JOHN DEERE
WORLDWIDE COMMERCIAL & CONSUMER
EQUIPMENT DIVISION
January 2011
John Deere Select Series Tractors
X300 Series
TM2308 JANUARY 2011
TECHNICAL MANUAL

North American Version
Litho In U.s.a.

INTRODUCTION
Manual Description
This technical manual is written for an experienced
technician and contains sections that are specifically for
this product. It is a part of a total product support program.
The manual is organized so that all the information on a
particular system is kept together. The order of grouping is
as follows:
Table of Contents
Specifications and Information

Identification Numbers
Tools and Materials
Component Location
Schematics and Harnesses
Theory of Operation
Operation and Diagnostics
Diagnostics
Tests and Adjustments
Repair
Other
Note: Depending on the particular section or system
being covered, not all of the above groups may be
used.
The bleed tabs for the pages of each section will align with
the sections listed on this page. Page numbering is
consecutive from the beginning of the Safety section
through the last section.
We appreciate your input on this manual. If you find any
errors or want to comment on the layout of the manual
please contact us.
All information, illustrations and specifications in this
manual are based on the latest information at the
time of publication. The right is reserved to make
changes at any time without notice.
COPYRIGHT 2011
Deere & Co.
John Deere Ag & Turf Division
All rights reserved
Previous Editions
COPYRIGHT 2006, 2007, 2008, 2009
Specifications and Information
Engine (FH491)
Power Train
Safety
Engine (FH661 and FH721)
Attachments
Electrical
Steering
Miscellaneous
Hydraulics
Engine - (FS541V)
Introduction
SAFETY
Safety
Recognize Safety Information
MIF
This is the safety-alert symbol. When you see this symbol
on your machine or in this manual, be alert to the potential
for personal injury.
Follow recommended precautions and safe servicing
practices.
Understand Signal Words
A signal word - DANGER, WARNING, or CAUTION - is
used with the safety-alert symbol. DANGER identifies the
most serious hazards.
DANGER or WARNING safety signs are located near
specific hazards. General precautions are listed on
CAUTION safety signs. CAUTION also calls attention to
safety messages in this manual.
Replace Safety Signs
MIF
Replace missing or damaged safety signs. See the
machine operator's manual for correct safety sign
placement.
Handle Fluids Safely - Avoid Fires
Be Prepared For Emergencies
MIF
When you work around fuel, do not smoke or work near
heaters or other fire hazards.
Store flammable fluids away from fire hazards. Do not
incinerate or puncture pressurized containers.
Make sure machine is clean of trash, grease, and
debris.
Do not store oily rags; they can ignite and burn
spontaneously.
Be prepared if a fire starts.
Keep a first aid kit and fire extinguisher handy.
Keep emergency numbers for doctors, ambulance
service, hospital, and fire department near your telephone.
Wear Protective Clothing
MIF
Wear close fitting clothing and safety equipment
appropriate to the job.
Prolonged exposure to loud noise can cause impairment or
loss of hearing. Wear a suitable hearing protective device
such as earmuffs or earplugs to protect against
objectionable or uncomfortable loud noises.
Operating equipment safely requires the full attention of the
operator. Do not wear radio or music headphones while
operating machine.
Safety - 1
SAFETY
Use Care In Handling and Servicing Batteries
MIF
Prevent Battery Explosions
Keep sparks, lighted matches, and open flame away
from the top of battery. Battery gas can explode.
Never check battery charge by placing a metal object
across the posts. Use a volt-meter or hydrometer.
Do not charge a frozen battery; it may explode. Warm
battery to 16C (60F).
Prevent Acid Burns
Sulfuric acid in battery electrolyte is poisonous. It is
strong enough to burn skin, eat holes in clothing, and
cause blindness if splashed into eyes.
Avoid acid burns by:
1. Filling batteries in a well-ventilated area.
2. Wearing eye protection and rubber gloves.
3. Avoiding breathing fumes when electrolyte is added.
4. Avoiding spilling or dripping electrolyte.
5. Use proper jump start procedure.
If you spill acid on yourself:
1. Flush your skin with water.
2. Apply baking soda or lime to help neutralize the acid.
3. Flush your eyes with water for 10 - 15 minutes.
4. Get medical attention immediately.
If acid is swallowed:
1. Drink large amounts of water or milk.
2. Then drink milk of magnesia, beaten eggs, or vegetable
oil.
3. Get medical attention immediately.
Service Machines Safely
Tie long hair behind your head. Do not wear a necktie,
scarf, loose clothing, or necklace when you work near
machine tools or moving parts. If these items were to get
caught, severe injury could result.
Remove rings and other jewelry to prevent electrical shorts
and entanglement in moving parts.
Use Proper Tools
Use tools appropriate to the work. Makeshift tools and
procedures can create safety hazards. Use power tools
only to loosen threaded parts and fasteners. For loosening
and tightening hardware, use the correct size tools. DO
NOT use U.S. measurement tools on metric fasteners.
Avoid bodily injury caused by slipping wrenches. Use only
service parts meeting John Deere specifications.
Work In Clean Area
Before starting a job:
1. Clean work area and machine.
2. Make sure you have all necessary tools to do your job.
3. Have the right parts on hand.
4. Read all instructions thoroughly; do not attempt
shortcuts.
Illuminate Work Area Safely
Illuminate your work area adequately but safely. Use a
portable safety light for working inside or under the
machine. Make sure the bulb is enclosed by a wire cage.
The hot filament of an accidentally broken bulb can ignite
spilled fuel or oil.
Using High Pressure Washers
Directing pressurized water at electronic/electrical
components or connectors, bearings, hydraulic seals, fuel
injection pumps or other sensitive parts and components
may cause product malfunctions. Reduce pressure and
spray at a 45 to 90 degree angle.
Safety - 2
SAFETY
Park Machine Safely
MIF
Before working on the machine:
1. Lower all equipment to the ground.
2. Lock the park brake.
3. Stop the engine and remove the key.
4. Disconnect the battery ground strap.
5. Hang a "DO NOT OPERATE" tag in operator station.
Work In Ventilated Area
MIF
Engine exhaust fumes can cause sickness or death. If it is
necessary to run an engine in an enclosed area, remove
the exhaust fumes from the area with an exhaust pipe
extension.
If you do not have an exhaust pipe extension, open the
doors and get outside air into the area.
Warning: California Proposition 65 Warning
Gasoline engine exhaust from this product contains
chemicals known to the State of California to cause cancer,
birth defects, or other reproductive harm.
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
Avoid Injury From Rotating Blades and Shafts
MIF
Keep hands and feet away while machine is running. Shut
off power to service, lubricate or remove mower blades,
augers or PTO shafts.
Dispose Of Waste Properly
Improperly disposing of waste can threaten the
environment and ecology. Potentially harmful waste used
with John Deere equipment include such items as oil, fuel,
coolant, brake fluid, filters, and batteries. Use leakproof
containers when draining fluids. Do not use food or
beverage containers that may mislead someone into
drinking from them. Do not pour waste onto the ground,
down a drain, or into any water source. Inquire on the
proper way to recycle or dispose of waste from your local
environmental or recycling center, or from your John Deere
dealer.
Handle Chemical Products Safely
MIF
Direct exposure to hazardous chemicals can cause serious
injury. Potentially hazardous chemicals used with John
Deere equipment include such items as lubricants,
coolants, paints, and adhesives.
A Material Safety Data Sheet (MSDS) provides specific
details on chemical products: physical and health hazards,
safety procedures, and emergency response techniques.
Check the MSDS before you start any job using a
hazardous chemical. That way you will know exactly what
the risks are and how to do the job safely. Then follow
procedures and recommended equipment.
Safety - 3
SAFETY
Live With Safety
MIF
Before returning machine to customer, make sure machine
is functioning properly, especially the safety systems. Install
all guards and shields.
Safety - 4
SPECIFICATIONS & INFORMATION TABLE OF CONTENTS
Specifications & Information
Table of Contents
General Specifications.....................................7
Metric Fastener Torque Values ......................7
Metric Fastener Torque ValuesGrade 7 .....8
Inch Fastener Torque Values .........................9
Gasket Sealant Application ..........................10
O-Ring Seal Service Recommendations ......11
Face Seal Fittings - Inch Stud Ends Torque.11
Face Seal Fittings - Metric Stud Ends
Torque ..........................................................12
O-Ring Face Seal Fittings ............................13
O-Ring Boss Fittings ....................................13
Fuels and Lubricants......................................14
Gasoline .......................................................14
Gasoline Storage..........................................14
Engine Oil.....................................................15
Engine Breakin Oil......................................15
Alternative Lubricants...................................15
Synthetic Lubricants .....................................15
Lubricant Storage .........................................16
Mixing Of Lubricants.....................................16
Chassis Grease............................................16
Mower Spindle Grease.................................16
Transaxle Oil - K46 and K58 Transaxles......16
Transaxle Oil - K58H Transaxle ...................16
Serial Number Locations ...............................17
Product Identification Numbers ....................17
Specifications & Information Table of Contents - 5
SPECIFICATIONS & INFORMATION TABLE OF CONTENTS

