fd620D not reaching high idle rpm

[coachlarry]

Hello all
Gator 2006 HPX 4x4 w Kawi FD620D
Rebuilt carb, new main and pilot jets, heater, solenoid, needle, clean.
Fuel pump tests to spec
Spark tests to spec
Compression tests to spec

Engine idles fairly smooth, soft popping once in a while during idle. Full throttle reaches 2900 rpm (spec 3400), and runs a little rough at 2900. High idle governor screw not an issue. I assume there is a leak of some kind somewhere. Any thoughts? Thank you.

 

[beenthere]

Interested as I am working on the same model Kawasaki engine.. (tore down to replace plastic cam gear and now re-assembling).

Question: how was the engine acting before the carb work? Was it backfiring then? Have you done any adjusting of the valves?

 

[coachlarry]

Interested as I am working on the same model Kawasaki engine.. (tore down to replace plastic cam gear and now re-assembling).

Question: how was the engine acting before the carb work? Was it backfiring then? Have you done any adjusting of the valves?

Engine was hesitating badly before carb rebuild. Occasional loud backfire. Those issues are gone. Have not checked valve lash yet. It’s such a pain to get the engine out and access is poor while it’s in the machine. Might get one of those harbor freight cranes and do an overhaul if i can’t figure this out.

 

[Richard001]

Don't know if you have the service manual for that engine, but here is the page that shows how to adjust the fast idle.



Richard

 

[coachlarry]

Decided to go to ignition and removed blower housing. Anything look interesting in this picture?

 

[Richard001]

A lot of dirt built up in the front of the trigger coil, but unless it has some magnetic partials in it, it should effect the timing.

What did I miss?

Richard

 

[beenthere]

One pulser coil missing, appears?

 

[coachlarry]

An ignition module missing?

Yes, that痴 what i thought when i posted, but it seem there is only one pulser coil on this setup. My mistake! and it drove me crazy because there was no other connector. I almost bought a new coil too. I thought i had found my problem but not yet.

 

[beenthere]

Causes me to wonder.. being a two-cyl engine.. here is schematic showing one ign module and a pulser for each cyl. From the FD620D manual.

 

[coachlarry]

Yes, i saw that and that’s when i figured i was home free. However, the absence of a connector for the second coil, and this schematic seemed enough for me to accept that there is only one. It seems curious though. Take a look.