This 152-page Kawasaki FX751V, FX801V, FX850V service manual PDF covers the 4-stroke air-cooled gasoline engine in all three variants. Charging and ignition wiring diagrams lay out each circuit, and exploded views break down the carburetor, shroud and cylinder head so reassembly order is never a guess. Valve seat repair, oil pump and relief valve service, and a symptom-based troubleshooting guide round out the book. Gap the plugs at 0.7 to 0.8 mm before torquing them to 22 N·m (16 ft·lb); the carburetor and inlet pipe mounting bolts take 5.9 N·m. Chapter bookmarks and a searchable text layer keep every clearance and torque value close before it goes back together, and the exploded views confirm which gasket you're holding so your parts order is right the first time.
What's Inside This Kawasaki FX751V, FX801V, FX850V Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 9-14 | Before Servicing, Model Identification, General Specifications |
| Periodic Maintenance | 15-30 | Periodic Maintenance Chart, Torque and Locking Agent, Specifications, Special Tools |
| Fuel System | 31-56 | Governor Link Mechanism, Carburetor, Inlet Manifold |
| Cooling System | 57-62 | Cooling Fan, Engine Shroud |
| Engine Top End | 63-84 | Cylinder Head, Valves, Cylinder, Piston |
| Lubrication System | 85-96 | Engine Oil, Oil Filter and Oil Cooler, Oil Pump, Relief Valve, Oil Screen |
| Camshaft/Crankshaft | 97-116 | Crankcase, Breather, Camshaft, Tappet |
| Starter System | 117-130 | Electric Starter System, Starter Motor Brush Inspection |
| Electrical System | 131-146 | Charging System, Ignition System |
| Troubleshooting | 147-152 | Engine Troubleshooting Guide |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Spark Plug Torque | 22 N·m (2.2 kgf·m, 16 ft·lb) | p. 18 |
| Spark Plug Gap | 0.7 - 0.8 mm (0.028 - 0.031 in.) | p. 9 |
| Carburetor and Inlet Pipe Mounting Bolts Torque | 5.9 N·m (0.60 kgf·m, 52 in·lb) | p. 17 |
| Carburetor and Inlet Pipe Mounting Nuts Torque | 5.9 N·m (0.60 kgf·m, 52 in·lb) | p. 17 |
| Ignition Coil Bolts Torque | 5.9 N·m (0.60 kgf·m, 52 in·lb) | p. 17 |
| Rocker Arm Bracket Bolts Torque | 21 N·m (2.10 kgf·m, 15.0 ft·lb) | p. 17 |
| Carburetor and Inlet Pipe Mounting Bolts | 5.9 N·m (0.60 kgf·m, 52 in·lb) | p. 33 |
| Carburetor and Inlet Pipe Mounting Nuts | 5.9 N·m (0.60 kgf·m, 52 in·lb) | p. 33 |
| Cylinder Head Bolts Torque | 46 N·m (4.7 kgf·m, 34 ft·lb) | p. 65 |
| Valve Clearance | 0.05 - 0.10 mm (0.0020 - 0.039 in.) | p. 67 |
| Valve Clearance (when cold) | 0.05 - 0.10 mm | p. 19 |
| Ignition Coil Air Gap | 0.2 - 0.4 mm (0.008 - 0.016 in.) | p. 134 |
Kawasaki FX751V, FX801V, FX850V Common Problems This Manual Covers
Kawasaki FX751V FX801V FX850V cylinder compression reads below minimum on gauge test with engine hard to start
Verify the battery is fully charged and warm the engine thoroughly, then pull both plugs and crank with the throttle wide open until the gauge stops rising, following page 69. Ground the removed plugs to the engine well away from the plug holes to avoid fire. Below 440 kPa (64 psi), check head gasket leakage and head warp, valve seating, valve clearance, piston and cylinder wear, and rings and ring grooves.
Manual Section: Compression Measurement p. 69Lubrication circuit at 3,200 rpm shows oil pressure below specification on test gauge
Remove the oil passage plug, fit the gauge and adapter, and run the warmed engine at 3,200 rpm with oil at 50 to 60°C as page 92 lays out. A reading under 294 kPa (43 psi) means inspect the oil pump and relief valve first. Clean relief valve parts in a well ventilated area away from sparks or flame, never with gasoline or low-flash solvent (page 95). Replace them if cleaning fails.