Specifications & Information Table of Contents - 6
SPECIFICATIONS & INFORMATION GENERAL SPECIFICATIONS
General Specifications
Metric Fastener Torque Values
TS1163
DO NOT use these hand torque values if a different
torque value or tightening procedure is given for a specific
application. Torque values listed are for general use only
and include a 10% variance factor. Check tightness of
fasteners periodically. DO NOT use air powered wrenches.
Shear bolts are designed to fail under predetermined
loads. Always replace shear bolts with identical grade.
Fasteners should be replaced with the same class.
Make sure fastener threads are clean and that you properly
start thread engagement. This will prevent them from failing
when tightening.
When bolt and nut combination fasteners are used,
torque values should be applied to the NUT instead of the
bolt head.
Tighten toothed or serrated-type lock nuts to the full
torque value.
a "Lubricated" means coated with a lubricant such as
engine oil, or fasteners with phosphate and oil
coatings. "Dry" means plain or zinc plated (yellow
dichromateSpecification JDS117) without any
lubrication.
Reference: JDS-200
TS1163
4.8
8.8
9.8
10.9
12.9
5
10
12Property
Class
and
Head
Markings
Property
Class
and
Nut
Markings
4.8
4.8
55
8.8
8.8
9.8
9.8
10.9
10.9
12.9
12.9
12.9
12
12
10
10
10
1010Class 4.8
Class 8.8 or 9.8
Class 10.9
Class 12.9
Lubricateda Drya
Lubricateda Drya
Lubricateda Drya
Lubricateda Drya
SIZE Nm
lb-ft
Nm
lb-ft
Nm
lb-ft
Nm
lb-ft
Nm
lb-ft
Nm
lb-ft
Nm
lb-ft
Nm
lb-ft
M6
4.8
3.5
6
4.5
9
6.5
11
8.5
13
9.5
17
12
15
11.5 19
14.5
M8
12
8.5
15
11
22
16
28
20
32
24
40
30
37
28
47
35
M10 23
17
29
21
43
32
55
40
63
47
80
60
75
55
95
70
M12 40
29
50
37
75
55
95
70
110
80
140
105
130
95
165
120
M14 63
47
80
60
120
88
150
110
175
130
225
165
205
150
260
190
M16 100
73
125
92
190
140
240
175
275
200
350
225
320
240
400
300
M18 135
100
175
125
260
195
330
250
375
275
475
350
440
325
560
410
M20 190
140
240
180
375
275
475
350
530
400
675
500
625
460
800
580
M22 260
190
330
250
510
375
650
475
725
540
925
675
850
625
1075 800
M24 330
250
425
310
650
475
825
600
925
675
1150 850
1075 800
1350 1000
M27 490
360
625
450
950
700
1200 875
1350 1000 1700 1250 1600 1150 2000 1500
M30 675
490
850
625
1300 950
1650 1200 1850 1350 2300 1700 2150 1600 2700 2000
M33 900
675
1150 850
1750 1300 2200 1650 2500 1850 3150 2350 2900 2150 3700 2750
M36 1150 850
1450 1075 2250 1650 2850 2100 3200 2350 4050 3000 3750 2750 4750 3500
Specifications & Information General Specifications - 7
SPECIFICATIONS & INFORMATION GENERAL SPECIFICATIONS
Metric Fastener Torque ValuesGrade 7
Size
Steel or Gray
Iron Torque
Aluminum
Torque
Nm (lb-ft)
Nm (lb-ft)
M6
11 (8)
8 (6)
M8
24 (18)
19 (14)
M10
52 (38)
41 (30)
M12
88 (65)
70 (52)
M14
138 (102)
111 (82)
M16
224 (165)
179 (132)
Specifications & Information General Specifications - 8
SPECIFICATIONS & INFORMATION GENERAL SPECIFICATIONS
Inch Fastener Torque Values
TS1162
DO NOT use these hand torque values if a different
torque value or tightening procedure is given for a specific
application. Torque values listed are for general use only
and include a 10% variance factor. Check tightness of
fasteners periodically. DO NOT use air powered wrenches.
Shear bolts are designed to fail under predetermined
loads. Always replace shear bolts with identical grade.
Fasteners should be replaced with the same class.
Make sure fastener threads are clean and that you properly
start thread engagement. This will prevent them from failing
when tightening.
When bolt and nut combination fasteners are used,
torque values should be applied to the NUT instead of the
bolt head.
Tighten toothed or serrated-type lock nuts to the full
torque value.
a "Lubricated" means coated with a lubricant such as
engine oil, or fasteners with phosphate and oil
coatings. "Dry" means plain or zinc plated (yellow
dichromateSpecification JDS117) without any
lubrication.
b "Grade 2" applies for hex cap screws (not hex bolts)
up to 152 mm (6 in.) long "Grade 1" applies for hex cap
screws over 152 mm (6 in.) long, and for all other types
of bolts and screws of any length.
Reference: JDS-G200
TS1162
1 or 2b
2
5
5.1
5.2
5
8
8.2
8
No Marks
No Marks
SAE
Grade
and Nut
Markings
SAE
Grade
and Head
Markings
Grade 1
Grade 2b
Grade 5, 5.1 or 5.2
Grade 8 or 8.2
Lubricateda Drya
Lubricateda Drya
Lubricateda Drya
Lubricateda Drya
SIZE Nm
lb-ft
Nm
lb-ft
Nm
lb-ft
Nm
lb-ft
Nm
lb-ft
Nm
lb-ft
Nm
lb-ft
Nm
lb-ft
1/4
3.7
2.8
4.7
3.5
6
4.5
7.5
5.5
9.5
7
12
9
13.5 10
17
12.5
5/16
7.7
5.5
10
7
12
9
15
11
20
15
25
18
28
21
35
26
3/8
14
10
17
13
22
16
27
20
35
26
44
33
50
36
63
46
7/16
22
16
28
20
35
26
44
32
55
41
70
52
80
58
100
75
1/2
33
25
42
31
53
39
67
50
85
63
110
80
120
90
150
115
9/16
48
36
60
45
75
56
95
70
125
90
155
115
175
130
225
160
5/8
67
50
85
62
105
78
135
100
170
125
215
160
215
160
300
225
3/4
120
87
150
110
190
140
240
175
300
225
375
280
425
310
550
400
7/8
190
140
240
175
190
140
240
175
490
360
625
450
700
500
875
650
1
290
210
360
270
290
210
360
270
725
540
925
675
1050 750
1300 975
1-1/8 470
300
510
375
470
300
510
375
900
675
1150 850
1450 1075 1850 1350
1-1/4 570
425
725
530
570
425
725
530
1300 950
1650 1200 2050 1500 2600 1950
1-3/8 750
550
950
700
750
550
950
700
1700 1250 2150 1550 2700 2000 3400 2550
1-1/2 1000 725
1250 925
990
725
1250 930
2250 1650 2850 2100 3600 2650 4550 3350
Specifications & Information General Specifications - 9
SPECIFICATIONS & INFORMATION GENERAL SPECIFICATIONS
Gasket Sealant Application
Cleaning:
Clean both surfaces that will be joined using 100%
isopropyl alcohol. Wipe excess off with a clean cloth.
Cleaner/degreaser can be substituted for isopropyl alcohol.
How to Dispense/Apply/Assemble Gasket Sealants:
Dispense approximately 1 to 2 ounces of flexible form-in-
place gasket on a clean sheet or table top. Avoid using
excess amounts that may be exposed for long periods of
time. This will help prevent contamination from surrounding
atmosphere such as dust with metal content.
Using an ink roller or similar devise, apply to one surface of
the joint by loading the roller from a plastic sheet and
transferring the material in a thin film to the joint. The
application should be the thinnest film possible, but
providing complete coverage. This can be judged by the
appearance of the joint once it is put together. Excessive
amounts of will cause incorrect bearing end play, extend
cure time, and will cause runoff of the material. A small
bead or buildup at the joint is permissible and indicates
good dispersion through the joint. Excess can be wiped
from the joint. Joining should take place within three
minutes after sealant application.
Apply proper cap screw torque and sequence as
applicable. Allow a minimum of 30 minutes before air test or
adding oil for test stand usage.
Disassembly:
Cured material can be removed with a wire brush or
scraper. Chemical cleaners are available for customer use,
should they be deemed necessary.
Specifications & Information General Specifications - 10
SPECIFICATIONS & INFORMATION O-RING SEAL SERVICE
O-Ring Seal Service Recommendations
Face Seal Fittings - Inch Stud Ends Torque
MIF
Note: Torque tolerance is +15%, -20%
Stud End
Tube Nut
Swivel Nut
Lock Nut
Tube Nut
Stud End
Straight Stud and Tube Nut
Bulkhead Union and Bulkhead Lock Nut
90 Swivel Elbow and Tube Nut
90 Adjustable Stud Elbow
Nominal Tube OD/Hose ID
Face Seal Tube/Hose End
O-Ring Stud Ends
Metric
Tube
OD
Inch Tube OD
Thread
Size
Tube Nut/
Swivel Nut
Torque
Bulkhead
Lock Nut
Torque
Thread
Size
Straight Fitting
or Lock Nut
Torque
mm
Dash
Size
in.
mm
in.
Nm
lb-ft
Nm lb-ft
in.
Nm
lb-ft
-3
0.188 4.76
3/8-24
8
6
6
-4
0.250 6.35
9/16-18
16
12
12
9
7/16-20
12
9
8
-5
0.312 7.94
1/2-20
16
12
10
-6
0.375 9.52
11/16-16
24
18
24
18
9/16-18
24
18
12
-8
0.500 12.70 13/16-16
50
37
46
34
3/4-16
46
34
16
-10
0.625 15.88 1-14
69
51
62
46
7/8-14
62
46
-12
0.750 19.05 1-3/16-12
102
75
102 75
1-1/16-12
102
75
22
-14
0.875 22.22 1-3/16-12
102
75
102 75
1-3/16-12
122
90
25
-16
1.000 25.40 1-7/16-12
142
105
142 105 1-5/16-12
142
105
32
-20
1.25
31.75 1-11/16-12 190
140
190 140 1-5/8-12
190
140
38
-24
1.50
38.10 2-12
217
160
217 160 1-7/8-12
217
160
Specifications & Information O-Ring Seal Service Recommendations - 11
SPECIFICATIONS & INFORMATION O-RING SEAL SERVICE
Face Seal Fittings - Metric Stud Ends Torque
MIF
Note: Torque tolerance is +15%, -20%
Stud End
Tube Nut
Straight Stud and Tube Nut
Bulkhead Union and Bulkhead Lock Nut
Swivel Nut
Lock Nut
Tube Nut
Stud End
90 Swivel Elbow and Tube Nut
90 Adjustable Stud Elbow
Groove for Metric
Identification
Groove for Metric Identification
Nominal Tube OD/Hose ID
Face Seal Tube/Hose End
O-Ring Stud Ends, Straight Fitting or
Lock Nut
Metric
Tube
OD
Inch Tube OD
Thread
Size
Hex
Size
Tube Nut/
Swivel
Nut
Torque
Bulkhead
Lock Nut
Torque
Thread
Size
Hex
Size
Steel or
Gray Iron
Torque
Aluminum
Torque
mm
Dash
Size
in.
mm
in.
mm Nm lb-ft Nm lb-ft mm
mm Nm lb-ft Nm lb-ft
6
-4
0.250 6.35
9/16-18
17
16
12
12
9
M12X1.5 17
21
15.5 9
6.6
8
-5
0.312 7.94
M14X1.5 19
33
24
15
11
10
-6
0.375 9.52
11/16-16
22
24
18
24
18
M16X1.5 22
41
30
18
13
12
-8
0.500 12.70 13/16-16
24
50
37
46
34
M18X1.5 24
50
37
21
15
16
-10
0.625 15.88 1-14
30
69
51
62
46
M22X1.5 27
69
51
28
21
-12
0.750 19.05 1-3/16-12
36
102 75
102
75
M27X2
32
102
75
46
34
22
-14
0.875 22.22 1-3/16-12
36
102 75
102
75
M30X2
36
25
-16
1.000 25.40 1-7/16-12
41
142 105 142
105 M33X2
41
158
116 71
52
28
M38X2
46
176
130 79
58
32
-20
1.25
31.75 1-11/16-12 50
190 140 190
140 M42X2
50
190
140 85
63
38
-24
1.50
38.10 2-12
60
217 160 217
160 M48X2
55
217
160 98
72
Specifications & Information O-Ring Seal Service Recommendations - 12
SPECIFICATIONS & INFORMATION O-RING SEAL SERVICE
O-Ring Face Seal Fittings
MIF
1. Inspect the fitting sealing surfaces (A). They must be
free of dirt or defects.
2. Inspect the O-ring (B). It must be free of damage or
defects.
3. Lubricate O-rings and install into groove using
petroleum jelly to hold in place.
4. Push O-ring into the groove with plenty of petroleum
jelly so O-ring is not displaced during assembly.
5. Index angle fittings and tighten by hand-pressing joint
together to ensure O-ring remains in place.
6. Tighten fitting or nut to torque value shown on the chart
per dash size stamped on the fitting.
O-Ring Boss Fittings
1. Inspect boss O-ring boss seat. It must be free of dirt and
defects. If repeated leaks occur, inspect for defects with a
magnifying glass. Some raised defects can be removed
with a slip stone.
MIF
2. Put hydraulic oil or petroleum jelly on the O-ring (A).
Place electrical tape over the threads to protect
O-ring from nicks. Slide O-ring over the tape and into the
groove (B) of fitting. Remove tape.
MIF
3. For angle fittings, loosen special nut (A) and push
special washer (B) against threads so O-ring can be
installed into the groove of fitting.
4. Turn fitting into the boss by hand until special washer or
washer face (straight fitting) contacts boss face and O-ring
is squeezed into its seat.
5. To position angle fittings (C), turn the fitting counter-
clockwise a maximum of one turn.
6. Tighten straight fittings to torque value shown on chart.
For angle fittings, tighten the special nut to value shown in
the chart while holding body of fitting with a wrench.
aTorque tolerance is 10 percent.
bTo be used if a torque wrench cannot be used. After
tightening fitting by hand, put a mark on nut or boss; then
tighten special nut or straight fitting the number of flats
shown.
Important: Avoid Damage! DO NOT allow hoses
to twist when tightening fittings. Use two
wrenches to tighten hose connections; one to
hold the hose, and the other to tighten the swivel
fitting.
A
B
A
A
B
Thread Size
Torquea
Number of
Flatsb
Nm
lb-ft
3/8-24 UNF
8
6
2
7/16-20 UNF
12
9
2
1/2-20 UNF
16
12
2
9/16-18 UNF
24
18
2
3/4-16 UNF
46
34
2
7/8-14 UNF
62
46
1-1/2
1-1/16-12 UN
102
75
1
1-3/16-12 UN
122
90
1
1-5/16-12 UN
142
105
3/4
1-5/8-12 UN
190
140
3/4
1-7/8-12 UN
217
160
1/2
A
B
C
Specifications & Information O-Ring Seal Service Recommendations - 13
SPECIFICATIONS & INFORMATION FUELS AND LUBRICANTS
Fuels and Lubricants
Gasoline
To avoid engine damage:
DO NOT mix oil with gasoline
ONLY use clean, fresh unleaded gasoline with an
octane rating (anti-knock index) of 87 or higher

