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Kawasaki FD661D Engine

General Technical Data

Kawasaki FD661D Engine Specifications

Engine Model .............. Kawasaki FD661D
Engine Type .............. 4-cycle horizontal shaft overhead valve liquid-cooled gasoline engine
Number of Cylinders .............. 2
Cylinder Layout .............. 90 deg, V-Twin
Cylinder Liners .............. Cast iron
Displacement, cc (cu.in) .............. 617 (37.7)
Engine Bore, mm (in) .............. 76.0 (2.99)
Engine Stroke, mm (in) .............. 68.0 (2.68)
Maximum Horse Power, hp (kW) .............. 22.0 (16.4)
Rated Engine Speed, rpm .............. 3600
Maximum Torque, Nm (ft-lb) .............. 45.7 (33.8)
Torque Speed, rpm .............. 2800
Compression Ratio .............. 10.3:1
Lubrication System .............. Pressurised feed by positive displacement pump
Oil Filter Type .............. Cartridge, full flow
Air Cleaner Type .............. Dual stage element
Cooling System .............. Pressurized forced circulation type
Coolant Capacity, L (qts) .............. 2.7 (2.9)
Ignition System .............. Transistorized
Starting System .............. Shift type electric starter
Electrical System Rating, Volts .............. 12

Fuel System

Fuel System .............. Carburetor
Carburetor Type .............. Float (down draft) with fixed main jet
Fuel Pump Type .............. Electo magnetic
Governor Type .............. Mechanical
Fuel Filter Type .............. Replaceable paper element
Fuel Type .............. Gasoline (86 or higher)

Dimensions and Weight

Overall Length, mm (in) .............. 555 (21.9)
Overall Width, mm (in) .............. 440 (17.3)
Overall Height, mm (in) .............. 590 (23.2)
Net weight, kg (lbs) .............. 41.5 (91.6)

Kawasaki FD661D Maintenance Data

Cylinder Block and Valves

Cylinder Inside Diameter (Max), mm (in) .............. 76.067 (2.9948)
Cylinder Head Warp, mm (in) .............. 0.05 (0.002)
Cylinder Compression, kPa (psi) .............. 1170 (170)
Intake Valve Clearance (Cold), mm (in) .............. 0.25 (0.010)
Exhaust Valve Clearance (Cold), mm (in) .............. 0.25 (0.010)

Engine Oil and Filters

Engine Oil Type .............. SAE 10W-30, 10W-40, 5W-20
API Service Classifications .............. SF, SG, SH or SJ
Oil Capacity (w/o Filter), L (qts) .............. 1.5 (1.6)
Oil Capacity (with New Filter), L (qts) .............. 1.8 (1.9)
Oil Filter Part Number .............. 49065-2071
Air Filter Element Part Number .............. 11013-2204
Air Filter Pre-Cleaner Part Number .............. 11013-2114

Carburetor Adjustment

Caburetor Model .............. Teikei FD22K-1K
Main Bore Diameter, mm (in) .............. 26.0 (1.02)
Venturi Diameter, mm (in) .............. 22.0 (0.87)
Main Jet .............. #110
Pilot Jet .............. #58
Main Air Jet .............. 1.4
Pilot Air Jet .............. 0.8
Pilot Screw Setting- 1-1/4±1/4 turns out
Low Idle Speed, rpm .............. 1450±100
High Idle Speed, rpm .............. 3525±75

Ignition System

Spark Plug Type .............. NGK BMR6A
Spark Plug Gap, mm (in) .............. 0.6-0.7 (0.0237-0.0277)
Coil Air Gap, mm (in) .............. 0.3-1.2 (0.0119-0.0474)
Spark Plug Torgue, Nm (ft-lb) .............. 15 (11.1)

Service Intervals

Check Engine Oil Level .............. Every 10 hours
Service Air Filter Pre-Cleaner .............. Every 25 hours
Clean Fuel Filter .............. Every 50 hours
Change Engine Oil .............. Every 50 hours
Clean and Adjust Spark Plug .............. Every 100 hours
Service Air Filter Element .............. Every 100 hours
Replace Engine Oil Filter .............. Every 200 hours
Check Radiator and Hoses .............. Every 200 hours
Check Carburetor Adjustment .............. Every 200 hours
Check and Adjust Idle Speed .............. Every 200 hours
Check and Adjust Valve Clearance .............. Every 300 hours
Clean Combustion Chamber .............. Every 300 hours
Replace Spark Plug .............. Every 300 hours
Replace Air Filter Element .............. Every 300 hours
Clean Fuel Hose .............. Every 300 hours
Change Engine Coolant .............. Every 400 hours

