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Kawasaki FD851D - User Manual

Kawasaki FD851D
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FD851D
Part No. 99920-2279-01
OWNER’S MANUAL
4-Stroke Air-Cooled V-Twin Gasoline Engine
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Summary

Safety Awareness

DANGER

Indicates a hazardous situation that will result in death or serious injury if not avoided.

WARNING

Indicates a hazardous situation that could result in death or serious injury if not avoided.

CAUTION

Indicates a hazardous situation that could result in minor or moderate injury if not avoided.

NOTICE

Used to address practices not related to personal injury.

NOTE

Indicates points of particular interest for more efficient and convenient operation.

Read This First

DANGER: Exhaust Gas and Gasoline Hazards

Hazards related to carbon monoxide and flammable gasoline, including safety precautions.

Fire Hazard Prevention

Precautions to prevent fire hazards from the engine, such as keeping distance from flammable objects.

Electric Shock Prevention

Safety advice to avoid electric shock, specifically regarding spark plugs and leads.

Burn Prevention

Warning about touching hot engine or muffler and the need for cooling before servicing.

Moving Parts Safety

Safety instruction to keep hands and feet away from moving or rotating engine parts.

Excessive Speed Warning

Warning against running the engine at excessive speeds to prevent injury.

Prevent Accidental Starting

Safety measure to prevent accidental starting by removing spark plug caps during servicing.

Emission Control Information

Fuel Information

Information about the recommended fuel type and octane rating for the engine.

Emission Control System Overview

Details on Kawasaki's emission control system and compliance with EPA and CARB regulations.

Exhaust Emission Control System Details

Explanation of the engine's exhaust emission control system, including fuel and ignition systems.

Engine Emissions Compliance Period

Specifies the emissions durability period for engines based on model year and location.

High Altitude Performance Adjustment

Note on Emission Modifications

Note regarding modifications for emission performance not being considered tampering.

Maintenance and Warranty

Emphasizes proper maintenance for emission levels and warranty compliance.

Tampering Prohibitions

Legal prohibition against tampering with emission control systems.

Tampering with Emission Control Parts

Prohibited Emission Related Parts

Lists specific engine components that should not be tampered with regarding emission control.

Foreword

Read and Understand Manual

Emphasizes the importance of reading and understanding the manual before operating the engine.

Proper Care and Maintenance

Advises on proper care and maintenance according to the manual for a long engine life.

General Information

Location of Safety Labels

Identifies the locations of important safety labels on the engine.

Engine Serial Number Identification

Explains the importance of the engine serial number for identification and parts ordering.

General Information

Parts Location

Illustrates and labels the various parts of the engine.

General Information

Tune-up Specifications

Provides essential tune-up specifications like ignition timing, spark plugs, and idle speeds.

Coolant and Engine Oil Capacity

Details the required capacities for coolant and engine oil.

Fuel and Oil Recommendations

Fuel Type and Usage

Information on recommended fuel type, octane rating, and oxygenated fuel usage.

Octane Rating Importance

Explains octane rating and its importance for engine performance and preventing knocking.

Oxygenated Fuel Guidelines

Guidelines for using gasoline containing oxygenates like ethanol, MTBE, and methanol.

Fuel and Oil Recommendations

Engine Oil Recommendations

Recommendations for engine oil viscosity and API service classification.

Oil Viscosity Selection

Chart showing recommended oil viscosity based on ambient temperature.

Preparation

Fueling Procedure and Safety

Safety warnings and instructions for refueling the engine.

Engine Oil Level Check

Daily engine oil check procedure and capacity information.

Engine Oil Overfill Warning

Warning against overfilling engine oil, which can cause smoking and overheating.

Engine Shipped Without Fluids Notice

Important notice that the engine is shipped without essential fluids.

Preparation

Coolant Level Check

Instructions for checking and maintaining the engine's coolant level.

Recommended Coolant Solution

Specifies the recommended coolant mixture ratio and type of antifreeze.

Starting

Engine Start Procedure

Step-by-step instructions for starting the engine, including safety warnings.

DANGER: Exhaust Gas Poisoning

Safety warning about carbon monoxide poisoning from exhaust gas in enclosed areas.