fill gas tank at the end of each day's operation to help
prevent condensation from forming inside a partially filled
tank
keep up with specified service intervals
Use of alternative oxygenated, gasohol blended, unleaded
gasoline is acceptable as long as:

the ethyl or grain alcohol blends DO NOT exceed 10%
by volume or
MIF
methyl tertiary butyl ether (MTBE) blends DO NOT
exceed 15% by volume
Gasoline Storage
Keep gasoline stored in a safe, protected area. Storage of
gasoline in a clean, properly marked ("UNLEADED
GASOLINE") POLYETHYLENE PLASTIC container
WITHOUT any metal screen or filter is recommended. DO
NOT use de-icers to attempt to remove water from gasoline
or depend on fuel filters to remove water from gasoline.
Use a water separator installed in the storage tank outlet.
BE SURE to properly discard unstable or contaminated
gasoline. When storing machine or gasoline, it is
recommended that you add John Deere Gasoline
Conditioner and Stabilizer (TY15977) or an equivalent to
the gasoline. BE SURE to follow directions on container
and to properly discard empty container.
c Caution: Avoid Injury! Gasoline is HIGHLY
FLAMMABLE, handle it with care.DO NOT
refuel machine while:
indoors, always fill gas tank outdoors
machine is near an open flame or sparks
engine is running, STOP engine
engine is hot, allow it to cool sufficiently first
smoking
Help prevent fires:
fill gas tank to bottom of filler neck only
be sure fill cap is tight after fueling
clean up any gas spills IMMEDIATELY
keep machine clean and in good repair-free of
excess grease, oil, debris, and faulty or
damaged parts
any storage of machines with gas left in tank
should be in an area that is well ventilated to
prevent possible igniting of fumes by an open
flame or spark, this includes any appliance
with a pilot light
To prevent fire or explosion caused by STATIC
ELECTRIC DISCHARGE during fueling:
ONLY use a clean, approved POLYETHYLENE
PLASTIC fuel container and funnel WITHOUT
any metal screen or filter
Important: Avoid Damage! DO NOT use METHANOL
gasolines because METHANOL is harmful to the
environment and to your health.
c Caution: Avoid Injury! California Proposition 65
Warning: Gasoline engine exhaust from this
product contains chemicals known to the State
of California to cause cancer, birth defects, or
other reproductive harm.
Important: Avoid Damage! Keep all dirt, scale, water
or other foreign material out of gasoline.
Specifications & Information Fuels and Lubricants - 14
SPECIFICATIONS & INFORMATION FUELS AND LUBRICANTS
Engine Oil
Use the appropriate oil viscosity based on the expected air
temperature range during the period between
recommended oil changes. Operating outside of these
recommended oil air temperature ranges may cause
premature engine failure.
The following John Deere oils are PREFERRED:
TURF-GARD - SAE 10W-30;
PLUS-4 - SAE 10W-30;
The following John Deere oils are also recommended,
based on their specified temperature range:
TORQ-GARD SUPREME - SAE 30;
Other oils may be used if above John Deere oils are not
available, provided they meet one of the following
specifications:
SAE 30 - API Service Classification SJ or higher;
SAE 10W-30 - API Service Classification SJ or higher;
MIF
Engine Breakin Oil
The following John Deere oil is PREFERRED:
BREAKIN ENGINE OIL.
John Deere BREAKIN ENGINE OIL is formulated with
special additives for aluminum and cast iron type engines
to allow the power cylinder components (pistons, rings, and
liners as well) to "wear-in" while protecting other engine
components, valve train and gears, from abnormal wear.
Engine rebuild instructions should be followed closely to
determine if special requirements are necessary.
John Deere BREAKIN ENGINE OIL is also recommended
for non-John Deere engines, both aluminum and cast iron
types.
The following John Deere oil is also recommended as a
break-in engine oil:
TORQGARD SUPREMESAE 5W-30.
If the above recommended John Deere oils are not
available, use a break-in engine oil meeting the following
specification during the first 5 hours (maximum) of
operation:
SAE 5W-30API Service Classification SE or higher.
Alternative Lubricants
Conditions in certain geographical areas outside the United
States and Canada may require different lubricant
recommendations than the ones printed in this technical
manual or the operator's manual. Consult with your John
Deere Dealer, or Sales Branch, to obtain the alternative
lubricant recommendations.
If alternative lubricants are to be used, it is recommended
that the factory fill be thoroughly removed before switching
to any alternative lubricant.
Synthetic Lubricants
Synthetic lubricants may be used in John Deere equipment
if they meet the applicable performance requirements
(industry classification and/or military specification) as
shown in this manual.
The recommended air temperature limits and service or
lubricant change intervals should be maintained as shown
in the operator's manual.
Avoid mixing different brands, grades, or types of oil. Oil
manufacturers blend additives in their oils to meet certain
specifications and performance requirements. Mixing
different oils can interfere with the proper functioning of
Important: Avoid Damage! ONLY use a quality
break-in oil in rebuilt or remanufactured engines
for the first 5 hours (maximum) of operation. DO
NOT use oils with heavier viscosity weights than
SAE 5W-30 or oils meeting specifications API SG
or SH, these oils will not allow rebuilt or
remanufactured engines to break-in properly.
32
0
10
20
30
40
-10
-20
-30
-22
-4
14
50
68
86
104
50
122
-40
-40
F
C
SAE 10W-30
SAE 30
Important: Avoid Damage! After the break-in
period, use the John Deere oil that is
recommended for this engine.
Important: Avoid Damage! Use of alternative
lubricants could cause reduced life of the
component.
32
0
10
20
30
40
-10
-20
-30
-22
-4
14
50
68
86
104
50
122
-40
-40
F
C
BREAK-IN OIL
SAE 5W-30
Specifications & Information Fuels and Lubricants - 15
SPECIFICATIONS & INFORMATION FUELS AND LUBRICANTS
these additives and degrade lubricant performance.
Lubricant Storage
All machines operate at top efficiency only when clean
lubricants are used. Use clean storage containers to
handle all lubricants. Store them in an area protected from
dust, moisture, and other contamination. Store drums on
their sides. Make sure all containers are properly marked
as to their contents. Dispose of all old, used containers and
their contents properly.
Mixing Of Lubricants
In general, avoid mixing different brands or types of
lubricants. Manufacturers blend additives in their lubricants
to meet certain specifications and performance
requirements. Mixing different lubricants can interfere with
the proper functioning of these additives and lubricant
properties which will downgrade their intended specified
performance.
Chassis Grease
Use the following grease based on the air temperature
range. Operating outside of the recommended grease air
temperature range may cause premature failures.
The following John Deere grease is PREFERRED:
NON-CLAY HIGH-TEMPERATURE EP GREASE
JDM J13E4, NLGI Grade 2.
Multi-Purpose SD Polyurea Grease
Multi-Purpose HD Lithium Complex Grease
Other greases may be used if above preferred John Deere
grease is not available, provided they meet the following
specification:

John Deere Standard JDM J13E4, NLGI Grade 2.
Mower Spindle Grease
This premium, multi-purpose grease is specially formulated
as a high-temperature, extreme-pressure grease,
especially effective in rolling contact applications.
The following water resistant grease is preferred:
Multi-Purpose SD Polyurea Grease - TY6341.
The following multi-purpose grease may also be used:
Multi-Purpose HD Lithium Complex Grease - TY24416.
Other greases may be used if they meet or exceed the
following specification:

John Deere Standard JDM J13E4, NLGI Grade 2.
Transaxle Oil - K46 and K58 Transaxles
These machines are equipped with a internal wet disc
brake transmission (Hydrostatic transmission).
Note: The K46 and K58 transaxles (without power
steering or attachment lift cylinders) are filled with
10W30 engine oil at the factory.
For the transaxles used in extreme or high-hour
applications, J20C Hygard Hydraulic oil or 5W-50
Synthetic Engine Oil is approved as an optional fill.
Use only after a complete drain of the factory oil.
Transaxle Oil - K58H Transaxle
These machines are equipped with an internal wet disc
brake transmission.
32
0
10
20
30
40
-10
-20
-30
-22
-4
14
50
68
86
104
50
122
-40
-40
F
C
JDM J13E4 NLGI Grade 2
Important: Avoid Damage! Use ONLY the following
oils for service. DO NOT use automatic transmission
fluid.
32
0
10
20
30
40
-10
-20
-30
-22
-4
14
50
68
86
104
50
122
-40
-40
F
C
J13E4 NLGI Grade 2
32
0
10
20
30
40
-10
-20
-30
-22
-4
14
50
68
86
104
50
122
-40
-40
F
C
HY-GARD J20C
Low Viscosity HY-GARD J20D
Specifications & Information Fuels and Lubricants - 16
SPECIFICATIONS & INFORMATION SERIAL NUMBER LOCATIONS
Use the appropriate oil viscosity based on these air
temperature ranges. Operating outside of these
recommended oil air temperature ranges may cause
premature hydrostatic transmission or hydraulic system
failures.
John Deere J20D Low Viscosity transmission and hydraulic
oil is recommended. John Deere John Deere J20C HY-
GARD transmission and hydraulic oil may be used, if
within the specified temperature range.
Other oils may be used if above recommended John Deere
oils are not available, provided they meet one of the
following specifications:

John Deere Standard JDM J20D;
John Deere Standard JDM J20C.
Serial Number Locations
Product Identification Numbers
When ordering parts or submitting a warranty claim, it is
IMPORTANT that the machine product identification
number (PIN) and component serial numbers are included.
The location of the PIN and component serial numbers are
shown.
MX36205
The machine identification (A) is located on right side of
frame.
The engine identification number (B) is located on the
engine housing.
Important: Avoid Damage! Mixing of LOW
VISCOSITY HY - GARD and HY - GARD oils
is permitted. DO NOT mix any other oils in this
transmission. DO NOT use engine oil or "Type F"
(Red) Automatic Transmission Fluid in this
transmission.
A
B
Specifications & Information Serial Number Locations - 17
SPECIFICATIONS & INFORMATION SERIAL NUMBER LOCATIONS

