FR651V, FR691V, FR730V FS651V, FS691V, FS730V FX651V ...

1 FR651V, FR691V, FR730 VFS651V, FS691V, FS730 VFX651V, FX691V, FX730V4-Stroke Air-Cooled V-Twin Gasoline EngineService ManualThis quick reference guide will assistyou in locating a desired topic or pro-cedure. Bend the pages back to match theblack tab of the desired chapter num-ber with the black tab on the edge ateach tableof contents page. Refer to the sectional table of contentsfor the exact pages to locate the spe-cific topic Reference GuideGeneral Information1jPeriodic Maintenance2jFuel System3jCooling System4jEngine Top End5jLubrication System6jCamshaft/Crankshaft7jStarter System8jElectrical System9jTroubleshooting10jFR651V, FR691V, FR730 VFS651V, FS691V, FS730 VFX651V, FX691V, FX730V4-Stroke Air-Cooled V-Twin Gasoline EngineService ManualAll rights reserved.

2 No parts of this publication may be reproduced, stored in a retrieval system, ortransmitted in any form or by any means, electronic mechanical photocopying, recording or otherwise,without the prior written permission of Quality Assurance Division/Consumer Products & MachineryCompany/Kawasaki Heavy Industries, Ltd., liability can be accepted for any inaccuracies or omissions in this publication, although every possiblecare has been taken to make it as complete and accurate as right is reserved to make changes at any time withoutprior notice and without incurring an obligationto make such changes to products manufactured information contained in this publication is based onthe latest product information available at the timeof publication.

3 Illustrations and photographs in this publication are intended for reference use only and maynot depict actual model component parts. 2009 Kawasaki Heavy Industries, Edition (1):Jan. 9, 2009 (K)LIST OF ABBREVIATIONSA ampere(s)lbpound(s)ABDC after bottom dead centermmeter(s)ACalternating currentminminute(s)ATDC after top dead centerNnewton(s)BBDC before bottom dead centerPapascal(s)BDCbottom dead centerPShorsepowerBTDC before top dead centerpsipound(s) per square inch Cdegree(s) CelsiusrrevolutionDCdirect currentrpmrevolution(s) per minuteFfarad(s)TDCtopdeadcenter Fdegree(s) FahrenheitTIRtotal indicator readingftfoot, feetVvolt(s)ggram(s)Wwatt(s)hhour(s) ohm(s)Lliter(s)

4 EMISSION CONTROL INFORMATIONTo protect the environment in which we all live, Kawasaki has incorporated crankcase emission(1) and exhaust emission (2) control systems (EM) in compliance with applicable regulations ofthe United States Environmental Protection Agency and California Air Resources Emission Control SystemA sealed-type crankcase emission control system is used to eliminate blow-by gases. Theblow-by gases are led to the breather chamber through the crankcase. Then, it is led to the is separated from the gases while passing through the inside of the breather chamber fromthe crankcase.

5 And then returned back to the bottom of Emission Control SystemThe exhaust emission control system applied to this engine consists of a carburetor and anignition system having optimum ignition timing carburetor has been calibrated to provide lean air/fuel mixture characteristics and opti-mum fuel economy with a suitable air cleaner and exhaust WITH EMISSION CONTROL SYSTEM PROHIBITEDF ederal law and California State law prohibits the following acts or the causing thereof: (1) theremoval or rendering inoperative by any person other than for purposes of maintenance, repair,or replacement, of any device or element of design incorporated into any new engine for thepurpose of emission control prior to its sale or delivery to the ultimate purchaser or while it is inuse, or (2) the use of the engine after such device or element of design has been removed orrendered inoperative by any those acts presumed to constitute tampering arethe acts listed below.

6 Do not tamper with the original emission related part: Carburetor and internal parts Spark plugs Magneto or electronic ignition system Fuel filter element Air cleaner elements Crankcase Cylinder heads Breather chamber and internal parts Inlet pipe and tubeForewordThis manual is designed primarily for use bytrained mechanics in a properly equipped , it contains enough detail and basic in-formation to make it useful to the owner who de-sires to perform his own basic maintenance andrepair work. A basic knowledge of mechanics,the proper use of tools, and workshop proce-dures must be understood in order to carry outmaintenance and repair satisfactorily.

7 When-ever the owner has insufficient experience ordoubts as to his ability to do the work, all ad-justments, maintenance, and repair should becarried out only by qualified order to perform the work efficiently andto avoid costly mistakes, read the text, thor-oughly familiarize yourself with the proceduresbefore starting work, and then do the work care-fully in a clean area. Whenever special tools orequipment are specified, do not use makeshifttools or equipment. Precision measurementscan only be made if the proper instruments areused, and the use of substitute tools may ad-versely affect safe get the longest life out of your engine: Follow the Periodic Maintenance Chart in theService Manual.

8 Be alert for problems and non-scheduledmaintenance. Use proper tools and genuine Kawasaki en-gine parts. Genuine parts provided as spareparts are listed in the Parts Catalog. Follow the procedures in this manual care-fully. Don t take shortcuts. Remember to keep complete records of main-tenance and repair with dates and any newparts to Use This ManualIn this manual, the product is divided intoits major systems and these systems make upthe manual s chapters. The Quick ReferenceGuide shows you all of the product s systemand assists in locating their chapters.

9 Eachchapter in turn has its own comprehensive Ta-ble of , example, if you want ignition coil informa-tion, use the Quick Reference Guide to locatethe Electrical System chapter. Then, use theTable of Contents on the first page of the chap-ter to find the Ignition Coil you see these WARNING andCAUTION symbols, heed their instructions!Always follow safe operating and warning symbol identifies specialinstructions or procedures which, if notcorrectly followed, could result in per-sonal injury, or loss of caution symbol identifies specialinstructions or procedures which, if notstrictly observed, could result in dam-age to or destruction of manual contains four more symbols (inaddition to WARNING and CAUTION)

10 Which willhelp you distinguish different types of This note symbol indicates points of par-ticular interest for more efficient and con-venient operation. Indicates a procedural step or work to bedone. Indicates a procedural sub-step or how to dothe work of the procedural step it follows. Italso precedes the text of a WARNING, CAU-TION, or a conditional step or what action totake based on the results of the test or inspec-tion in the procedural step or sub-step it most chapters an exploded view illustrationof the system components follows the Table ofContents.