Manual Section: Oil Pressure Measurement p. 92Fuel pump outlet delivers little or no fuel during flow test into container
Remove the pump outlet nozzle from its tube, run a hose into a container, start the engine and watch the flow as page 53 shows. Work in a well ventilated area with no smoking and no flame, sparks or pilot light nearby. If flow is none or little, replace the fuel pump, then check the tubes and fuel filter for clogging or damage. Fit a new filter with the arrow toward the pump.
Manual Section: Fuel Flow Test p. 53Carburetor drain screw releases water or dirt from bowl during fuel cleanliness check
Drain the carburetor through the drain screw into a container with the ignition switch OFF, no smoking, and no flame or sparks nearby, as page 22 directs. If water or dirt shows up, clean the carburetor and fuel tank and check the fuel filter. Clean the carburetor in a ventilated area without gasoline or low-flash solvent, and never use compressed air on it assembled (page 47).
Manual Section: Fuel System Cleanliness Inspection p. 22Starter solenoid does not click and tester reads above 0 Ω with switch in START
Verify the battery is fully charged, disconnect the starter motor lead from the solenoid terminal, and connect the tester on R × 1 Ω across the large terminals as page 122 shows. Turn the switch to START: no click or more than 0 Ω means replace the solenoid. If it never clicks, check switch lead voltage on the 25 V DC range; well below battery voltage points to wiring or the engine switch.
Manual Section: Starter Solenoid and Circuit Test p. 122Valve clearance between rocker arm and valve stem end out of specification when checked cold
Check clearance cold with the piston at TDC of the compression stroke, aligning the flywheel projection with the ignition coil leg following page 24. Measure with a thickness gauge against 0.05 to 0.10 mm for inlet and exhaust. Adjust with the locknut loose, then hold the adjusting bolt and torque the locknut to 11 N·m without overtightening. Measure again before the rocker cover goes back on.
Manual Section: Valve Clearance Inspection p. 24Frequently Asked Questions
How do I troubleshoot a Kawasaki FX751V, FX801V, or FX850V that will not start?
If the engine fails to start, first check for spark by removing the spark plug and cranking the engine while it is grounded to the block. If there is no spark, check the ignition coil and flywheel air gap; if there is spark, check for fuel delivery issues such as a plugged fuel line, air filter, or high fuel level in the float bowl. Detailed troubleshooting steps are provided in the Engine Troubleshooting Guide on page 148. p. 148
What are the torque specifications for major fasteners on the Kawasaki FX751V, FX801V, and FX850V engines?
Torque specifications vary by system; for example, cylinder head bolts must be tightened to 46 N·m (34 ft-lb) in a specific sequence. Carburetor and inlet pipe mounting bolts require 5.9 N·m (52 in-lb), while the flywheel bolt requires 56 N·m (41 ft-lb). A complete table of torque values for all major fasteners is available on pages 17 and 18. p. 17
How do I adjust the governor and high-idle speed on a Kawasaki FX engine?
High idle speed should be adjusted after the low idle speed is set. With the engine warmed up, loosen the locknut and adjust the high idle set screw until the engine reaches 3,600 rpm, then tighten the locknut. Do not adjust the high idle speed with the air cleaner removed, as noted on page 21. p. 21
What are the spark plug replacement specifications for the Kawasaki FX751V, FX801V, FX850V?
The standard spark plug for these engines is the NGK BPR4ES. The spark plug gap should be maintained between 0.7 and 0.8 mm (0.028 to 0.031 in.). p. 19
What is the oil capacity for the Kawasaki FX751V, FX801V, and FX850V engines?
The total oil capacity when the engine is completely dry is 2.4 L (2.5 US-qt). When performing a standard oil change where the oil filter is not removed, the capacity is 2.1 L (2.2 US-qt), and 2.3 L (2.4 US-qt) if the filter is removed. p. 13
Do I get instant access to this Kawasaki FX751V Service Manual?
You download the Service Manual yourself: 152 pages, searchable PDF, available immediately. Keep a copy on every device you use.
Can I print this Kawasaki FX751V manual?
Yes. It prints from any PDF reader, so run off the pages you need for your own repair work.
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