Specifications & Information Serial Number Locations - 18
ENGINE - KAWASAKI (FH491V) TABLE OF CONTENTS
Engine - Kawasaki (FH491V)
Table of Contents
Specifications .................................................21
General Specifications .................................21
Test and Adjustment Specifications .............21
Repair Specifications....................................21
Torque Specifications...................................23
Tools.............................................................24
Other Materials.............................................24
Component Location......................................25
Carburetor Components...............................25
Engine Block ................................................26
Engine Valves and Governor .......................28
Engine Shields .............................................30
Theory of Operation .......................................31
Engine Oil Flow Chart ..................................31
Lubrication System Operation ......................31
Carburetor Operation ...................................32
Diagnostics .....................................................35
Engine Troubleshooting Guide.....................35
Starting Motor Troubleshooting Guide .........37
Carburetor Troubleshooting Guide...............37
Carburetor Air/Fuel Diagnosis ......................38
Carburetor Diagnostic Inspection .................40
General Information........................................41
Cleaning Carburetors ...................................41
Cleaning Methods ........................................42
Fuel ..............................................................42
Tests and Adjustments ..................................43
Throttle Cable Check and Adjustment..........43
Choke Cable Adjustment .............................44
Governor Adjustment ...................................45
Slow Idle Speed Adjustment ........................46
Fast Idle Speed Adjustment .........................46
Valve Clearance, Check and Adjustment.....47
Cylinder Leak-Down Test .............................48
Cylinder Compression Pressure Test...........49
Crankcase Vacuum Test ..............................49
Engine Oil Pressure Test .............................50
Fuel Pump Test ............................................51
Spark Test ....................................................51
Spark Plug Gap ............................................52
Ignition Coil Air Gap Adjustment ..................52
Repair.............................................................. 53
Engine Removal and Installation ................. 53
Air Cleaner Assembly .................................. 55
Carburetor Removal, Disassembly, and
Installation.................................................... 55
Fuel Pump Removal and Installation ........... 57
Blower Housing Removal and Installation ... 57
Flywheel Removal and Installation .............. 58
Muffler Removal and Installation ................. 58
Breather Inspection...................................... 59
Rocker Arm Removal and Installation ......... 60
Cylinder Head Removal and Installation...... 61
Cylinder Head Inspection............................. 61
Recondition Valve Seats.............................. 63
Lap Valves................................................... 64
Crankcase Cover Removal and Installation. 64
Piston and Connecting Rod......................... 65
Camshaft and Tappets ................................ 69
Crankshaft and Main Bearings .................... 70
Crankshaft Oil Seals .................................... 72
Deglaze Cylinder Bore................................. 72
Resize Cylinder Bore ................................... 72
Oil Pump Disassembly and Assembly ......... 73
Governor Removal, Inspection, and
Replacement................................................ 75
Governor Shaft Inspection and
Replacement................................................ 75
Stator Removal and Installation................... 76
Ignition Coil Removal and Installation.......... 76
Starting Motor .............................................. 76
No-Load Amperage Draw and RPM Test .... 79
Starting Solenoid Test ................................. 79
Engine - Kawasaki (FH491V) Table of Contents - 19
ENGINE - KAWASAKI (FH491V) TABLE OF CONTENTS

