Kawasaki FD620D running poorly. Help?!

[fmints]

Hey Green,,, hows the Argo coming buddy?

[gimmegreens336]

lol Plott

I am - for sure - good to go now!

Result: stronger pull, less hesitation under load, smooth turns, and faster doughnuts :-D



I think all I needed was the correct plugs and a clean carb, but I ended up getting: new fuel line, new filter, new pump, corrected valve lash, clean carb, new plugs, new oil and a new-to-me driven clutch (thanks lewis).

Waiting on some videos to upload, we moved a big stump yesterday with the rejuvenated beast.

Everything seemed well, until I found this: (left side rear axle) Get to learn new facets of the machine every day it seems.



Nothing special about the video, we were able to move the log on it's side with 4 grown men. It's gotta weigh 1,000 lbs. (The best part of the video is around 28 seconds, Kayden was mean mugging until he saw he was on camera... then he's a ham - lol)

Quality is terrible here. I don't know why it is so fuzzy, it's a shame too cause little Kayden is knocked out. His head is bouncing all over the place while he's sleeping... lol

[plott hound]

i veto the motion on the grounds that i like 2 of everything.thats why "THEY" come in pairs.

[Rock Doctor]

Nah, you're good to go now.

If I Second that, does it mean the motion is carried?

RD

[JohnF]

... I am going to buy a new carb for sure, I'll use the current for parts. ...

Nah, you're good to go now.

[sparkola]

Ultrasonic Cleaner - 2.5 Liter

[Slimpickin]

Glad you found that inlet plugged was the problem. I took the carb apart so many times on the first one I had trouble with I thought I was going to have to order new screws. I did everything to it I could think of and it wouldn't run properly. For some reason dawned on me to blow through that inlet and out flew the crap. Walla, its runing good. Had to do it twice cause I'm sure there was loose rubber bits in the new hose between the new filter and the carb.

[Slimpickin]

I had the problem of the float being to close and hanging up on the center section of the carb as well. Did some adjusting and it works well now. Email me if you want to get a little more out of the engine. Easy adjustment to the governor spring and if you're not happy with it its easy to return to standard.

[gimmegreens336]

Those are clean as a whistle. It was amazing to look through it before and after... I could see a HUGE difference when shining a light though the air jet and looking into the fuel jet. I'm glad to got to take her apart and see how she works.

You helped remind me to show the solenoid clipped off.

This was also how much fuel was in the bowl after idling for a few minutes...?

[plott hound]

make sure the main jet is clear bud.its the one behind the fuel shut off solenoid.solenoid must be removed so you can extract it.turns out with a flat screw driver.

[gimmegreens336]

Well, that sounds right. But you gotta admit, that's a terrible picture.

Yeah the pics in the manuals are awful. Makes it harder on someone trying to learn like myself!

If you got the dough, I would buy a new carb. You can always get a rebuild kit for your old one and keep it as a spare for when the new one clogs up. I'm tellin ya you gotta sonicly clean that thing for like an hour. It will clear those main jet passages like you wouldn't believe.

I'm not sure what the sonic cleaner you're talking about is, but, my wife is a dental hygienist and I used her water pick and some scalers. lol.. I am going to buy a new carb for sure, I'll use the current for parts.

Check the needle and seat. I've had two 620's act the same as yours and the intake above the seat was plugged or partialy plugged. Use an air hose to blow back where the needle seats. Carefull using anything metal to unplug it cause you will damage the seat. Blow back and forth both ways. Not a very big hole coming into the seat so it could easily be plugged. I changed lines and filters on these machines and a little rubber or dirt plugged the seat.

I was so embarrassed last night to admit I neglected that particular hole while cleaning. The bottom half of the carb got the deep cleaning. There wasn't a speck of grime on the bottom half. BUT - I neglected to clean the very FIRST hole fuel passes through. Fuel cannot even get to the other jets or bowl or anything without first passing that hole. I'm not sure if she's fully fixed (because it was 3am and I was too tired to take a drive) but she cranks up and revs and operates correctly in neutral after cleaning that hole. I also did a float adjustment but I'm almost positive that hole was clogged.



Two major issues fixed: cleaned the hole at the fuel inlet on the carb and bent the float, it was slightly off center. I don't believe the flloat had free flow in the narrow channel in the bowl. I think with it being off-center it was preventing it from rising up and down like it's supposed to.


Anyway, I'm going to try and ride this evening to see what happens.


This is how I interpreted the float adjustment:

[Slimpickin]

Check the needle and seat. I've had two 620's act the same as yours and the intake above the seat was plugged or partialy plugged. Use an air hose to blow back where the needle seats. Carefull using anything metal to unplug it cause you will damage the seat. Blow back and forth both ways. Not a very big hole coming into the seat so it could easily be plugged. I changed lines and filters on these machines and a little rubber or dirt plugged the seat.

[sparkola]

If you got the dough, I would buy a new carb. You can always get a rebuild kit for your old one and keep it as a spare for when the new one clogs up. I'm tellin ya you gotta sonicly clean that thing for like an hour. It will clear those main jet passages like you wouldn't believe.

[JohnF]

Well, that sounds right. But you gotta admit, that's a terrible picture.

[gimmegreens336]

I'm headed home shortly. I will have a pic by tomorrow.



There is a little wire, maybe the "keeper wire" that "clips" (fits in a groove) on the needle. The wire has a little rectangle that slides into the tab on the float assembly. The needle is connected to a tab on the float assembly by the little wire thing.

I adjusted the tab according to the directions above.