

• Measure coil and winding resistance when the part is cold (at room temperature).

Charging System Operational Inspection

1. Check the battery condition. A fully charged battery is necessary for accurate tests.

2. Warm up the engine to bring components to normal operating temperatures.

3. Connect a voltmeter across the battery terminals.

4. Measure the regulated output voltage at various engine speeds. The readings should show nearly battery voltage at low speeds and should rise as the engine speed increases, but must stay within the specified range.

Regulated Output Voltage: Battery Voltage to 15 VDC

5. If the output voltage is much higher than specified, the regulator is defective or its leads are loose/open.

6. If the output voltage does not rise with engine speed, the regulator is defective or the alternator output is insufficient.

Unregulated Stator Output

1. Disconnect the stator coil connector.

2. Connect an AC voltmeter to the stator pins.

3. Start the engine and run it at 3,000 rpm.

4. The voltage reading should be a minimum of 26 VAC/3,000 rpm.

5. If the reading is less than specified, replace the stator.

If your KAWASAKI FH680V engine is hard to start, follow this troubleshooting guide:

1. Check for Spark: Remove the spark plug and ground it against the engine block while cranking. Are sparks produced?

• YES: Is the spark plug that was replaced faulty? If so, replace the faulty spark plug.

• NO: Are sparks produced when the ignition coil is replaced?

• YES: You likely have a faulty ignition coil. Replace it.

• NO: You may have an incorrect air gap or a faulty flywheel. Correct the air gap or replace the flywheel.

2. Check Compression: Is the compression sufficient?

• YES: Proceed to step 3.

• NO: Make starting attempts a number of times and then remove the spark plug to observe the electrodes. Are they wet?

• YES: This could be due to excessive use of the choke, a plugged air cleaner, or too high a fuel level in the float bowl. To fix, remove the plug and turn the crankshaft without loading. Adjust the fuel level.

• NO: Check for fuel system issues.

• Is there fuel in the tank? Add fuel if needed.

• Is there dust or air in the fuel system? Clean it.

• Is the plugged air hole in the tank? Clean it.

• Is the fuel filter plugged? Clean it.

• Is the fuel line plugged? Clean it.

3. Check Carburetor:

• Check for a plugged fuel line.

• Check for a plugged air passage.

• Check the float level.

• Check the carburetor setting.

If issues persist, check for:

• Worn piston/piston rings: Replace or clean.

• Stuck piston rings: Clean or replace.

• Worn cylinder bore: Bore or replace.

• Insufficient cyl. head tightening: Retighten.

• Poor contact of valve seat: Lap the valve seat.

• Warped by valve: Adjust valve clearance.

• Wronged valve spring: Replace.

• Stuck valve: Clean or replace.

• Burned head gasket: Replace.

If your KAWASAKI FH680V engine is experiencing a loss of power, check the following potential causes:

• Is the engine overheated?

• YES:

• Crankcase low on oil: Adjust level or add oil.

• Too much oil in crankcase: Adjust level.

• Excessive engine load: Decrease load.

• Carburetor not properly adjusted: Adjust.

• Carbon deposit in combustion chamber: Clean.

• Clogging of cooling system: Clean.

• Damaged cooling fan: Replace.

• NO: Proceed to the next check.

• Is the ignition spark normal?

• NO:

• Wrong spark plug: Replace.

• Faulty ignition coil: Replace.

• Incorrect air gap: Adjust gap.

• Is the lubrication condition normal?

• NO:

• Too much or too little oil in crankcase: Correct.

• Excessively contaminated lubricating oil: Change.

• Clogged oil filter: Replace.

• Faulty relief valve: Replace.

• Faulty oil pump: Replace.

• Clogging of oil system: Clean.

• Is unusual smoke emitted out of the muffler?

• YES:

• Plugged air cleaner: Clean.

• Carbon deposit in exhaust hole and muffler: Clean.

• Is compression sufficient?

• NO: Refer to troubleshooting for hard starting related to compression.

If the starter motor does not rotate, follow these steps:

1. Listen for a click from the solenoid.

• NO click:

• Faulty battery: Charge or replace.

• Faulty leads or connection: Repair or replace.

• Melted fuse: Replace.

• Faulty engine switch: Repair or replace.

• Faulty solenoid (switch): Replace.

• YES, a click is heard:

• Weak battery: Charge or replace.

• Faulty leads or connection (Solenoid to motor): Repair or replace.

• Faulty solenoid (switch) (Main terminal to solenoid): Replace.

• Faulty starter motor: Repair or replace.