Engine - Kawasaki (FH491V) Table of Contents - 20
ENGINE - KAWASAKI (FH491V) SPECIFICATIONS
Specifications
General Specifications
General Specifications:
Engine Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . X300 and X304
Make. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Kawasaki V-Twin
Model Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FH491V
Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68 mm (2.68 in.)
Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 mm (2.56 in.)
Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 472cm3 (28.8 cu in.)
Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 (V-Twin)
Stroke Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Overhead
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fully Pressurized
Oil Capacity w/ Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8 L (1.9 qt)
Oil Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Element, Full Flow, Spin-On
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air
Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horizontal Discharge Below Frame
Spark Plug Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.76 mm (0.030 in.)
Spark Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm (195 lb-in.)
Test and Adjustment Specifications
Test and Adjustment Specifications:
Governed Low Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1850 100 rpm
Fast Idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3350 100 rpm
Low Speed Carb Idle Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1450 100 rpm
Ignition Coil Air Gap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.25 - 0.40 mm (0.010 - 0.016 in.)
Oil Pressure @ 3000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240 - 310 kPa (35 - 45 psi)
Crankcase Vacuum. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3 - 25.4 cm (0.5 - 10.0 in.)
Cylinder Compression (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390 kPa (57 psi)
Valve Clearance (Intake and Exhaust) (Cold). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.075 - 0.125 mm (0.003 - 0.005 in.)
Fuel Pump Pressure (Slow Idle) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.45 kPa (0.36 psi)
Minimum Fuel Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 mL (2.2 oz)/15 seconds
Repair Specifications
Cylinder Head:
Cylinder Head Distortion (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm (0.001 in.)
Valve Guides ID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.00 - 6.01 mm (0.0236 - 0.237 in.)
Valve Guides ID (Maximum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.08 mm (0.239 in.)
Valve Seat Width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.6 - 0.9 mm (0.024 - 0.035 in.)
Valve Spring Free Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.0 mm (1.22 in.)
Intake and Exhaust Valves:
Valve Clearance (Intake and Exhaust) (Cold). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.075 - 0.125 mm (0.003 - 0.005 in.)
Valve Stem OD (Intake) (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.93 mm (0.233 in.)
Engine - Kawasaki (FH491V) Specifications - 21
ENGINE - KAWASAKI (FH491V) SPECIFICATIONS
Valve Stem OD (Exhaust) (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.93 mm (0.233 in.)
Valve Stem Bend (Maximum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.03 mm (0.001 in.)
Valve Guide ID (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.00 - 6.012 mm (0.236 - 0.237 in.)
Valve Guide ID (Maximum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.08 mm (0.239 in.)
Valve Seating Surface (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.60 - 0.90 mm (0.024 - 0.035 in.)
Valve Seat and Face Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Valve Margin (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.35 mm (0.014 in.)
Valve Seat Narrowing Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Piston Assembly:
Piston Ring Side Clearance (Top Ring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.15 mm (0.006 in.)
Piston Ring Side Clearance (Second Ring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.12 mm (0.005 in.)
Piston Ring Side Clearance (Oil Ring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Not Measured
Piston Ring Thickness (Top and Second) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.40 mm (0.055 in.)
Piston Ring End Gap Maximum (Top Ring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.70 mm (0.028 in.)
Piston Ring End Gap Maximum (Second Ring). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.78 mm (0.031 in.)
Piston Ring End Gap Maximum (Oil Ring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.05 mm (0.041 in.)
Piston Pin OD (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.96 mm (0.628 in.)
Piston Pin Bore OD (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.08 mm (0.633 in.)
Piston OD (Standard Minimum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.79 mm (2.669 in.)
Piston OD (Oversize 0.50 mm (0.020 in.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.29 mm (2.689 in.)
Piston-to-Cylinder Bore Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.015 - 0.15 mm (0.001 - 0.006 in.)
Cylinder Bore ID (Standard). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67.98 - 68.00 mm (2.676 - 2.677 in.)
Cylinder Bore ID (Wear Limit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.10 mm (2.681 in.)
Cylinder Bore ID (Oversize 0.50 mm (0.020 in.)) . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.48 - 68.50 mm (2.696 - 2.697 in.)
Cylinder Bore ID (Oversize 0.50 mm (0.020 in.) Wear Limit). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.60 mm (2.701 in.)
Connecting Rod:
Crankshaft Bearing ID (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.06 mm (1.380 in.)
Piston Pin Bearing ID (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.05 mm (0.632 in.)
Crankshaft:
Crankpin Width (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.50 mm (1.380 in.)
Crankpin OD (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.94 mm (1.376 in.)
Journal Diameter (PTO Side) (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.90 mm (1.374 in.)
Journal Diameter (Flywheel Side) (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34.93 mm (1.375 in.)
Crankcase Cover PTO Shaft ID (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.15 mm (1.384 in.)
Crankcase Crankshaft Journal Bearing ID (Maximum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.15 mm (1.384 in.)
Camshaft:
Lobe Height (Intake and Exhaust) (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29.13 mm (1.147 in.)
Journal Diameter (PTO and Flywheel) (Minimum). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15.99 mm (0.629 in.)
Bearing ID (Crankcase and Cover) (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16.14 mm (0.635 in.)
Oil Pump:
Rotor Shaft OD (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.92 mm (0.430 in.)
Rotor Shaft Bearing ID (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11.07 mm (0.436 in.)
Outer Rotor OD (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.47 mm (1.593 in.)
Outer Rotor Bearing ID (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40.80 mm (1.606 in.)
Engine - Kawasaki (FH491V) Specifications - 22
ENGINE - KAWASAKI (FH491V) SPECIFICATIONS
Outer Rotor Thickness (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.83 mm (0.387 in.)
Inner and Outer Rotor Clearance (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.2 mm (0.008 in.)
Pump Housing Depth (Maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23 mm (0.403 in.)
Spring Free Length (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19.5 mm (0.768 in.)
Oil Pressure Sensor Continuity (On) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 kPa (14.2 psi)
Oil Filter Bypass Valve Opening Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78.5 - 117.5 kPa (11.4 - 17.1 psi)
Starting Motor:
Maximum Amperage (No Load). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 amps @ 6000 rpm
Brush Length (Minimum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4 mm (0.25 in.)
Torque Specifications
Torque Specifications:
Breather Cover Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9 Nm (61 lb-in.)
Carburetor Mounting Stud Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9 Nm (61 lb-in.)
Connecting Rod Cap Screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9 Nm (52 lb-in.)
Cooling Shroud Mounting Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9 Nm (52 lb-in.)
Cylinder Head Cap Screws (Initial Torque) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Nm (115 lb-in.)
Cylinder Head Cap Screws (Final Torque) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm (221 lb-in.)
Crankcase Cover Mounting Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Nm (221 lb-in.)
Engine Mounting Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Nm (25 lb-ft)
Exhaust Pipe Nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm (16 lb-ft)
Fan Housing Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9 Nm (52 lb-in.)
Flywheel Cap Screw. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Nm (41 lb-ft)
Fuel Pump Mounting Cap Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9 Nm (52 lb-in.)
Fuel Solenoid to Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9 Nm (61 lb-in.)
Governor Arm Clamp Nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8 Nm (69 lb-in.)
Governor Shaft Plate Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Nm (17 lb-in.)
Ignition Coil Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.8 Nm (69 lb-in.)
Intake Manifold Cap Screws (Initial Torque) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Nm (27 lb-in.)
Intake Manifold Cap Screws (Final Torque) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9 Nm (61 lb-in.)
Oil Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9 Nm (61 lb-in.)
Oil Pump Cover Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.9 Nm (52 lb-in.)
Rocker Arm Stud Bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Nm (247 lb-in.)
Rocker Cover Cap Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.9 Nm (61 lb-in.)
Spark Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Nm (16 lb-ft)
Starting Motor Mounting Cap Screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Nm (133 lb-in.)
Stator Coil Cap Screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.9 Nm (35 lb-in.)
Engine - Kawasaki (FH491V) Specifications - 23
ENGINE - KAWASAKI (FH491V) SPECIFICATIONS
Tools
Note: Order tools according to information given in the
U.S. SERVICE-GARD Catalog or in the European
Microfiche Tool Catalog (MTC).
Other Materials
LOCTITE is a registered trademark of the Loctite Corp.
SCOTCH-BRITE is a registered trademark of the 3M Co.
TEFLON is a registered trademark of DuPont.
Special or Required Tools
Tool Name
Tool No.
Tool Use
Hand-Held
Digital
Tachometer
JT05719
Used to check idle
speed and starter
performance.
Digital Pulse
Tachometer
JT07270
Used to check idle
speed and starter
performance.
Compression
Gauge
JDM59
Used to check engine
compression.
U-Tube
Manometer Test
Kit
JT05698
Used to check engine
crankcase vacuum.
Vacuum Gauge
JT03503
Used to check engine
crankcase vacuum.
Drill Bit
6.4 mm (0.25
in.)
Throttle adjustment.
Lapping Tool
- - -
Valve lapping
Dial Indicator
- - -
Automatic
compression relief
test, valve inspection,
crankshaft end play.
Spark Plug
Ground
JDM74A5
Used to prevent
accidental engine
starting during tests.
Reaming Tool
(7.05 mm)
D20020WI
Clean or size valve
guide.
Reaming Tool
(7.25 mm)
D20020WI
Clean or size oversize
valve guide.
90 Elbow
Fitting
Hose Assembly
JT03338
JT03017
Used to connect
pressure gauge to
engine when
performing engine oil
pressure test.
Pressure Gauge
Assembly
JT03344
Used to read engine
oil pressure when
performing engine oil
pressure test.
Pressure Gauge JDG356
Used to check fuel
pump performance.
Spark Tester
D-05351ST
Used to check overall
condition of ignition
system.
Valve Spring
Compressor
JDM70
Used to remove and
install valve springs.
Current Gun
JT05712
Used to check starter
performance.
Other Material
Part No.
Part Name
Part Use
TY24416
Multipurpose Lithium
Grease
Apply to engine
crankshaft
SCOTCH-BRITE
Abrasive Sheets/
Pads
Clean cylinder head
Valve Guide Cleaner Clean valve guides
Prussian Blue
Compound
Check valve seat
contact
TY24416
Lithium Base Grease Pack oil seals
Zinc Oxide/Wood
Alcohol
Check block for
cracks
Mineral Spirits
Clean armature
Valve Lap Compound Lap valves
PM37418
LOCTITE
242
Thread Lock and
Sealer (Medium
Strength)
Apply to threads of
throttle and choke
plate screws
PM37565
LOCTITE
587
Canada
PM38616
RTV Silicone Form-
in-Place Gasket
Rocker arm cover
mating surfaces
PM37397
LOCTITE
592
Thread Sealant
(General Purpose)
with TEFLON
Apply to threads of
pipe plugs
Special or Required Tools
Tool Name
Tool No.
Tool Use
Engine - Kawasaki (FH491V) Specifications - 24
ENGINE - KAWASAKI (FH491V) COMPONENT LOCATION
Component Location
Carburetor Components
MX19760
O
P
Q
R
S
T
V
U
A
B
C
D
E
F
G
H
I
J
N
L
M
K
A- Limiter
B- Pilot Air Screw
C- Spring
D- Low Idle Screw
E- Spring
F- Seal
G- Throttle Valve
H- Throttle Shaft
I- Choke Shaft
J- Choke Valve
K- Seal
L- Main Nozzle
M- Valve Seat
N- Float
O- Gasket
P- Float Bowl
Q- Solenoid Harness
R- Fuel Solenoid
S- Gasket
T- Pin
U- Gasket
V- Float Valve
Engine - Kawasaki (FH491V) Component Location - 25
ENGINE - KAWASAKI (FH491V) COMPONENT LOCATION
Engine Block
MX39857
ah
ag
af
A
B
C
D
E
F
ae
ac
G
J
H
I
L
M
P
N
K
N
O
Q
R
T
S
U
J
V
W
X
U
Y
J
X
ab
J
I
Z
ad
N
R
Q
O
P
N
K
M
L
D
F
E
E
C
B
A
E
S
aa
A- Cap Screw M6x12 (4 used)
B- Valve Cover
C- Gasket
D- Bolt (17 used)
E- Seal
F- Bolt (2 used)
G- Cylinder Head No. 1
H- Stud (4 used)
I- Head Gasket
J- Pin (6 used)
K- Piston Ring, Compression
L- Piston Ring, Chrome Compression
M- Piston Ring, Oil Ring Assembly
N- Snap Ring
O- Piston Pin
P- Piston
Q- Connecting Rod
R- Connecting Rod Cap
S- Cap Screw M6x30
T- Crankshaft
U- Clip
Engine - Kawasaki (FH491V) Component Location - 26
ENGINE - KAWASAKI (FH491V) COMPONENT LOCATION
V- Crankcase Cover
W- Seal
X- Bolt
Y- Seal
Z- Cylinder Head No. 2
AA- Gasket
AB- Fitting
AC- Plug
AD- Crankcase
AE- Seal
AF- Gasket
AG- Cover
AH- Screw M6x12
Engine - Kawasaki (FH491V) Component Location - 27
ENGINE - KAWASAKI (FH491V) COMPONENT LOCATION
Engine Valves and Governor
MX37029
ag
af
ae
ah
ak
aj
ai
D
Z
ac
J
H
I
L
M
P
K
N
O
Q
N
S
R
T
U
V
W
X
ab
Y
ad
aa
C
D
F
G
E
A
an
am
al
B
A- Lock Screw
B- Rocker Nut
C- Rocker Arm
D- Spring Collet
Engine - Kawasaki (FH491V) Component Location - 28
ENGINE - KAWASAKI (FH491V) COMPONENT LOCATION
E- Stud
F- Spring Retainer
G- Valve Spring
H- Intake Valve
I- Exhaust Valve
J- Spring
K- Cam Shaft
L- Plate
M- Guide
N- Snap Ring
O- Ball
P- Concave Plate
Q- Sleeve
R- Washer
S- Screw
T- Retainer
U- Sump
V- Seal
W- Governor Link
X- Governor Spring
Y- Screw
Z- Governor Shaft
AA- Governor Arm
AB- Washer
AC- Nut
AD- Spring
AE- Cable Retainer
AF- Screw
AG- Screw
AH- Spring
AI- Screw
AJ- Plate
AK- Screw
AL- Pushrod Guide
AM- Pushrod
AN- Tappets
Engine - Kawasaki (FH491V) Component Location - 29
ENGINE - KAWASAKI (FH491V) COMPONENT LOCATION
Engine Shields
MX37031
C
B
A
D
G
G
F
F
F
K
K
K
I
G
F
D
D
G
H
L
J
M
E
D
A- Muffler
B- Gasket (2 used)
C- Flange Nut M8 (4 used)
D- Screw (6 used)
E- Engine Base Plate
F- Clip Nut (8 used)
G- Screw M6x25
H- Shield LH
I- Screw M6x12
J- Shield, Upper
K- Screw M6x16 (6 used)
L- Shield, Lower
M- Shield RH
Engine - Kawasaki (FH491V) Component Location - 30
ENGINE - KAWASAKI (FH491V) THEORY OF OPERATION
Theory of Operation
Engine Oil Flow Chart
M99565
Lubrication System Operation
Function:
To provide pressurized oil to lubricate internal engine
components.
Theory of Operation:
A positive displacement gerotor pump is used to pressurize
the lubrication system. The lubrication system is protected
by an oil pressure relief valve, low oil pressure switch, and
an oil filter with bypass valve.
The oil pump draws oil from the sump through the pick-up
screen. Pressure oil from the pump flows through the pump
outlet passage past the oil pressure relief valve. The oil
pressure relief valve limits the oil pressure to approximately
296 kPa (43 psi) and protects the oil pump from damage if
A
B
C
D
E
F
G
H
I
J
K
L
M
N
A- Rocker Arms and Valves
B- Piston
C- Connecting Rods
D- Crankshaft
E- Crankshaft Main Bearings
F- Oil Pump Gear
G- Oil Pump
H- Pick-up Screen
I- Oil Pressure Relief Valve
J- Oil Filter
K- Oil Pressure Sensor
L- Camshaft
M- Tappets
N- Push Rods
Engine - Kawasaki (FH491V) Theory of Operation - 31
ENGINE - KAWASAKI (FH491V) THEORY OF OPERATION
an oil passage becomes blocked. If the oil pressure
exceeds 296 kPa (43 psi), the relief valve opens allowing oil
to return to the sump. The relief valve is not adjustable.
Pressure oil flows past the relief valve to the oil filter. The
filter contains a bypass valve which opens at 78.5 - 117.5
kPa (11.4 - 17.1 psi) if the element becomes plugged to
ensure engine lubrication.
An oil pressure switch mounted above the oil filter turns on
a warning light if oil pressure is below 98 kPa (14.2 psi).
Filtered pressure oil flows through a passage in the oil
sump to the crankshaft main bearing (PTO side). Drilled
passages in the crankshaft distribute oil from the main
bearings to the connecting rod journals and crankshaft
main bearings (flywheel side). A drilled passage in the
connecting rods allows oil from the connecting rod journal
to lubricate the piston and cylinder walls.
In the cylinder head, the rocker arms, valves, and pushrods
are lubricated by an oil/air mixture carried through an upper
