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1 For Kawasaki Discount Parts Call 606-678-9623 or Kawasaki Discount Parts Call 606-678-9623 or 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 table of contents page. Refer to the sectional table of contentsfor the exact pages to locate the spe-cific topic Reference GuideGeneral Information1 jPeriodic Maintenance2 jFuel System3 jCooling System4 jEngine Top End5 jLubrication System6 jCamshaft/Crankshaft7 jStarter System8 jElectrical System9 jTroubleshooting10 jFor Kawasaki Discount Parts Call 606-678-9623 or Kawasaki Discount Parts Call 606-678-9623 or , FH500V, FH531 VFH541V, FH580V, FH601 VFH641V, FH661V, FH680 VFH721V4-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 Division/Consumer Products & Machinery Company/KawasakiHeavy 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. 2006 Kawasaki Heavy Industries, Edition (1):Mar. 31, 2006 (K)For Kawasaki Discount Parts Call 606-678-9623 or 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)TDCtop dead center Fdegree(s) FahrenheitTIRtotal indicator readingftfoot, feetVvolt(s)ggram(s)Wwatt(s)hhour(s) ohm(s)Lliter(s)For Kawasaki Discount Parts Call 606-678-9623 or CONTROL INFORMATIONTo protect the environment in which we all live, Kawasaki has incorporated crankcase emission(1) and exhaust emission (2)

4 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 passingthrough the inside of the breather chamber fromthe crankcase, 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.

5 (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 are the acts listed below: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 tubeFor Kawasaki Discount Parts Call 606-678-9623 or 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.

6 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. 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 .

7 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 preparing this manual , we divided the prod-uct into its major systems. These systems be-came the manual s chapters. All informationfor a particular system from adjustment throughdisassembly and inspection is located in a sin-gle Quick Reference Guide shows you allof the product s system and assists in locatingtheir chapters. Each chapter in turn has its owncomprehensive Table of Periodic Maintenance Chart is locatedin the General Information chapter.

8 The chartgives a time schedule for required you want spark plug information, for exam-ple, go to the Periodic Maintenance Chart chart tells you how frequently to clean andgap the plug. Next, use the Quick ReferenceGuide to locate the Electrical System , use the Table of Contents on the firstpage of the chapter to find the Spark Plug 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) which willhelp you distinguish different types of This note symbol indicates points of par-ticular interest for more efficient and con-venient operation.

9 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. In these illustrations you will find theinstructions indicating which parts require spec-ified tightening torque, oil, grease or a lockingagent during Kawasaki Discount Parts Call 606-678-9623 or INFORMATION 1-11 General InformationTable of ContentsBefore Servicing ..1-2 Model Kawasaki Discount Parts Call 606-678-9623 or GENERAL INFORMATIONB efore ServicingBefore starting to service the engine, carefully read the applicable section to eliminate unnecessarywork.

10 Photographs, diagrams, notes, cautions, warnings, and detailed descriptions have been in-cluded wherever necessary. Nevertheless, even adetailed account has limitations, a certain amountof basic knowledge is required for successful note the following:(1) DirtBefore removal and disassembly, clean the engine. Any dirt entering the engine, carburetor, orother parts, will work as an abrasive and shorten the life of engine. For the same reason, beforeinstalling a new part, clean off any dust or metal filings.(2) Battery GroundRemove the ground ( ) lead from the battery before performing any disassembly operations onthe equipment. This prevents:(a)the possibility of accidentally turning the engine over while partially disassembled.(b)sparks at electrical connections which will occur when they are disconnected.