Kawasaki FD661D Service Specifications

Cylinder Block

Cylinder Inside Diameter (Max), mm (in) .............. 76.067 (2.9948)
Cylinder Bore Out Round, mm (in) .............. 0.056 (0.0022)
Connecting Rod Bend, mm (in) .............. 0.15/100 (0.006/3.94)
Connecting Rod Big End Width, mm (in) .............. 21.2 (0.83)
Connecting Rod Big End Inside Diameter, mm (in) .............. 34.055 (1.3407)
Connecting Rod Small End Inside Diameter, mm (in) .............. 17.051 (0.6713)
Crankpin Width, mm (in) .............. 44.5 (1.75)
Crankpin Outside Diameter, mm (in) .............. 33.927 (1.3357)
Crankshaft Runout, mm (in) .............. 0.05 (0.002)
Crankshaft Journal Diameter (PTO), mm (in) .............. 33.91 (1.335)
Crankshaft Journal Diameter (Flywheel), mm (in) .............. 33.91 (1.335)
Crankshaft Bearing Inside Diameter, mm (in) .............. 34.114 (1.3431)
Camshaft Bearing Inside Diameter, mm (in) .............. 16.068 (0.6326)
Camshaft Journal Diameter (PTO), mm (in) .............. 15.907 (0.6263)
Camshaft Journal Diameter (Flywheel), mm (in) .............. 15.917 (0.6267)

Cylinder Head and Valves

Cylinder Head Warp, mm (in) .............. 0.05 (0.002)
Valve Clearance, mm (in) .............. 0.25 (0.010)
Valve Seat Angle, deg .............. 45
Valve Seat Width, mm (in) .............. 0.5-1.1 (0.02-0.043)
Valve Guide Inside Diameter, mm (in) .............. 6.00-6.012 (0.2362-0.2367)
Valve Head Thickness, mm (in) .............. 0.60 (0.024)
Valve Stem Runout, mm (in) .............. 0.05 (0.002)
Valve Stem Diameter (Intake), mm (in) .............. 5.945 (0.2341)
Valve Stem Diameter (Exhaust), mm (in) .............. 5.925 (0.2332)
Valve Guide Inside Diameter (Intake), mm (in) .............. 6.045 (0.2397)
Valve Guide Inside Diameter (Exhaust), mm (in) .............. 6.055 (0.2384)
Valve Spring Free Length, mm (in) .............. 29.7 (1.17)
Rocker Arm Push Rod Runout, mm (in) .............. 0.80 (0.03)
Cam Lobe Height (Intake), mm (in) .............. 25.21 (0.993)
Cam Lobe Height (Exhaust), mm (in) .............. 25.46 (1.002)

Piston and Piston Rings

Piston Pin Outside Diameter, mm (in) .............. 16.975 (0.6683)
Piston Pin Hole Inside Diameter, mm (in) .............. 17.041 (0.6709)
Top Ring Groove Clearance, mm (in) .............. 0.15 (0.006)
Second Ring Groove Clearance, mm (in) .............. 0.15 (0.006)
Top Ring Thickness, mm (in) .............. 1.12 (0.044)
Second Ring Thickness, mm (in) .............. 1.12 (0.044)
Top Ring End Gap, mm (in) .............. 1.2 (0.05)
Second Ring End Gap, mm (in) .............. 1.2 (0.05)
Oil Ring End Gap, mm (in) .............. 1.5 (0.06)

Tightening Torque Specs

Cylinder Head, Nm (ft-lb) .............. 21 (15.5)
Connecting Rod, Nm (ft-lb) .............. 21 (15.5)
Flywheel, Nm (ft-lb) .............. 110 (80.5)
Crankcase Cover, Nm (ft-lb) .............. 25 (19.1)
Intake Manifold, Nm (ft-lb) .............. 7.8 (5.9)
Oil Drain Plug, Nm (ft-lb) .............. 23 (16.5)
Spark Plug, Nm (ft-lb) .............. 15 (11.1)
Carburetor, Nm (ft-lb) .............. 17 (12.1)
Radiator, Nm (ft-lb) .............. 17 (12.1)
Governor Arm, Nm (ft-lb) .............. 7.8 (5.8)
Valve Clearance Lock Nut, Nm (ft-lb) .............. 8.8 (6.5)