WARNING: Exhaust Fire Hazard

Warning about engine exhaust igniting combustible materials and causing fire.

NOTE: Cold Weather Starting Tips

Tips for easier engine starting in cold weather.

NOTICE: Starter Limit Warning

Warning about continuous starter operation to prevent battery discharge.

Starting

NOTICE: Warning Light Check

Instruction to check oil level if warning light illuminates upon starting.

NOTICE: Self-Diagnosis Light Check

Guidance on checking the self-diagnosis light function before and during engine start.

Operating

Engine Warming Up Procedure

Procedure for warming up the engine before applying load.

NOTICE: Warm-up Benefits

Explains the benefits of warming up the engine for proper lubrication and clearance.

NOTICE: Monitoring During Warm-up

Advises to monitor warning lights during engine warm-up.

Operating

Engine Inclination Limits

Specifies the maximum operating angle for the engine and potential lubrication issues.

NOTICE: Angle Operation Restrictions

Warning against continuous operation at angles exceeding 25 degrees to prevent engine damage.

Stopping

Ordinary Engine Stop

Steps for a normal engine shutdown procedure.

NOTICE: Prevent Engine Run-on

Warning about stopping the engine suddenly from high load and the need to idle first.

Emergency Engine Stop

Instructions for an emergency engine shutdown procedure.

WARNING: Key in Ignition Hazard

Warning about the risks of leaving the ignition key in unattended equipment.

Adjustment

Throttle Cable Installation and Adjustment

Guides on how to install and adjust the throttle cable for proper operation.

Adjustment

Engine Speed Adjustment Guidelines

Information regarding engine speed adjustment and the prohibition of tampering with settings.

NOTE: Tampering with Governor;Carburetor

Warning against unauthorized adjustments to the governor, carburetor, or DFI system.

Maintenance

Periodic Maintenance Chart

A comprehensive chart detailing maintenance tasks and their recommended intervals.

WARNING: Prevent Accidental Starting

Safety warning to remove spark plug caps before engine service to prevent accidental starting.

NOTE: Service Interval Guidance

Note that service intervals are a guide and may need adjustment based on operating conditions.

Maintenance

Daily Checks

Covers daily checks like oil level and fastener security.

First 8 Hour Checks

Specific checks recommended after the first 8 hours of operation.

Check and Add Engine Oil

Procedure for checking and topping up engine oil.

Check Fasteners and Leaks

Periodic inspection for loose fasteners and fuel/oil leaks.

Check Battery Electrolyte

Procedure for checking the battery electrolyte level.

Check Radiator Screen

Inspection and cleaning of the radiator screen.

Tighten Fasteners

Recommended tightening of bolts, nuts, and screws at specific intervals.

Maintenance

Change Engine Oil

Procedure and interval for changing engine oil.

Spark Plug Maintenance

Procedure for cleaning, inspecting, and replacing spark plugs.

Oil Filter Change

Instructions and interval for changing the engine oil filter.

Air Cleaner Primary Element

Schedule for replacing the primary air cleaner element.

Air Cleaner Secondary Element Service

Checking and replacing the secondary air cleaner element.

Combustion Chamber Cleaning

Cleaning of combustion chambers, typically dealer-performed.

Valve Clearance Adjustment

Procedure for checking and adjusting valve clearance.

Radiator and Hose Inspection

Inspection of the radiator and hoses for proper function and integrity.

Fan Belt Check

Checking the condition and tension of the fan belt.

Coolant Change

Procedure for changing the engine coolant.

Maintenance

Engine Oil Level Check

Detailed instructions on how to check the engine oil level.

Engine Oil Change Procedure

Step-by-step guide for changing the engine oil, including intervals and safety.

WARNING: Hot Oil Burn Hazard

Warning about the risk of burns from hot engine oil during draining.

WARNING: Used Oil Disposal

Guidance on the proper disposal of used engine oil due to its toxic nature.

Maintenance

Oil Filter Change Procedure

Procedure for replacing the engine oil filter, including hours of operation and installation steps.

NOTICE: Oil Filter Pan Placement

Advice to place a pan to catch oil before removing the oil filter.

