Kawasaki 4 Stroke Engine Rebuild. Piston Ring Repair , Head Gasket Replace
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- Опубликовано: 24 июл 2024
- We have the kawasaki 4 stroke engine put back together and on the walk behind mower. We replaced both sets of pistons rings and we also put on new head gaskets and other gaskets as needed. The exhaust valve was stuck open and we got that fixed before we started this rebuild. The engine runs good but at a high rpm. We believe it is because of the governor spring that I stretched out on accident. I ordered a new gov spring and throttle link & spring. Hopefully this fixing that problem and the mower will be done. Thanks you for watching and if you have anything to add to this rebuild please do.
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My God it is amazing that thing held together...put together dry then went directly to 6K RPMs on the first pull because the governor arm wasn't properly installed.
Ikr!!!!!!!
And it doesn't appear he honed it
This video is great. To help give specific torque values. This helps I have a broken piston rod. Thanks guys.
should've put a thin layer of oil on the cylinder and on top of the pistons so it doesn't start dry
Great job! I wanted to see a real-life repair like this one.
Looks great guys! One tip I have is coat the internal parts with oil as you assemble them so they don't run dry on initial start up. Can't wait to see some more truck talk and mowing with the ex mark.
Blessings Lawn & Outdoor Services That's a great tip man. I wish I would have thought of that. LOL . We have been so busy dealing with rain here that we haven't had the chance to do any truck talk or a lot of videoing but I assure you that there will be more.
Great work guys! I bet that will be an awesome feeling when she's out working again, knowing that you did it yourselves.
Parker Hagenow Exactly, I can't wait man!
Good video. I am not an expert but I am taking a marine engine repair class. For a few things we were taught... The piston and the piston rod are suppose to be oriented a certain way in many engines. Put the piston back in the same cylinder with the the end bolted around the crankshaft in the same direction as it came off. Do not swap ends. Be sure to torque everything in the engine that takes much time to replace. After going to that much work, I would replace the bearings and seals whether they look acceptable or not. They are the parts that take the most abuse and I don't have time to do a bunch of rebuilds for inexpensive parts.
Getting ready to attempt on my 48 Exmark. we have an oil leak from the top of the engine, thanks for the insight. I have been out of school over 30 years, hoping it comes back really quick. LOL
If you have no ring compressor, just use a large hose clamp. Put it around the rings, and using a screwdriver to tighten the clamp and compress the rings works like a charm.
Looking good! Been waiting for the reassembly video. Glad it's back up and running.
gouldjohnathan It went well, thanks!
use engine oil putting the pistons in, also you can use large hose clamps to compress rings while installing so you dont break a ring. also pour oil in pump so it will prime before starting
You guys did a great job gettin that thing back together! One quick tip. When you are tightening down those heads with the torque wrench make sure you go over every bolt twice because as you tighten one the other will get looser.
Nathan Levin I will keep an eye out for that. Thanks Nathan.
Watched entire video. Read quite a few of the comments. Lords willing, I will be rebuilding my Kawasaki FH680V soon!
you can use a filter wrench if you dont have a ring compressor..
Great video! I also have an FH580V and I think I will give it a go on rebuilding it.
Loved your rebuild video. You had nothing to loose.
Jordi Hester Your right there. Thanks!!
Yes said your not pro's, but you could have fooled me! Good job guys. Looked like it went nice and smooth. Thanks for sharing.
Ken Heller It wasn't bad at all. I thought the rebuild was going to be way worse than the breakdown.
this video made me wanna fix my engine. thanks brian
Sounds healthy. Great work!
Cracking vid fella ... As someone else has already said ... if you do this again (hope you don't have to) make sure you use plenty of oil ... assembly lube is best, redline do a nice product that's never failed me that I imagine you could get cheaper than I can!
Cheers for putting the video together ... really enjoyed it.
Matt Allen I will do that. Thanks!
