KAWASAKI FS691V (01) PDF DOCUMENT

For your safety, please adhere to the following critical warnings when operating your KAWASAKI FS691V engine:

Exhaust Fumes: DO NOT run the engine in a closed area. Exhaust gas contains carbon monoxide, an odorless and deadly poison.

Fuel Handling: Gasoline is extremely flammable and can be explosive. Stop the engine and allow it to cool before refueling. DO NOT smoke. Refuel in a well-ventilated area away from any flames or sparks. Do not overfill the fuel tank. Wipe up any spilled gasoline immediately.

Fire Prevention: Keep the engine at least 1 meter (3.3 ft) away from buildings and other burnable objects. DO NOT place flammable objects near the engine or expose combustible materials to the engine exhaust.

Electric Shock: To avoid electric shock, DO NOT touch spark plugs, plug caps, or spark plug leads while the engine is running.

Burn Prevention: To avoid serious burns, DO NOT touch a hot engine or muffler. The engine becomes hot during operation. Allow the engine to cool completely before servicing or removing parts.

Moving Parts: DO NOT place hands or feet near moving or rotating parts. Ensure a protective cover is placed over the pulley, V-belt, or coupling.

Engine Speed: DO NOT run the engine at excessive speeds, as this may result in injury.

Servicing: Always remove the spark plug caps from the spark plugs when servicing the engine to prevent accidental starting.

NOTE: High and low idle speeds may vary depending on the equipment on which the engine is used. Refer to the equipment specification.

Use only clean, fresh, unleaded regular grade gasoline. This engine is certified to operate on unleaded regular grade gasoline only.

Octane Rating: A minimum of 87 octane by the antiknock index is recommended. The antiknock index is calculated as (RON + MON)/2. If you notice “knocking or pinging,” use a different brand of gasoline or a higher octane rating.

Oxygenated Fuel: If you use oxygenated fuel, ensure it is unleaded and meets the minimum octane rating.

ETHANOL (Ethyl or Grain Alcohol): You may use gasoline containing up to 10% ethanol by volume.

MTBE (Methyl Tertiary Butyl Ether): You may use gasoline containing up to 15% MTBE by volume.

METHANOL (Methyl or Wood Alcohol): You may use gasoline containing up to 5% methanol by volume, as long as it also contains cosolvents and corrosion inhibitors to protect the fuel system. Gasoline with more than 5% methanol may cause starting/performance problems and damage fuel system parts.

CAUTION: Do not mix oil with gasoline.

The recommended engine oil for your KAWASAKI FS691V has an API Service Classification of SF, SG, SH, SJ, or SL.

Oil Viscosity: Choose the oil viscosity based on the ambient temperature:

SAE 10W-40 is the recommended oil for most conditions. However, you may need to change the viscosity to accommodate atmospheric conditions. For example, using 20W-50 oil in higher ambient temperatures may reduce oil consumption.

Temperature Range Guide:

SAE 5W-20: Below 0°C (32°F)

SAE 10W-30: -20°C to 30°C (-4°F to 86°F)

SAE 10W-40: -20°C to 40°C (-4°F to 104°F)

SAE 20W-50: -10°C to 40°C+ (14°F to 104°F+)

SAE 30: 0°C to 40°C (32°F to 104°F)

SAE 40: 20°C to 40°C+ (68°F to 104°F+)

Check the engine oil daily before starting the engine to prevent serious damage like seizure. The engine is shipped without engine oil.

1. Place the engine on a level surface. Clean the area around the oil gauge before removing it.

2. Remove the oil gauge and wipe it with a clean cloth.

3. If adding oil, pour the oil slowly to the “FULL” mark on the oil gauge.

4. To check the level, insert the oil gauge into the tube WITHOUT SCREWING IT IN.

5. Remove the oil gauge again to check the oil level. The level should be between the “ADD” and “FULL” marks. Do not overfill.

6. Install and tighten the oil gauge.

CAUTION: Do not fill above the “FULL” mark. Excess oil will cause a smoking condition and may cause the engine to overheat.

Follow these steps to start your KAWASAKI FS691V engine:

1. Before starting, disconnect all possible external loads.

2. Open the fuel valve on the equipment.

3. Move the throttle lever to the half-throttle position.

4. Use full choke if the engine is cold. In hot weather or if the engine is already warm, use half choke or leave the choke fully open.

5. Insert the key into the engine switch.

6. Turn the switch key to the START position. The engine will usually start within 3 seconds.

7. After the engine starts, gradually return the choke lever to the fully open position.

CAUTION: Do not run the electric starter continuously for more than 5 seconds, as the battery may discharge quickly. If the engine doesn’t start, wait 15 seconds before trying again.

NOTE: If the engine is very warm and does not start immediately, do not keep trying with the choke closed. This will cause flooding. Instead, fully open the choke and start the engine.

Warming Up:

After the engine starts, move the throttle lever to halfway between “FAST” and “SLOW”. To warm up the engine, run it for 3 to 5 minutes in this position before putting the equipment under load. Then, move the throttle lever to its “FAST” position.

CAUTION: Allow the engine to warm up sufficiently (3 to 5 minutes at idle) before applying a load. This allows oil to reach all engine parts and for piston clearance to reach design specifications.

Engine Inclination:

This engine will operate continuously at angles up to 25 degrees in any direction. However, refer to the operating instructions of the equipment this engine powers, as there may be more stringent restrictions. Do not operate this engine continuously at angles exceeding 25 degrees, as engine damage could result from insufficient lubrication.