WARNING: Engine Oil Disposal

Reiterates the toxic nature of engine oil and the need for proper disposal.

Maintenance

Cooling System Inspection

Instructions for inspecting the radiator and hoses for damage and cleanliness.

NOTICE: High-Pressure Washer Use

Warning against using high-pressure water on radiator fins, which can cause damage.

WARNING: Coolant Disposal

Information on the toxic nature of coolant and its proper disposal.

Maintenance

Air Cleaner Service

Instructions for air cleaner service, including element replacement.

NOTICE: Improper Air Cleaner Installation

Warning that incorrect installation of air cleaner parts can lead to engine damage.

NOTICE: Engine Wear Warning

Advice against operating the engine with air cleaner parts removed to prevent wear.

Primary Air Cleaner Element

Schedule for replacing the primary air cleaner element.

Secondary Air Cleaner Element

Schedule for replacing the secondary air cleaner element.

Dust Ejector Valve Cap

How to operate the dust ejector valve cap.

NOTE: Dusty Conditions

Note that dusty operating conditions may require more frequent air cleaner maintenance.

NOTICE: Air Cleaner Cleaning Restrictions

Prohibits washing, oiling, or using pressurized air on air cleaner elements.

Maintenance

Fuel Filter and Fuel Pump Service

Information regarding service for the fuel filter and fuel pump.

WARNING: Solvent Safety Precautions

Safety warning about the flammability and explosion risks associated with solvents.

Maintenance

Spark Plug Service

Detailed procedure for cleaning, inspecting, and replacing spark plugs.

WARNING: Hot Engine Components

Warning about hot engine components causing burns and the need for cooling before servicing.

Storage

Fuel System Draining for Storage

Instructions for draining the fuel system for extended storage to prevent fuel deterioration.

WARNING: Gasoline Storage Safety

Safety precautions for handling and storing gasoline due to its flammability.

WARNING: Gasoline Environmental Disposal

Information on the environmental impact of gasoline and proper disposal methods.

Storage

Cylinder Rust Prevention

Procedure for protecting engine cylinders from rust during storage by adding oil.

Spark Plug Cap Securement

Ensuring spark plug caps are securely fitted.

Exterior Protection

Cleaning the engine exterior with an oily cloth for protection.

Engine Storage

Instructions for wrapping and storing the engine in a dry environment.

Post-Storage Oil Change

Recommendation to change engine oil after storage before the next use.

Troubleshooting Guide

Engine Start;Output Issues

Troubleshooting steps for common engine starting and low output issues.

Fuel Delivery Problems

Diagnosing and resolving issues related to fuel delivery to the combustion chambers.

Fuel-Fouled Spark Plugs

Solutions for spark plugs fouled by fuel, including cleaning and checking mixture.

Troubleshooting Guide

Ignition Problems (No;Weak Spark)

Troubleshooting steps for ignition system problems causing no or weak spark.

Engine Overheating Causes

Common causes and remedies for engine overheating issues.

Engine Speed Increase Issues

Troubleshooting steps when the engine speed fails to increase as expected.

Environmental Protection

Proper Disposal of Engine Components

Guidance on environmentally responsible disposal of engine components and fluids.

Specifications

Engine Type

Specifies the engine type as liquid-cooled, 4-stroke OHV, V-twin gasoline.

Bore and Stroke

Engine bore and stroke dimensions.

Displacement

The engine's displacement volume.

Ignition System

Details the type of ignition system used.

Direction of Rotation

Specifies the engine's direction of rotation relative to the PTO shaft.

Starting System

Identifies the engine's starting system.

Dry Weight

The dry weight of the engine.

NOTE: Specification Changes

A note indicating that specifications are subject to change without notice.

Wiring Diagram

Wiring Diagram

The schematic diagram illustrating the engine's electrical connections.

Final Warnings

California Proposition 65 Warning

California Proposition 65 warning regarding engine exhaust chemicals.

Engine Oil Toxicity and Disposal

Warning about engine oil toxicity and the need for proper disposal.

Repair;Warranty Assistance Contact

Contact information for obtaining repair or warranty assistance.

Gasoline Toxicity and Disposal

Warning about gasoline toxicity and the requirement for proper disposal.