Hey guys if you have no ring squeezer, try zip ties on each ring. One at a time. It worked for me. :)
phillymacify buy ring compressors end of story and oil everything up putting it together gee wiz
If you don’t have a piston ring compressor you can also use a hose clamp. Me and my buddy used one today while we were rebuilding my Kawasaki engine.
great job guys, i have been waiting for this video, glad everything went together well!!!
Brian Lee It was a lot of fun man! Thanks
need to remove valve train before head install, then pushrods and adjust valves. your engine is racing at the end due to governor. adjust properly its fine. you can spin engine w starter and plugs out prior to first start up. solves lube issue and primes carb w fuel
Hope everything works out the way you have plan. Man those guys really help you on your business. Good luck.
Romero lawn care Yea, they are pretty good boys.
Top Notch Lawn Care what happened to this mower?
Assembly lube on all moving parts.
Pre-position governor lever.
Always install new crankshaft seal in oil sump, make sure lip on seal doesn't roll over when assembling sump (oil pan). Loctite sump bolts.
Gradually tighten bolts to torque...not to full torque as you go.
Loctite engine to frame mounting bolts.
Anti-seize pto end of crankshaft...make sure key is in good condition before installing pto. Loctite on bolt.
Anti-seize and check key for flywheel.
Adjust valves.
Working on a 31hp motor today. Luckily I was able to use this video to get an idea of what needed to be done. Because it is impossible to find videos on the 31hp 6 valve motors
kick ass, great job!
You should have used a gasket sealer. Also if you ever have to do that again get a piston ring compressor to make sure they seat properly for the correct compression. Also when you torque things to spec adding a extension will alter the torque so you have to adjust accordingly. Just for future reference! Love the videos! Keep up the good work!
Anthony Rappazzo Appreciate the feedback Anthony!
TopNotchLawns No problem
At around 1:40 that ring is the oil slinger (sprayer) the middle ring is the oil scraper and top ring is the compression just a little info,
Another great video!!! Great Job Guys!!!!!
We'll I don't need to attend small engine repair class now, you guys have taught us all the 101 on SER
Great video
Shadow Thanks Shadow. I learned a lot as well.
Yea very instructional
I was wondering if you had a email because I had a few questions about a lawn service bc I'm just starting one up and I need help
Thanks
Sure, my email is in the description at the bottom.
Thanks I'll shoot some questions your way soon
I have been working on lawnmowers for nearly 60 years, and have never used a torque wrench on anything on a small engine , have never had a problem.
Jerome, Like a good many of (us) artists, we do so many and develop a feel for what we do. It's not something you can teach anyone. You can tell them, but it's something they have to learn.
when rebuilding any engine oil de heck out of the pisten rings everything,if oils will tuch it when running then over oil it add stp in the oil too.sounds good run twin stanks
Old School Repair Shop ?
Assembly lube or hell wd-40 atleast. when he turned the crank it was like nails on a chalkboard. Lol
Great job! Just one tip- always put some oil in the cylinder when installing the piston to lube the walls so the rings can create there own seal marks when you break in the new rings. Never install in a dry cylinder. sound good though.
max98138 I should have known that one. LOL
these two guys get the employee of the year for sure GREAT choice in choosing them as partners i could grow old with them by my side mowing lol
TOMMY .K They do a great job most of the time. LOL
TopNotchLawns lol as always its a blessing to see guys sticking together man
Your absolutely right man.
I've used a 4 inch hose clamp on rings
Finally, I've been waiting for this one!
Kole Ligouri Hope you like it.
This video is awesome Brian and company I will use the cardboard with bolts trick from now on nothing like having 3 bolts leftover and stuff still works
toes stepped , are toes broken We had some stuff left over too. LOL
Oh damn LOL
I got AWL kinds of small engines around my garage 6 that I know of
Time to start timkering
Yea I probably will... I'll have that duel back pack blower in NO time LOL
Good job and good video. Can I ask , what is your compression like and how is it running? You did not feel the need to hone the cylinder when putting new rings in?
Great video, UP TOWN MECHANICS ( THAT CREW IS OFF THE CHAIN )
Lamont Hunt Haha, thanks
Thats is Amazing Guys. Those two are Smart!!