Ordinary Stop:

1. Move the throttle lever to the “slow” position.

2. Lower the engine speed to idle and keep it running at idle for about one minute.

3. Turn the engine switch or switch key to the “OFF” position.

CAUTION: Engine damage can occur from run-on or after-burning if the engine is stopped suddenly from a high-speed loaded operation. Reduce engine speed to idle for one minute before shutting the engine off.

Emergency Stop:

1. Immediately turn the engine switch or switch key to the “OFF” position.

2. Close the fuel valve on the equipment.

Throttle Cable Installation, Adjustment:

1. Link the throttle cable to the speed control lever and loosely clamp the throttle cable outer housing with the cable clamp bolt.

2. Move the equipment’s throttle lever to the “FAST” position.

3. Pull up the outer housing of the throttle cable until the inner wire has almost no slack, and then tighten the cable clamp bolt.

4. Move the throttle lever to the “SLOW” position and ensure the carburetor throttle valve moves smoothly.

Choke Cable Installation, Adjustment:

1. Link the choke cable to the choke control lever and loosely clamp the choke cable outer housing with the cable clamp bolt.

2. Move the equipment’s choke control to the “OPEN” position. Make sure the carburetor choke valve is fully opened.

3. Pull up the outer housing of the choke cable until the inner wire has almost no slack, and then tighten the cable clamp bolt.

4. Move the equipment choke control to the “CHOKE” position. Make sure the carburetor choke valve is completely closed.

5. Check that the choke valve turns from the fully closed to the fully opened position when actuating the equipment choke control.

NOTE: The service intervals can be used as a guide. Service more frequently as necessary depending on operating conditions, especially in dusty conditions.

Oil Change (Every 100 hours):

1. Run the engine to warm the oil.

2. Ensure the engine is level and then stop it.

3. Remove the oil drain plug and drain the oil into a suitable container while the engine is warm. WARNING: Hot engine oil can cause severe burns. Allow the engine temperature to drop to a warm level before handling.

4. Install the oil drain plug.

5. Remove the oil gauge and refill with fresh oil as specified in the “FUEL AND OIL RECOMMENDATIONS” section.

6. Check the oil level as described in the preparation chapter.

Oil Filter Change (Every 200 hours):

1. Drain the engine oil into a suitable container.

2. Rotate the oil filter counterclockwise to remove it. CAUTION: Before removing the filter, place a suitable pan under the filter connection.

3. Coat a film of clean engine oil on the seal of the new filter.

4. Install the new filter by rotating it clockwise until the seal contacts the mounting surface. Then, rotate the filter an additional 3/4 turn by hand.

5. Supply engine oil as specified.

6. Run the engine for about 3 minutes, stop the engine, and check for any oil leakage around the filter.

7. Add oil to compensate for the level drop due to the oil filter capacity and re-check the oil level.

CAUTION: To prevent excessive engine wear, do not run the engine with the air cleaner removed.

Foam Element (Clean every 25 hours):

Wash the foam element in detergent and water, and then dry it thoroughly.

Paper Element (Clean every 100 hours, Replace yearly or every 200 hours):

Clean the paper element by tapping it gently to remove dust. If it is very dirty, replace it with a new one. Replace the paper element yearly or every 200 hours, whichever comes first. Operating in dusty conditions may require more frequent maintenance.

CAUTION:

Do not wash the paper element.

Do not oil the foam or paper element.

Do not use pressurized air to clean the paper element.

Clean or replace the spark plugs and reset the spark plug gap every 100 hours of operation.

WARNING: Hot engine components can cause severe burns. Stop the engine and allow it to cool before checking spark plugs.

1. Disconnect the spark plug caps from the spark plugs and remove the plugs.

2. Clean the electrodes by scraping with a wire brush to remove carbon deposits.

3. Inspect for cracked porcelain or other wear and damage. Replace the spark plug with a new one if necessary.

4. Check the spark plug gap. The gap must be 0.75 mm (0.030 in). To change the gap, bend only the side-electrode using a spark plug tool.

5. Install and tighten the spark plugs to 22 N·m (16 ft·lb). Reconnect the spark plug caps.

Recommended Spark Plug: NGK BPR4ES

CAUTION: Do not run the engine before all cooling system parts are reinstalled to keep cooling and carburetion as intended.

Before each use: Check that the air inlet (rotary) screen is free from grass and debris and clean if necessary. When checking or cleaning, remove the air inlet guard.

Every 25 hours (For Inspection Port Model): Detach the air cleaner cover and check inside the shroud through the inspection ports. Clean or blow out inside debris or dust if needed.

Every 100 hours: Check and clean the cooling fins and inside of the engine shrouds to remove grass, chaff, or dirt that may be clogging the cooling system and causing overheating. To clean, remove the air cleaner, loosen the specified bolts, and then remove the fan housing.

If not operating your KAWASAKI FS691V for more than 30 days, follow these storage procedures:

1. Add fuel stabilizer to the fuel tank and run the engine for 5 minutes. Then, drain the fuel tank.

2. After draining the tank, run the engine at a low idle until it stalls to remove fuel from the carburetor.

3. Clean every part of the engine. Ensure the engine switch is “OFF”.

4. Remove the spark plugs and pour approx. 1-2 mL (0.06-0.1 cu. in.) of engine oil through the spark plug holes.

5. Screw the spark plugs back in after turning the engine a few times. Slowly turn the engine until you feel compression and leave it there to prevent rust.

6. Wipe the engine body with an oily cloth.

7. Wrap the engine with plastic sheeting and store it in a dry place.

8. Change the engine oil before the next use after a period of storage.

Note: Specifications are subject to change without notice. Dry weight excludes that of the fuel tank and muffler.

For electrical safety, always remove the cable from the negative (-) side of the battery before attempting any repair or maintenance.