lubrication passage from the breather chamber. As this oil/
air mixture is swirled around the rocker arm chamber, the
oil particles cling to the moving parts, lubricating them.
Eventually these oil particles collect into a liquid state again
in the lower portion of the rocker arm chamber. A small
return passage is provided to return this liquid state oil back
into the crankcase.
The breather creates a negative pressure in the crankcase
which prevents oil from being forced out of the engine
through the piston rings, oil seals or gaskets.Cylinder blow-
by gases go through the crankcase to the breather
chamber. They are drawn into the engine side of the air
cleaner through the cylinder head and mixed with the clean
air flow as part of the emission control system.
The camshaft gear, camshaft, tappets, coolant pump gear,
governor gear, oil pump gear, and crankshaft gear are
lubricated by oil splash generated by the internal moving
parts during operation.
Carburetor Operation
Function
MX47326
The function of the carburetor is to create fuel flow, atomize
the fuel, and meter the air/fuel mixture so it can be
combusted in the engine. To create fuel flow through the
carburetor, there must be a pressure differential between
the fuel bowl and the throat of the carburetor.
Venturi
Air goes through the carburetor throat. When it reaches the
venturi, the air speed is increased and the air pressure Is
decreased. The venturi is a restriction in the carburetor
located between the choke and throttle valves. The
restriction causes air to speed up resulting in a lower than
atmospheric pressure area in the carburetor throat.
A- Venturi
B- Carburetor Throat
C- Increased Air Speed
D- Fuel Bowl
A
B
C
D
Engine - Kawasaki (FH491V) Theory of Operation - 32
ENGINE - KAWASAKI (FH491V) THEORY OF OPERATION
MX47327
A vent passage in the carburetor maintains pressure from
the atmosphere on the fuel in the fuel bowl. Since fluids
flow from areas of higher pressure to areas of lower
pressure the resulting pressure differential between the fuel
bowl (high pressure) and the venturi (low pressure), causes
fuel to be pushed (flow) from the fuel bowl to the venturi.
There are two types of bowl venting: external and internal.
Note: Late model carburetors are internally vented to
meet emissions standards.
Externally vented carburetors exert direct atmospheric
pressure from outside of the air filter onto the fuel in the
bowl.
Internally vented carburetors exert indirect atmospheric
pressure from inside the air filter, ahead of the choke valve,
onto the fuel in the bowl.
Fuel Bowl and Float
The fuel bowl is the fuel reservoir for the carburetor. In
order to maintain the proper fuel air/mixture, the fuel level
must be constant. The float maintains the level of fuel in the
bowl while regulating the fuel flow to match the demands of
the engine by controlling the inlet float valve (needle).
Control Valves
MX47328
The carburetor has two control valves: throttle valve and
choke valve.
The throttle valve is operated by the throttle lever and
controlled by the governor. The throttle valve controls how
much air and fuel enters the cylinder(s).
The choke valve, located before the venturi, creates a
restriction when closed. The function of the choke valve is
to increase the pressure differential between the fuel bowl
and the venturi area. This results in increased fuel flow
from the bowl to the venturi, enriching the air/fuel mixture.
In some engines, a primer is used in place of a choke valve
to push fuel into the venturi.
Concept of Idle
Governed engines are designed to maintain a specific
engine speed.
Governed engines with no load (PTO disengaged, drive in
neutral) are said to be at "idle" regardless of engine speed.
When the operator selects the low speed position with no
load, the engine is at low idle. When the operator selects
the high speed position with no load, the engine is at high
idle.
Carbureted engines account for these situations with two
circuits; an idle circuit (no load) and a main circuit (under
A- Venturi Low Pressure
B- High Pressure
C- Fuel Bowl
A
B
C
A- Choke Valve
B- Throttle Valve
C- Fuel Bowl
A
B
C
Engine - Kawasaki (FH491V) Theory of Operation - 33
ENGINE - KAWASAKI (FH491V) THEORY OF OPERATION
load).
Idle Circuit
MX47329
The idle circuit, on a governed engine, delivers air and fuel
primarily when the engine is not under load (PTO
disengaged, drives in neutral).
Fuel flow enters the idle circuit from the main jet but is
metered by the idle jet. The fuel is then emulsified with air
passing through an air bleed and combining with the fuel.
The air/fuel mixture travels to the transitional bypass
openings and the pilot opening.
When the throttle valve is closed, the engine receives its
air/fuel mixture through the pilot opening. The pilot opening
is used for low idle operation. The pilot opening is located
between the closed throttle plate and the intake manifold.
The opening has a pilot screw that allows for some
adjustment. This adjustment primarily affects low idle.
When the governor slightly opens the throttle valve for high
idle or when a load is applied, the transitional bypass
openings are exposed. These additional openings increase
air/fuel flow to the engine.
Once the engine is under a heavier load, the throttle valve
is opened beyond the transitional bypass openings. At this
point the carburetor receives fuel primarily from the main
circuit.
Main Circuit
MX47330
The main circuit, on a governed engine, is used only when
the engine is under load. Fuel flows from the fuel bowl
through the fixed main jet into the main circuit.
Air enters through a metered orifice (air-bleed) and
emulsifies (mixes) air and fuel as it travels up the emulsion
tube to the venturi.
Emulsification is an important process to properly atomize
the fuel and promote efficient combustion.
Fuel Shutoff Solenoid
The fuel shut-off solenoid reduces fuel flow to the main
circuit. The function of the fuel shut-off solenoid is to
minimize after-bang.
At engine start up, the fuel shut-off solenoid is energized
and the poppet retracts from the seat in the bowl, allowing
fuel to enter into the main jets.
To bench test the fuel shut-off solenoid, apply light
pressure to the tip to simulate its mounting in the fuel bowl
and apply 12 volts DC. If the needle retracts, the solenoid is
working. Verify the tip is secured to the plunger.
A- Air Bleed
B- Idle Circuit
C- Transitional Bypass Openings
D- Pilot Valve
E- Pilot Opening
A
B
E
C
D
A- Emulsion Tube
B- Fuel Bowl
C- Main Jet
A
C
B
Engine - Kawasaki (FH491V) Theory of Operation - 34
ENGINE - KAWASAKI (FH491V) DIAGNOSTICS
Diagnostics
Engine Troubleshooting Guide
Note: To test specific electrical components, see
Electrical Section and refer to either Diagnostics or
Tests & Adjustments for further guidance.
Engine Diagnostics
Engine Doesn't Crank
1. Are battery cables loose or dirty?
Yes: Tighten or clean.
No: Go to next step
2. Is battery fully charged? See "Battery Test" on
page 343 in the Electrical section.
Yes: Go to next step
No: Charge Battery. See "Charge Battery" on page 344
in the Electrical Section.
3. Is key switch working correctly?
Yes: Go to next step.
No: Test Switch, Replace as needed.
4. Is starter motor defective? See "Starting Motor
Troubleshooting Guide" on page 37.
Yes: Repair or replace.
No: Go to next step.
5. Is alternator defective?
Yes: Repair or replace.
No: Go to next step.
6. Has engine seized?
Yes: See engine Repair Section.
No: Go to next step
7. Is starting motor or solenoid defective?
Yes: Repair or replace. See "Starting Solenoid Test" on
page 349.
No: Go to next step.
8. Is there a open circuit in wiring?
Yes: Repair or replace.
No: Go to next step.
9. Is the fuel shutoff solenoid operating correctly?
Yes: Go to next step.
No: Repair or replace.
10. Is the fuel filter or fuel lines clogged?
Yes: Clean or replace as necessary.
No: Go to next step.
11. Is the fuel pump operating correctly? See "Fuel
Pump Test" on page 51.
Yes: Go to next step.
No: Clean or replace as necessary.
12. Is their water in the fuel?
Yes: Drain and replace fuel.
No: Go to next step.
13. Are the valves adjusted properly?
Yes: Go to next step.
No: Adjust valve clearance.See "Valve Clearance,
Check and Adjustment" on page 47.
14. Does engine have correct compression? See
"Cylinder Compression Pressure Test" on page 49.
Yes: Go to next step.
No: Check for seized or burned valves, broken piston
rings, or worn cylinder
15. Is air sucked through carburetor or intake manifold
flanges?
Yes: Tighten manifold flange nuts or replace damaged
gasket.
No: Go to next step
Engine Hard To Start
1. Are battery cables loose or dirty?
Yes: Repair.
No: Go to next step.
2. Is there a strong blue spark?See "Spark Test" on
page 51.
Yes: Go to next step.
No: Repair or replace ignition module.
3. Are sparks jumping from produced between high
tension lead and ignition block. Check high tension
lead, ignition coil air gap, pulser coil.
c Caution: Avoid Injury! The engine may start to
rotate at any time. Keep hands away from
moving parts when testing.
Test Conditions:
Operator on seat.
PTO switch in off position.
Brake on.
Engine - Kawasaki (FH491V) Diagnostics - 35
ENGINE - KAWASAKI (FH491V) DIAGNOSTICS
Yes: Repair or Replace parts as needed
No: Go to next step
4. Is engine compression good? See "Cylinder
Compression Pressure Test" on page 49.
Yes: Go to next step.
No: Check piston rings and cylinder for wear. See
"Piston Inspection:" on page 67. Inspect Cylinder head.
See "Cylinder Head Inspection" on page 61.
5. Make starting attempts a number of times, remove
spark plug and observe electrodes. After starting
attempts, are spark plug electrodes wet?
Yes: Check for excessive use of choke, plugged air
cleaner, float bowl level too high.
No: Go to next step
Engine Runs Erratically
1. Is fuel delivery correct? See "Fuel Pump Test" on
page 51.
Yes: Go to next step.
No: Check for defective fuel pump or plugged fuel lines
or fuel tank.
2. Is fuel present in carburetor?
Yes: Go to next step.
No: Check for plugged air/fuel passages in carburetor.
See "Carburetor Removal, Disassembly, and
Installation" on page 55.
3. Is there contamination in fuel lines, or fuel tank?
Yes: Repair or replace parts as needed
No: Go to next step
Engine Malfunctions At Low Speed
1. Is unusual smoke emitted out of muffler?
Yes: Check choke. See "Choke Cable Adjustment" on
page 44.
No: Go to next step.
2. Does engine rpm drop or engine stall at a certain
point when throttle is gradually opened by hand?
Yes: Check for obstruction or plugged passage in
carburetor. See "Carburetor Removal, Disassembly,
and Installation" on page 55.
No: Go to next step.
3. Is air sucked through carburetor or intake manifold
flanges?
Yes: Tighten manifold flange nuts or replace damaged
gasket.
No: Go to next step
4. Are valve clearances set correctly? See "Valve
Clearance, Check and Adjustment" on page 47.
Yes: Go to next step.
No: Adjust valves.
Oil Consumption Is Excessive
1. Check for oil leaks, high oil level, clogged breather
valve, plugged drain back hole in breather, Is oil
viscosity correct?
Yes: Repair as required.
No: Go to next step.
2. Is compression correct? See "Cylinder Compression
Pressure Test" on page 49.
Yes: Go to next step.
No: Check for worn, stuck, or broken piston rings, or
worn cylinder bore.
Low Oil Pressure
1. Is oil level correct?
Yes: Go to next step.
No: top off oil to correct level.
2. Is oil filter clogged?
Yes: Replace Oil Filter.
No: Go to next step.
3. Is oil of correct viscosity?
Yes: Go to next step.
No: Change engine oil.
4. Check for oil leaks, high oil level, clogged breather
valve, plugged drain back hole in breather, Is oil
viscosity correct?
Yes: Repair as required.
No: Go to next step.
5. Is oil relief valve worn?
Yes: Clean, adjust or replace relief valve.
No: Go to next step.
6. Is oil pump operating correctly? See "Engine Oil
Pressure Test" on page 50.
Yes: Go to next step.
No: Replace oil pump.
7. Is there fuel in the oil?
c Caution: Avoid Injury! Keep spark plug as far
away from the plug hole as possible. Gasoline
spray from the open cylinders may be ignited
by ignition spark and cause an explosion or
fire.
Engine - Kawasaki (FH491V) Diagnostics - 36
ENGINE - KAWASAKI (FH491V) DIAGNOSTICS
Yes: Check for broken or seized piston Rings or worn
cylinder.
No: Go to next step.
8. Is oil pump screen clogged or pick up tube cracked?
Yes: Clean screen and repair or replace pick up tube.
No: Go to next step.
9. Is there excessive crankshaft or rod bearing
clearance?
Yes: Regrind crankshaft and install undersize
connecting rods.
No: Go to next step.
10. Intake/exhaust valves or guides worn?
Yes: Replace valves and head.
No: Go to next step.
Contamination in Crankcase
1. Is there fuel in the crankcase?
Yes: Check for broken or seized piston rings or worn
cylinder. Check for worn or seized exhaust valve.
No: Go to next step.
2. Is there water in the crankcase?
Yes: Check to make sure that crankcase breather is
working correctly. See "Crankcase Vacuum Test" on
page 49. See "Breather Inspection" on page 59.
No: Go to next step
Starting Motor Troubleshooting Guide
Note: To test specific electrical components, see
Electrical Section and refer to either Diagnostics or
Tests & Adjustments for further guidance.
Starting Motor Diagnostics
Starter Does Not Rotate
1. Is there a click sound from the starter solenoid?
Yes: Go to next step.
No: Repair starter motor. See "Starting Motor" on
page 76.
2. Check that all starting conditions are met?
Yes: Go to next step.
No: Make sure all starting conditions are met.
3. Are battery cables loose or dirty?
Yes: Clean and tighten.
No: Go to next step.
4. Is battery fully charged? See "Battery Test" on
page 343 in the Electrical Section.
Yes: Go to next step.
No: Charge battery. See "Charge Battery" on
page 344.
5. Is key switch working correctly?
Yes: Go to next step.
No: Repair or replace key switch
6. Is engine seized?
Yes: See Engine Repair section.
No: Go to next step
Starter Rotates Slowly
1. Are battery cables loose or dirty?
Yes: Clean and Tighten.
No: Go to next step.
2. Is battery fully charged?
Yes: Go to next step.
No: Charge battery. See "Charge Battery" on
page 344.
3. Is there a click sound from the starter solenoid?
Yes: Go to next step.
No: Repair starter motor. See "Starting Motor" on
page 76.
4. Is engine seized?
Yes: See Engine Repair section.
No: Go to next step
5. Is starting motor or solenoid defective?
Yes: Repair or replace. See "Starting Solenoid Test" on
page 349.
No: Go to next step.
Carburetor Troubleshooting Guide
Engine Will Not Start
1. Is there fuel?
c Caution: Avoid Injury! The engine may start to
rotate at any time. Keep hands away from
moving parts when testing.
Important: Avoid Damage! If starting motor does not
stop rotating by turning ignition switch to Off
position, disconnect negative (-) lead from battery
as soon as possible.
Engine - Kawasaki (FH491V) Diagnostics - 37
ENGINE - KAWASAKI (FH491V) DIAGNOSTICS
Yes: Go to next step.
No: Add fuel, check fuel lines.
2. Is fuel line plugged?
Yes: Clean fuel line and fuel filter. Check for fuel supply
at carburetor.
No: Go to next step.
3. Does the fuel solenoid open?
Yes: Go to next step.
No: Test solenoid and power to solenoid. See Electrical
section.
4. Is the main jet clogged?
Yes: Disassemble and clean jet and passages.
No: Go to next step.
5. Is the needle valve stuck closed?
Yes: Check for old or gummy fuel. Clean carburetor.
Check valve tip.
No: Go to next step.
Engine Cranks But Is Hard to Start
1. Is the air filter clean?
Yes: Go to next step.
No: Clean or replace air filter.
2. Is the choke plate opening properly?
Yes: Go to next step.
No: Adjust choke cable. See choke cable and throttle
cable adjustment.
3. Check passages in carburetor. Are passages open
and free of debris or varnish?
No: Clean carburetor.
Engine Idles But Does Not Run Under Load
1. Check main jet. Is main jet dirty?
Yes: Clean carburetor.
No: Go to next step.
2. Check main jet for proper size. Is correct main jet
used?
No: Replace main jet.
Engine Idles, Runs (loaded or not) Then Stops
1. Is the fuel system properly vented?
Yes: Go to next step.
No: Check fuel cap if vented cap is used. Check vent
lines to carburetor for kinks, or collapsed or weak
areas.
2. Is dirt in the bowl being sucked into main jet?
Yes: Check float bowl for dirt or corrosion, clean bowl.
Check main jet for loose debris.
Engine Does Not Idle Properly (hunts or surges)
1. Check to see if the problem is governor or
carburetor: Hold the throttle plate closed to force
engine to idle. Does the engine continues to run?
check governor. If the engine stalls - suspect idle
circuit.
Yes: Check governor for proper operation.
No: If engine stalls, check idle circuit. Clean carburetor
with attention to idle circuit passages.
Engine Idles, Does Not Run Properly At Wide Open
Throttle (WOT)
1. Check float bowl for dirt or corrosion. Check for dirt
between needle valve and seat. Is dirt or debris
present?
Yes: Clean bowl and valve seat.
No: Go to next step.
2. Is float sticking or not set properly?
Yes: Clean float pivot. Adjust float.
No: Go to next step.
3. Check air passage and pilot jet for debris or varnish.
Is there debris in the idle air bleed or pilot jet?
Yes: Clean carburetor.
Carburetor Air/Fuel Diagnosis
Defects in carburetors would be apparent very early in the
life of the engine. The majority of fuel system problems are
related to stale or improper fuel or dirt. This section is to
help you diagnose fuel system problems.
Initial Checklist
How old is the fuel?
Does the fuel have a foul smell?