Summary

Safety Awareness

DANGER

Indicates a hazardous situation that will result in death or serious injury if not avoided.

WARNING

Indicates a hazardous situation that could result in death or serious injury if not avoided.

CAUTION

Indicates a hazardous situation that could result in minor or moderate injury if not avoided.

NOTICE

Used to address practices not related to personal injury.

NOTE

Indicates points of particular interest for more efficient and convenient operation.

Read This First

DANGER: Exhaust Gas and Gasoline Hazards

Hazards related to carbon monoxide and flammable gasoline, including safety precautions.

Fire Hazard Prevention

Precautions to prevent fire hazards from the engine, such as keeping distance from flammable objects.

Electric Shock Prevention

Safety advice to avoid electric shock, specifically regarding spark plugs and leads.

Burn Prevention

Warning about touching hot engine or muffler and the need for cooling before servicing.

Moving Parts Safety

Safety instruction to keep hands and feet away from moving or rotating engine parts.

Excessive Speed Warning

Warning against running the engine at excessive speeds to prevent injury.

Prevent Accidental Starting

Safety measure to prevent accidental starting by removing spark plug caps during servicing.

Emission Control Information

Fuel Information

Information about the recommended fuel type and octane rating for the engine.

Emission Control System Overview

Details on Kawasaki's emission control system and compliance with EPA and CARB regulations.

Exhaust Emission Control System Details

Explanation of the engine's exhaust emission control system, including fuel and ignition systems.

Engine Emissions Compliance Period

Specifies the emissions durability period for engines based on model year and location.

High Altitude Performance Adjustment

Note on Emission Modifications

Note regarding modifications for emission performance not being considered tampering.

Maintenance and Warranty

Emphasizes proper maintenance for emission levels and warranty compliance.

Tampering Prohibitions

Legal prohibition against tampering with emission control systems.

Tampering with Emission Control Parts

Prohibited Emission Related Parts

Lists specific engine components that should not be tampered with regarding emission control.

Foreword

Read and Understand Manual

Emphasizes the importance of reading and understanding the manual before operating the engine.

Proper Care and Maintenance

Advises on proper care and maintenance according to the manual for a long engine life.

General Information

Location of Safety Labels

Identifies the locations of important safety labels on the engine.

Engine Serial Number Identification

Explains the importance of the engine serial number for identification and parts ordering.

General Information

Parts Location

Illustrates and labels the various parts of the engine.

General Information

Tune-up Specifications

Provides essential tune-up specifications like ignition timing, spark plugs, and idle speeds.

Coolant and Engine Oil Capacity

Details the required capacities for coolant and engine oil.

Fuel and Oil Recommendations

Fuel Type and Usage

Information on recommended fuel type, octane rating, and oxygenated fuel usage.

Octane Rating Importance

Explains octane rating and its importance for engine performance and preventing knocking.

Oxygenated Fuel Guidelines

Guidelines for using gasoline containing oxygenates like ethanol, MTBE, and methanol.

Fuel and Oil Recommendations

Engine Oil Recommendations

Recommendations for engine oil viscosity and API service classification.

Oil Viscosity Selection

Chart showing recommended oil viscosity based on ambient temperature.

Preparation

Fueling Procedure and Safety

Safety warnings and instructions for refueling the engine.

Engine Oil Level Check

Daily engine oil check procedure and capacity information.

Engine Oil Overfill Warning

Warning against overfilling engine oil, which can cause smoking and overheating.

Engine Shipped Without Fluids Notice

Important notice that the engine is shipped without essential fluids.

Preparation

Coolant Level Check

Instructions for checking and maintaining the engine's coolant level.

Recommended Coolant Solution

Specifies the recommended coolant mixture ratio and type of antifreeze.

Starting

Engine Start Procedure

Step-by-step instructions for starting the engine, including safety warnings.

DANGER: Exhaust Gas Poisoning

Safety warning about carbon monoxide poisoning from exhaust gas in enclosed areas.

WARNING: Exhaust Fire Hazard

Warning about engine exhaust igniting combustible materials and causing fire.

NOTE: Cold Weather Starting Tips

Tips for easier engine starting in cold weather.