LAWN CARE LIFE I think it went very well. I could not have done it without them for sure.
Hell of a job
You can use a big hose clamp as a piston ring compressor
Needed to adjust or gauge the valve guides to appropriate gaps, somewhere around 0.006. Look at what your valves call for on this engine. Then your engine should run smoother. There are RUclips videos on how to do that also.
great for people learning
This video really helped me with my first engine rebuild. My only question though, is the exhaust and intake valves were already installed and you didn't mention them. I tried to put the camshaft back in after the pistons and head were installed, but the valves won't go in far enough to clear the cam installation. What am I doing wrong?
if you upgrade the airfilter to a canister filter, should you replace the jets as well? have you seen any issues with it running too rich or lean?
TopNotchLawns great video man there always fun to watch thanks for supporting my channel so much!!#
Nick's Lawn Service Your a good young man Nick!
TopNotchLawns thanks buddy your an awesome youtuber lol!!!!
Sweet video I Ben working on a free weed eater from the 80s and I got it running lol it's the best running weed eater I've had
jackson knafel That's great man.
jackson knafel is it a homelight by chance?
i have one i just refurbished from wayyy back thats like that then i go look and they are using those engines for remote control airplanes.
JUNKY the brand is weed eater
succesfully rebuilt my engine only to come to a oil in piston problem again after two weeks. Damm it . Did the rings on piston using the spec sheet from kawasaki and it still failed .I have low rpm when blades engaged. what a nasty feeling.
Gotta prelude your rings and cylinder walls, to prevent scoring of the cylinder walls
More likely the problem lies with the governor arm not being rotated properly when the engine case went back together. It's a common gotcha problem with small engine overhauls and the more mechanics you have and the more distractions from same, the higher the chances someone will forget to do this part correctly. You might be able to to remove all the parts from the shaft and rotate it now to save taking the engine apart again. Valve clearance must be set correctly and I believe that this was the original issue - you set those valves EVER? You should. Bent pushrods are still in your future if you don't.
You are correct that ended up being the problem.
That's nice and quick !! I was looking for the video that might have some info on it and just got done with the hammer and home made gasket one - nice fix there, but I would use RTV silicone thinly on the gasket alone there to keep all the 90w I could in place. Just a dollop between forefinger and thumb, then massage that onto the entire gasket alone, less is better with RTV. Hoping you are doing valve lash these days as all air cooled engines that get long in the tooth as they say tend to 'grow' a bit in the valve stem leading to over heated valves that stick and bend pushrods. They especially must have time sitting on the valve seat to transfer heat out of them, the more lash they have, the more time they get to cool off. Classic symptom of a hard to start, worn out engine gets way worse to start when it's hot - exhaust valve isn't closing, no compression, no start. Cools off and wants to start again.
Top Notch Lawn Care did you have to dismantle engine to correct governor
I'm usually very critical on "how to" videos but your initial disclaimer of not knowing what you are doing saved you and is accurate. I actually enjoyed watching this as comical entertainment. So many misconceptions that overtly wrong.
I have a Kawasaki bayou 220 that leaks a ton of oil out of the breather tube although it still runs well. What do you think my problem is?
I highly recomend putting assembly lube on next time it reduces the risk of wearing everything ut again due to the fact that itll need more lubrication when you start it for the first time afte you rebuild an engine especielly big engines
to clean the insides how an what did yall use??
What are the crank case torque ft pounds? I have a FH 580V to rebuild. Please list all the torque numbers.
Good Job guys !
Chet Burke Thanks Chet!
how did you torque those rod bolts theres like no room to get a torque wrench in there?
Nice job guys! So whats next TopNotchLawns & Repairs!!! LOL
Michael Ciulla Haha!!
Lube components to prevent a dry start .. And gotta adjust the valve clearances and also i didnt see any honing/ de glazing of the cyclinder... Just enough to get the cross hatch pattern ... Also you need to know if the torque values on the hardware are when wet or dry.. And what does the spec reccomemd for lube when torquing bolts wet .. A wet torque is differemt than a dry torque do to friction ..
you took the push rods out and put back in What the valve clearance?