Is the fuel cloudy, dark or dirty?

Is the fuel tank cap air vent clean and open?

Is a clean, correct air filter installed?
Has the ignition system been verified?

Is the air filter and carburetor attached properly?

Is the intake manifold loose and/or leaking?

Is the fuel shut-off solenoid operating properly?

Is the governor throttle linkage moving properly?

Is the float operating properly?

If the carburetor is externally vented, is the vent line
unrestricted?
Engine - Kawasaki (FH491V) Diagnostics - 38
ENGINE - KAWASAKI (FH491V) DIAGNOSTICS
Note: Other engine failures such as plugged exhaust
or improper valve clearance can cause symptoms
similar to faulty fuel supply. Verify the quality of the
engines mechanical and electrical systems.
Engine Surge
An engine that surges may have an improper air/fuel
mixture or a misadjusted or worn governor.
Attempt to manually control the throttle at low and high idle
to determine which system is causing the surge. If the
engine speed can be held constant check the governor
system. If the engine surge cannot be controlled manually,
check the fuel system.
Fuel system issues may consist of:

Improper air/fuel mixture caused by air leaks around the
throttle shaft, intake and/or insulator gaskets.
Minor restrictions inside the carburetor passages from
varnish and debris buildup in the idle circuit. Properly
cleaning the carburetor will likely fix the problem.
Rich Air/Fuel Mixture
There are several possible causes of a rich running
condition such as: improper or stale fuel, short-tripping, air
filter, choke adjustment and/or vent tube location.
Note: Verify the ignition system. A rich running
condition can have the same symptoms as an
improperly operating ignition system.
Float Valve
MX47331
Float Valve with Worn Tip Shown
Fuel level in the float bowl is regulated by the float and the
float valve. A worn float valve tip provides too much fuel
and will cause a rich condition.
Improper or Stale Fuel
Poor fuel quality can cause an engine to appear to be
running rich. Improper or stale fuel can cause engine
components to stick or deteriorate.
Short-Tripping
A common misdiagnosis comes from short-tripping
machines (engines that are started for short periods of
time). Short-tripping causes the engine to develop black,
sooty spark plugs and contamination in the oil. Over time,
short-tripping can lead to glazed cylinder walls.To prevent
this, every time the engine is started, allow the engine to
reach operating temperature and load the machine.
Air Filters
Note: Late model carburetors are internally vented to
meet emissions standards.
Engines with externally vented carburetors with a dirty air
filter will exhibit rich running conditions. When a dirty air
filter restricts air flow to the carburetor, the low pressure in
the venturi drops even further, resulting in a higher
pressure differential between the fuel bowl and the venturi.
Therefore, a dirty air filter can enrich the air/fuel mixture to
the point that performance will drop.
Engines with internally vented carburetors will not exhibit
rich running conditions with a dirty air filter. When a dirty air
filter restricts air flow to the throat of the carburetor, an
equal reduction will be applied to the bowl vent. Internally
vented carburetors maintain the pressure differential
between the bowl and the venturi resulting in a consistent
air/fuel mixture over the life of the air filter.
Vent Tube Location
With an externally vented carburetor, a rich or lean run
condition could also be caused by the location of the float
bowl vent tube. The purpose of the vent tube is to allow
atmospheric pressure into and out of the float bowl. Air
from the cooling fan at the vent tube opening can cause a
pressure increase or decrease on the fuel in the float bowl
and cause the engine to run rich or lean. Check for bulletins
and relocate the float bowl vent tube to a location away
from any source of turbulence.
Engine - Kawasaki (FH491V) Diagnostics - 39
ENGINE - KAWASAKI (FH491V) DIAGNOSTICS
Carburetor Diagnostic Inspection
Inspect the carburetor float bowl and passages for debris,
varnish buildup, and corrosion.
Check for damaged parts or parts installed incorrectly.
MX47332 and MX47333
MX47469
1. White corrosion or green corrosion is usually caused by
water. Water can combine with other chemicals and create
acids and salts which accelerate corrosion. Water can be
absorbed by ethanol, so the more ethanol, the worse the
problem.
Extreme corrosion may involve salt water. Sometimes the
exterior of the carburetor will also be corroded.The location
of the machine (such as coastal regions) will provide
additional clues to the cause of corrosion.
MX47472
2. Red or brown corrosion is usually caused by an iron or
steel part that has corroded. Look at steel fuel inlet fittings,
steel parts in fuel filters. It could also indicate some other
contaminant in the fuel. Some microbial contaminations
can be reddish.
MX47471
3. Brown varnish and gum deposits are generally from old
degraded fuel. It usually has a distinctive "old varnish"
smell. Look for it in areas that would be adversely affected,
such as fuel and air passages, needles and seats.
4. Damage from excessive ethanol, methanol, MTBE,
ethers, will usually be seen as damage to rubber parts.
Look for cracks, swelling, shrinking, loss of elasticity, takes
a permanent set or becomes hard or brittle. Look for plastic
damaged parts.
5. Debris stuck in small orifices and other critical areas.
Look in jets, fuel and air passages, fuel inlet needle and
seat, idle mixture adjustment needles and seats, idle
progression holes, fuel shutoff solenoid plunger, etc. The
Engine - Kawasaki (FH491V) Diagnostics - 40
ENGINE - KAWASAKI (FH491V) GENERAL INFORMATION
material of the debris can help determine the source. Look
for the following:
a. Cellulose and other organic fibers are usually grass
debris that was ingested by the engine air intake or fuel
system, they could also be fibers from the fuel filter
element.
b. Sand can come from ingesting dirt by the engine air
intake system or fuel system or from unclean
manufacturing and parts packaging.
c. Metallic particles such as aluminum, brass, and iron
chips typically come from the manufacturing process
and unclean parts packaging and assembly areas.
d. Plastic particles usually come from manufacturing
processes such as plastic molding, welding, adhesive
(epoxy used in fuel filters), and unclean part packaging
and assembly areas.
e. Rubber particles usually come from the fuel lines,
fuel pump diaphragms, or internal parts, and unclean
part packaging and assembly areas.
f. Cardboard particles and fibers usually come from
parts packaging and unclean assembly areas.
g. Hair fibers usually come from unclean parts
packaging and assembly areas.
6. Wrong parts, such as wrong size jet or left and right jets
switched.
7. Damaged parts, such as jets having tool marks that
affect the fuel flow, cracked plastic parts, etc.
8. Defective parts such as porosity in castings, excessive
flash on castings or molded parts, defective welds or
adhesive joints, throttle shafts that fit too tight or too loose,
throttle plates out of alignment or not matched to bores,
etc. Defective machining is difficult to diagnose unless it's
obvious.
General Information
Cleaning Carburetors
Debris, corrosion, rust, or varnish can build up in the
internal air/fuel passages. Many times the contamination is
located in an area of the carburetor that is not visible. In
most cases proper cleaning can resolve these issues.
Carburetors and carburetor components can be cleaned by
using one of several types of commercial cleaning
methods: aerosol sprays, caustic dip tanks, and ultrasonic
cleaners.
Note: Some cleaning chemicals may be flammable and
have toxic fumes. Always follow the chemical
manufacturer's recommendations. Always wear
personal protection gear such as safety glasses
protective gloves and work in a well ventilated area. Do
not use drill or hard wire to clean carburetor passage
ways.
Cleaning Procedure
Always follow the solvent manufacturer's recommendations
for material compatibility because some solvents may
attack metal, plastic or rubber components.
1. Clean debris off the outside of the carburetor before
disassembly.
2. Completely disassemble the carburetor per the
instructions in the Technical Manual and visually inspect.
3. Determine if carburetor is repairable, excessive
corrosion may determine this is not practical.
4. If repairable, clean any remaining dirt and old gaskets
from the carburetor.
The preferred method of cleaning is to use an ultrasonic
cleaner.
Carburetor Assembly
When the carburetor is ready for assembly, lay out all the
necessary components on a clean surface. Be aware that
even clean shop rags may contain dirt and metal shavings.
Assemble the carburetor in accordance with the
instructions in the Technical Manual. Keep the following in
mind:
Check the throttle shaft for excessive play or movement
and any signs of binding.
Never use oil on the throttle shaft because it attracts dirt
which can cause premature wear of the throttle shaft seals.

