Kawasaki FJ400D

Kawasaki FJ400DThe Kawasaki FJ400D is a 0.4 l (401 cc, 24.47 cu-in) single-cylinder air-cooled 4-stroke internal combustion small gasoline engine with horizontal shaft manufactured by Kawasaki Heavy Industries LTd., for general-purpose applications.

The FJ400D engine has an OHV (overhead valve) design; float type carburetor with fixed main jet; transistorized flywheel magneto ignition system; diaphragm type fuel pulse pump; mechanical governor and shift-type electric starter.

Bore and stroke are 82.0 mm (3.23 in) and 76.0 mm (2.99 in), respectively. Compression ratio rating is 8.2:1.

The Kawasaki FJ400D motor produced 13.2 PS (9.7 kW; 13.0 HP) at 3,600 rpm of maximum horsepower and 26.5 Nm (2.7 kg·m; 19.6 ft·lb) at 2,400 rpm of torque.

General information

Engine Specifications
Type4-stroke, OHV, single cylinder
Displacement401 cm 3 (24.47 cu-in)
Max. horsepower13.2 PS (9.7 KW; 13.0 HP) at 3,600 rpm
Max. torque (crank PTO)26.5 Nm (2.7 kg·m; 19.6 ft·lb) at 2,400 rpm
CarburetorFloat type with fixed main jet
Cooling systemForced-air
Ignition systemTransistorized flywheel magneto
Lubricating systemPressure feed
Starting systemShift type electric starter
Stoping systemIgnition primary circuit ground
Fuel usedUnleaded gasoline (octane number 86 or higher)
PTO shaft rotationCounterclockwise (from PTO shaft side)

Dimensions and Weight

Kawasaki FJ400D
Length407 mm (16.0 in)
Width472 mm (18.6 in)
Height319 mm (12.6 in)
Dry weight31.5 kg (69.5 lbs)

Cylinder Block and Head

Cylinder block
Compression ratio:8.2:1
Bore x stroke:82.0 x 76.0 mm (3.23 x 2.99 in)
Cylinder internal diameter (standard):81.980-82.000 mm (3.2276-3.2283 in.)
Piston skirt outer diameter (service limit):81.77 mm (3.2170 in)
Number of piston rings (compression / oil):2/1
Connecting rod small end diameter (service limit):19.060 mm (0.7500 in.)
Piston pin diameter:18.960 mm (0.746 in)
Pistin ring groove clearance:Top0.180 mm (0.0071 in)
Second0.180 mm (0.0071 in)
Ring end gap:Top0.700 mm (0.0280 in)
Second0.800 mm (0.0310 in)
Oil1.000 mm (0.0390 in)
Ring thickness:Top1.400 mm (0.0551 in)
Second1.400 mm (0.0551 in)
Cylinder head
Valve arrangement:OHV
Valve steam diameter:INTAKE6.950 mm (0.2740 in)
EXHAUST6.930 mm (0.2730 in)
Valve spring free length:INTAKE32.6 mm (1.280 in)
EXHAUST32.6 mm (1.280 in)

Service Information

Maximum speed3,750 ± 50 rpm
Idle speed1,125 ± 75 rpm
Cylinder compression pressure
Minimum294 kPa (43 psi)
Valve clearance
Inlet0.10-0.15 mm (0.0039-0.0059 in)
Exhaust0.10-0.15 mm (0.0039-0.0059 in)
Oil system
Oil type4-stroke or an equivalent (SF, SG, SH, or SJ)
Recommended oilSAE 10W-30
Oil capacity Without oil filter: 1.1 L
With oil filter: 1.3 L
Ignition system
Spark plugNGK: BPR5ES
Spark plug gap0.7-0.8 mm (0.028-0.031 in)
Ignition coil air gap0.3 mm (0.012 in)
Author: Sergei Wers
About: Co-founder and CEO of a multi-brand auto repair shop (engine repair, chassis repair, body repair and painting) for over 15 years. I have been developing internet sites with technical specifications for more than seven years.

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    • Depends if it has automatic compression release. If it is a 2015 or newer chances are it does. 126 psi min on the older ones. 90 psi on the 2015 and up. Normally you would be told that you cant get an accurate compression reading on the ACR equipped engine and they are correct. However after diagnosing these things for a few years now, I can say I’m pretty sure that it’s safe to compression check it if it has the ACR. Leak down test is better if you can get one. No more than a 15% loss. 20% percent is pushing it. I hope this helps.

  1. Is there a port that could feed an oil cooler on one of these ? Mine is from an EZGO golf cart.

  2. I have a club car with 401 and it starts hard and acts like it’s running out of fuel all the time I’ve changed the fuel pump and plug but it has no power I just bought it and the papers say the engine only has 15 hours on new crankshaft.

  3. Looking for the correct piston, rings, and connecting rod, for this motor; I am rebuilding it. Any help in locating the parts is appreciated.

  4. It only has 60 pounds of compression dry and 90 lbs of compression with a wet test I reall wonder if that’s enough and where is the compression release located

    • It’s a pulse pump. It uses the crankcase pressure oscillations to drive a diaphragm which in turn drives the pump. It sets directly on top of the tank. Checking for proper operation is simple. Disconnect the spark plug wire and fuel line at the carburetor and crank the engine. It should have pulse spurts of fuel. If so your good.

  5. Hello, I want to measure the tool used to pull the clutch Ezgo400cc fj 2016 model. I want to measure the right tool for it

  6. I want to change the clutch for a 2016 Ezgo wagon I want to measure the tool used to pull the clutch I have a 400cc fj engine

    • I am usually 30 minutes on a golf cart oil change.

      On a sunny day in the Mohawk Valley of New York before golf season – I drive my cart a distance at open throttle to warm the engine after storage – keep in mind I am a DIY mechanic who will usually change a truck or car oil at the same time, and the cart maintenance time is short, and clean motor oil is inexpensive.
      Based on my cart’s hour meter and having 5 golfers in my family, I will change oil in April and again in mid-July, or so each season to keep it cared for.

      I prop my 2012 E-Z Go cart up by backing the driver’s side rear wheel carefully up my oil change ramp normally used for my Rav4 Toyota. I use just 1 ramp and I chock the other wheels, so that they cannot move when I am under the edge of the machine.

      I drain the oil from the 19MM drain plug hole and replace it with a synthetic 10w-30 oil of my choice back to the 1.3L volume specification.

      I do deviate from spec and change the oil filter element with every other oil change, and I will give the warmed engine a few extra minutes to allow the slow drain of the last few drips of oil that wish to exit.

      Check out the other service points up under there and lube the cables and etc., while playing with the maintenance, and I am usually good to go inside of 30 to 40 minutes, the most time taken to clean the cart and the area around it and put the tools and props away after I am done.

      • Have a 2006 Ezgo 1200 mpt ! Used to be Beverage cart at Golf Course where was mechanic at! Blew Crankcase Gasket-1/8 oil caked on pan below engine! Plus electric problems! Pulled it rebuilt it! runs well but some how gas getting in oil! Air filter is fine! Wonder what sucking it in ??? any Thoughts

  7. I would like to buy a new fj400d. If you or someone you kno can steer me in the right direction please let me know thanks.

  8. I have a OX 400 Bass Tracker ATV work cart. It has a 401 CM 4 stroke Kalwasaki Engine. Have had ant trouble then all at once the dip stick starts jumping out of location and my ckeck engine light flashes.

  9. Will this engine swap out with the FE400? Its going in a Clubcar turf 272. What is the bolt pattern for the mounting?

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