NOTICE: Starter Limit Warning

Warning about continuous starter operation to prevent battery discharge.

Starting

NOTICE: Warning Light Check

Instruction to check oil level if warning light illuminates upon starting.

NOTICE: Self-Diagnosis Light Check

Guidance on checking the self-diagnosis light function before and during engine start.

Operating

Engine Warming Up Procedure

Procedure for warming up the engine before applying load.

NOTICE: Warm-up Benefits

Explains the benefits of warming up the engine for proper lubrication and clearance.

NOTICE: Monitoring During Warm-up

Advises to monitor warning lights during engine warm-up.

Operating

Engine Inclination Limits

Specifies the maximum operating angle for the engine and potential lubrication issues.

NOTICE: Angle Operation Restrictions

Warning against continuous operation at angles exceeding 25 degrees to prevent engine damage.

Stopping

Ordinary Engine Stop

Steps for a normal engine shutdown procedure.

NOTICE: Prevent Engine Run-on

Warning about stopping the engine suddenly from high load and the need to idle first.

Emergency Engine Stop

Instructions for an emergency engine shutdown procedure.

WARNING: Key in Ignition Hazard

Warning about the risks of leaving the ignition key in unattended equipment.

Adjustment

Throttle Cable Installation and Adjustment

Guides on how to install and adjust the throttle cable for proper operation.

Adjustment

Engine Speed Adjustment Guidelines

Information regarding engine speed adjustment and the prohibition of tampering with settings.

NOTE: Tampering with Governor;Carburetor

Warning against unauthorized adjustments to the governor, carburetor, or DFI system.

Maintenance

Periodic Maintenance Chart

A comprehensive chart detailing maintenance tasks and their recommended intervals.

WARNING: Prevent Accidental Starting

Safety warning to remove spark plug caps before engine service to prevent accidental starting.

NOTE: Service Interval Guidance

Note that service intervals are a guide and may need adjustment based on operating conditions.

Maintenance

Daily Checks

Covers daily checks like oil level and fastener security.

First 8 Hour Checks

Specific checks recommended after the first 8 hours of operation.

Check and Add Engine Oil

Procedure for checking and topping up engine oil.

Check Fasteners and Leaks

Periodic inspection for loose fasteners and fuel/oil leaks.

Check Battery Electrolyte

Procedure for checking the battery electrolyte level.

Check Radiator Screen

Inspection and cleaning of the radiator screen.

Tighten Fasteners

Recommended tightening of bolts, nuts, and screws at specific intervals.

Maintenance

Change Engine Oil

Procedure and interval for changing engine oil.

Spark Plug Maintenance

Procedure for cleaning, inspecting, and replacing spark plugs.

Oil Filter Change

Instructions and interval for changing the engine oil filter.

Air Cleaner Primary Element

Schedule for replacing the primary air cleaner element.

Air Cleaner Secondary Element Service

Checking and replacing the secondary air cleaner element.

Combustion Chamber Cleaning

Cleaning of combustion chambers, typically dealer-performed.

Valve Clearance Adjustment

Procedure for checking and adjusting valve clearance.

Radiator and Hose Inspection

Inspection of the radiator and hoses for proper function and integrity.

Fan Belt Check

Checking the condition and tension of the fan belt.

Coolant Change

Procedure for changing the engine coolant.

Maintenance

Engine Oil Level Check

Detailed instructions on how to check the engine oil level.

Engine Oil Change Procedure

Step-by-step guide for changing the engine oil, including intervals and safety.

WARNING: Hot Oil Burn Hazard

Warning about the risk of burns from hot engine oil during draining.

WARNING: Used Oil Disposal

Guidance on the proper disposal of used engine oil due to its toxic nature.

Maintenance

Oil Filter Change Procedure

Procedure for replacing the engine oil filter, including hours of operation and installation steps.

NOTICE: Oil Filter Pan Placement

Advice to place a pan to catch oil before removing the oil filter.

WARNING: Engine Oil Disposal

Reiterates the toxic nature of engine oil and the need for proper disposal.

Maintenance

Cooling System Inspection

Instructions for inspecting the radiator and hoses for damage and cleanliness.