If the throttle shaft was removed use new screws and
follow the service manual torque specifications.
Always check the float and float valve for binding with
the float valve installed in its proper position.
Replacement of all gaskets and seals is necessary
when servicing any carburetor.

Inspect the carburetor insulator for damage and replace
if necessary. Be sure to install the insulator using the
correct orientation.
Clean and flush the complete fuel system.
Fuel lines must be replaced if they are brittle, cracked,
excessively soft or damaged.
Replace the fuel filter and air filter after cleaning the
Important: Avoid Damage! Wires and metal
instruments should not be used. Light damage or
deposits on the surface of the float valve seat can be
removed using a cotton swab with a mild abrasive such
as toothpaste or 800 grit lapping compound.
Engine - Kawasaki (FH491V) General Information - 41
ENGINE - KAWASAKI (FH491V) GENERAL INFORMATION
carburetor.
Cleaning Methods
Ultrasonic Cleaning Systems
Ultrasonic cleaners use environmentally friendly cleaning
solution and sound waves to penetrate deep into
carburetor passages. Heating the solution is an option on
ultrasonic cleaners that significantly increases the
effectiveness of the system. Ultrasonic cleaner systems
work by creating sound wave pulses that are transmitted
through a cleaning solution. Manufactures of ultrasonic
cleaners claim the pulses create small bubbles that loosen
and pulverizes contaminates. Select a chemical solution
that is designed specifically for carburetor cleaning.
Generally, chemicals will need to be diluted with water prior
to use. When choosing a chemical, consider dilution rates
to help determine which chemical is the most cost effective.
Consider disposal of cleaning solution before ordering
chemicals. Check with local authorities on recommended
disposal methods before disposing of any cleaning
solution. Ultrasonic cleaners come in many sizes. Most 1.5-
2 gallon tanks will be sufficient for carburetors used by
John Deere gas engines.
If an Ultrasonic Cleaner is used, place carburetor in and
run for 30 minutes at 110 F in the proper solution mix. If the
solution is too strong or the carburetor is left in the cleaner
for too long, the aluminum body will have a residue on the
surface from the aluminum oxidizing.
Rinse the parts in water and dry with compressed air (up to
30 psi).
Wash off and blow ports out in carburetor body/ fuel
transfer tubes / and discharge port. Blow compressed air
through carburetor passages in the opposite direction of
the air/fuel flow (into the smallest passages to flush debris
out of the larger passages). This will prevent debris
lodging in difficult to clean areas.
Aerosol Cleaner
Personal safety, environmental concerns and cleaning
effectiveness make this method the least desirable. This
method can be used on carburetor components that may
be damaged by caustic cleaners (rubber seals or other
non-metallic components). When cleaning with aerosol
sprays, it is always best to spray in the opposite direction of
the air/fuel circuit (into the smallest passages to flush
debris out of the larger passages). This will prevent debris
lodging in difficult to clean areas.
Caustic Dip Tanks
Caustic dip tanks use aggressive chemicals to dissolve
carbon based contamination. This method is effective for
most carburetor cleaning needs.
Rotating the parts in the tank will ensure the cleaning
solution flushes out any air pockets left in the passages.
Follow the recommendation on the cleaner for submersion
times. Disadvantages of the caustic dip tanks are that
some carburetor parts may be damaged if left in solution
too long.
Personal safety and chemical disposal are additional
concerns. Because the chemical is caustic, exposure may
cause injury or death. Disposal of used solution can be
difficult because most cleaners are considered hazardous
waste.
Fuel
Use only fuels recommended in Operator's Manual:
Use regular grade unleaded fuel with an octane rating of 87
octane or higher. Fuel blends containing up to 10% ethanol
or up to 15% MTBE reformulated fuel are acceptable. DO
NOT use fuels with more than 10% ethanol (i.e. E85 should
not be used because it is 85% ethanol and 15% gasoline)
or fuels with more than 15% MTBE reformulated fuel as
these products will damage engine and or fuel system. Do
not use fuel or additives containing methanol as engine
damage can occur.
All fuel today is formulated for the automotive industry. Fuel
is "blended" differently for winter and summer use;
regardless of where you are. "Winter" fuel is blended for
improved vaporization in colder temperatures. Using left
over "Winter" fuel in warmer Spring/Summer temperatures
will likely cause vapor locking and surging. Newer
carburetors on current production machines have less
c Caution: Avoid Injury! Compressed air can
cause debris to fly a long distance.
Clear work area of bystanders.
Wear eye protection when using
compressed air for cleaning purposes.
Reduce compressed air pressure to 210 kPa
(30 psi).
c Caution: Avoid Injury! Vapors from solvents
can be explosive and flammable. Follow the
instructions on the container label for safe use
of the solvent:
Work in a well-ventilated area.
Wear protective clothing when handling
solvent.
Do not smoke while handling solvents.
Keep solvent away from flames or sparks.
Engine - Kawasaki (FH491V) General Information - 42
ENGINE - KAWASAKI (FH491V) TESTS AND ADJUSTMENTS
tolerance for poor quality fuel because of the tighter
specifications required to meet EPA certification.
Fuel Storage
Since it is difficult to know what type of fuel is in different
areas; it is best to handle and maintain fuel as outlined
below:
1. Deteriorated/stale fuel causes gum and varnish. This
creates deposits on engine valves and in carburetor jets
and passages. This is what causes most of the
performance problems.
2. Oxygenated (or blended) fuels can deteriorate faster
and require more specific storage and usage procedures.
3. The translucent fuel tanks on some model tractors allow
a certain amount of sunlight through the tank. This can
accelerate the deterioration of the fuel.
Note: There is no fuel stabilizer made that will "restore"
stale fuel. Fill tanks with fresh, stabilized fuel.
4. Use fuel from a major name brand supplier. At the same
time, add an appropriate amount of Fuel Stabilizer (such as
TY25808). Do this when you add fresh fuel to your tank.
5. If engine performance problems arise, try another brand
of fuel. You may have to try several different sources.
6. Any fuel over 30 days old is considered "stale".
For 2-cycle equipment, purchase as small a quantity of
fuel as feasible. If there is doubt about how long the fuel
may be stored, add stabilizer right away. JOHN DEERE
PREMIUM EXACT MIX 2-Cycle Oil (UP08127) already has
a fuel stabilizer added to the oil. When using this oil fuel
mix, it will stay fresh for up to 30 days. If storing a 2-cycle
powered unit for more than 3 weeks, it is recommended to
run the fuel out of the unit.
Tests and Adjustments
Throttle Cable Check and Adjustment
Reason:
To make sure the throttle control arm has the proper
amount of travel for maximum engine performance.
Equipment:
6 mm (1/4-in.) Bolt or Drill Bit
Check Procedure:
1. Park machine safely. See "Park Machine Safely" in the
Safety section.
2. Remove air filter cover and air filter.
MX37067
3. Remove the two flanged shoulder bolts (B) and two nuts
(A) that hold the air cleaner base to the carburetor.
4. Move throttle control lever from SLOW idle to FAST idle
position.
MX37638
5. Check hole alignment in control panel (C) and throttle
arm (D) by placing 6mm (1/4-in.) bolt or drill bit in hole. Bolt
c Caution: Avoid Injury! Fuel stabilizer is a
hazardous chemical and can be harmful or fatal
if swallowed. Do not take internally. Avoid
contact with eyes. Avoid breathing the
chemical vapors.
Read safety instructions on stabilizer container
label before using.
Fuel stabilizer contains 2,6-di-tert-butylphenol
(128-39-2) and aliphatic petroleum distillate
(64742-47-8). In case of emergency, contact a
physician immediately and call 1-800-424-9300
for material safety information.
A
B
C
D
Engine - Kawasaki (FH491V) Tests and Adjustments - 43
ENGINE - KAWASAKI (FH491V) TESTS AND ADJUSTMENTS
must go through both holes.
Results:

If holes align throttle cable adjustment is OK.

If holes DO NOT align, perform "Adjustment Procedure"
below.
Adjustment Procedure:
1. Move throttle control lever to FAST.
MX38033
2. Loosen cable retainer screw (F).
3. Move throttle arm (E) and throttle cable (H) to align
holes in control panel and throttle control plate. Insert a 6
mm (1/4 in.) bolt (G) or drill bit through holes to keep
throttle arm from moving. Be sure bolt or drill bit is
perpendicular to the control panel.
4. Make sure throttle control lever on dash is still in FAST
position. Tighten retaining screw (F).
5. Remove bolt or drill bit.
6. Repeat "Check Procedure".
7. Move throttle control lever through full range to be sure
linkage is not binding.
8. Install air filter housing and air filter.
Choke Cable Adjustment
Reason:
To make sure the choke is fully closed when the choke
control lever is in the full choke position.
Procedure:
1. Park machine safely. See "Park Machine Safely" in the
Safety section.
2. Remove hood.
3. Remove air filter cover and air filter.
MX37067
4. Remove the two flanged shoulder bolts (B) and two nuts
(A) that hold the air cleaner base to the carburetor.
MX37070
5. Move the engine choke lever to the choke position. The
carburetor choke butterfly (C) should be fully closed.
c Caution: Avoid Injury! Engine components are
HOT. Do not touch, exhaust pipe or muffler
while making adjustments.
F
G
H
E
A
B
C
Engine - Kawasaki (FH491V) Tests and Adjustments - 44
ENGINE - KAWASAKI (FH491V) TESTS AND ADJUSTMENTS
MX37071
6. If the choke butterfly does not completely close, loosen
cable clamp (D). Adjust position of choke cable to
completely close choke.
7. Move the choke control lever between the choke fully
open and fully closed position several times. Ensure the
choke plate fully opens and closes. Readjust cable as
needed.
Installation is done in the reverse order of removal.
Tighten fasteners to specification.

Install hood.
Torque Specifications:
Air Cleaner Base Nuts . . . . . . . . . . . . 6.9 Nm (61 lb-in.)
Air Cleaner Base Screws . . . . . . . . . . 3.9 Nm (35 lb-in.)
Governor Adjustment
Reason:
To ensure the governor shaft contacts the flyweight plunger
when the engine is stopped.
Procedure:
1. Park machine safely. See "Park Machine Safely" in the
Safety section.
2. Move throttle control lever to FAST idle position.
MX37639
3. Loosen nut (A).
MX37640
4. Insert small pin punch (C) in hole in governor shaft.
5. Hold governor arm (B) in the fully counterclockwise
position.
6. Rotate governor shaft counterclockwise as far as it will
go.
7. Hold governor shaft and governor arm in place and
tighten nut to specification.
8. Move throttle control lever through full range to be sure
linkage is not binding.
Specification:
Torque . . . . . . . . . . . . . . . . . . . . . . . . . 7.8 Nm (69 lb-in.)
D
A
B
C
Engine - Kawasaki (FH491V) Tests and Adjustments - 45



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