NOTICE: High-Pressure Washer Use

Warning against using high-pressure water on radiator fins, which can cause damage.

WARNING: Coolant Disposal

Information on the toxic nature of coolant and its proper disposal.

Maintenance

Air Cleaner Service

Instructions for air cleaner service, including element replacement.

NOTICE: Improper Air Cleaner Installation

Warning that incorrect installation of air cleaner parts can lead to engine damage.

NOTICE: Engine Wear Warning

Advice against operating the engine with air cleaner parts removed to prevent wear.

Primary Air Cleaner Element

Schedule for replacing the primary air cleaner element.

Secondary Air Cleaner Element

Schedule for replacing the secondary air cleaner element.

Dust Ejector Valve Cap

How to operate the dust ejector valve cap.

NOTE: Dusty Conditions

Note that dusty operating conditions may require more frequent air cleaner maintenance.

NOTICE: Air Cleaner Cleaning Restrictions

Prohibits washing, oiling, or using pressurized air on air cleaner elements.

Maintenance

Fuel Filter and Fuel Pump Service

Information regarding service for the fuel filter and fuel pump.

WARNING: Solvent Safety Precautions

Safety warning about the flammability and explosion risks associated with solvents.

Maintenance

Spark Plug Service

Detailed procedure for cleaning, inspecting, and replacing spark plugs.

WARNING: Hot Engine Components

Warning about hot engine components causing burns and the need for cooling before servicing.

Storage

Fuel System Draining for Storage

Instructions for draining the fuel system for extended storage to prevent fuel deterioration.

WARNING: Gasoline Storage Safety

Safety precautions for handling and storing gasoline due to its flammability.

WARNING: Gasoline Environmental Disposal

Information on the environmental impact of gasoline and proper disposal methods.

Storage

Cylinder Rust Prevention

Procedure for protecting engine cylinders from rust during storage by adding oil.

Spark Plug Cap Securement

Ensuring spark plug caps are securely fitted.

Exterior Protection

Cleaning the engine exterior with an oily cloth for protection.

Engine Storage

Instructions for wrapping and storing the engine in a dry environment.

Post-Storage Oil Change

Recommendation to change engine oil after storage before the next use.

Troubleshooting Guide

Engine Start;Output Issues

Troubleshooting steps for common engine starting and low output issues.

Fuel Delivery Problems

Diagnosing and resolving issues related to fuel delivery to the combustion chambers.

Fuel-Fouled Spark Plugs

Solutions for spark plugs fouled by fuel, including cleaning and checking mixture.

Troubleshooting Guide

Ignition Problems (No;Weak Spark)

Troubleshooting steps for ignition system problems causing no or weak spark.

Engine Overheating Causes

Common causes and remedies for engine overheating issues.

Engine Speed Increase Issues

Troubleshooting steps when the engine speed fails to increase as expected.

Environmental Protection

Proper Disposal of Engine Components

Guidance on environmentally responsible disposal of engine components and fluids.

Specifications

Engine Type

Specifies the engine type as liquid-cooled, 4-stroke OHV, V-twin gasoline.

Bore and Stroke

Engine bore and stroke dimensions.

Displacement

The engine's displacement volume.

Ignition System

Details the type of ignition system used.

Direction of Rotation

Specifies the engine's direction of rotation relative to the PTO shaft.

Starting System

Identifies the engine's starting system.

Dry Weight

The dry weight of the engine.

NOTE: Specification Changes

A note indicating that specifications are subject to change without notice.

Wiring Diagram

Wiring Diagram

The schematic diagram illustrating the engine's electrical connections.

Final Warnings

California Proposition 65 Warning

California Proposition 65 warning regarding engine exhaust chemicals.

Engine Oil Toxicity and Disposal

Warning about engine oil toxicity and the need for proper disposal.

Repair;Warranty Assistance Contact

Contact information for obtaining repair or warranty assistance.

Gasoline Toxicity and Disposal

Warning about gasoline toxicity and the requirement for proper disposal.

Kawasaki FD851D Specifications

General IconGeneral
BrandKawasaki
ModelFD851D
CategoryEngine
LanguageEnglish

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