Corner cutters lol they didnt relieve the pressure on rockers to rwmove rods just head.obviuosly you seen that but i was always told not to do it like that due to it could have the possibility of interfering with head torque down and possibly bend a rod.true or no?
Where did you find the pages for all the specs?
Its a pretty good idea to pre lube everything with oil before you put it in
Assembly Lube Please... Thank u
gotta oil everything
I was just ready to comment on that exact same thing. Hearing those rings scraping down the cylinder wall made me cringe.
I was about to comment the same. This video should be labeled how NOT to rebuild an engine. Lol
30 is fine for assembly. For a machine that isn't going to be stored.
How did you take off the flywheel?
Great video guys keep it up.
I could swear Thts a dip in your lip lol or am I wrong and great vid btw I recently started my own lawn care business and my mower engine quit working so these videos really helped me TopNotchLawns
levi coy Yes sir it is. I need to quit. LOL This rebuild helped me a ton man. I just have an overall better knowledge of how the engine works now.
Lol but yea it does engines are a tricky thing anyway thanks again for all the awesome vids your what made me start my lawn care business watching your videos just got me thinking cuz I love mowing lawns and now I just get paid to do what I love lol TopNotchLawns
We're did you get the repair manual from?
An overpriced small engine repair shop would have charged you a small fortune to do this work. Nice job only PLEASE in the future use assembly lube on the parts or at least a coating of engine oil on the cylinder walls and bearing surfaces.
+scdevon I know, we live and learn.
where are you buy the parts?
What he said.
no valve adjustment ?
Cool vid
Empire Lawns Thanks
I make those heads in Maryville Missouri.
Can you sneak me two out in your lunchbox?
Sounds like someone’s been listening to some Johnny Cash!
I lived there for a few years. Always wondered what they made there.
That was awesome!
Johnny Mow Thanks Johnny!
Great job guys! But man you wasted all that time. U could've just went to the pet store. Smh! 😉
Randy Mikhaiel Haha!! A $2 hamster would have solved it.
Would suggest adjusting the valves
Where did you get the parts from?
hey guys, good job and nice video, just curious did you replace bottom oil seal? usually when I rebuild these I always replace that while im in the engine
Matthew Wakefield Yes we did
Did the spring fix the throttle?
Where did you order that spring? Did it fix it once you put it on? Mines having the same problems.
Finally!
how many hours did it have prior to rebuild
Need to make sure you lube everything when putting together
Awesome! I think those kids deserve a raise now lol :)
Small Business & Fitness Haha!! I wish you guys would quit saying that. LOL
TopNotchLawns hey jut keeping ya from haveing to do that agen.little tips is all lol
A stator doesn't have anything to do with your spark. The rotation of the flywheel magnets passing the magnetos induces spark. The stator is there to keep the battery charged therefore keeping all electrical systems functional on the mower.
Magneto.. I think it's just a coil secondary.
I have a mower exactly like this. I replaced both heads. I am having same problem with carburetor and have been playing around with governor and throttle linkage and am still not able to get RPMs down. Can you do a video showing how to correct this?
+paul caywood I ended up just taking it to my dealer to get everything adjusted right.
Also torque I lost in a extension so all bolts were lower than spec
oiga disculpe a cuanto va torqueado la cabeza y ELA tapa del cartel?
El dijo 19 libras de pies
I hope it worked and give good service.i couldnt stand to watch all way thur between no ring install knowledge.possable scratched pistons bending rings to install. Then no squeezer.then no oil on rings piston or rod bearing surfaces.ouch.i had to stop at that point ....good luck....keep ur mechanics number close.lol
Check the valve guides. It’s a guide problem not a ring problem.
No assembly lube?
ahh , 4 stroke engines . always more difficult to take apart . have to deal with the ohv just to reach the jug and piston . thats why i try to stick to 2 stroke engine rebuilds . very simple :)
Who manufactures walk-behind mowers that are two smokes? Years ago Bunton had a 2 smoker on their mowers...YEARS AGO!
Lawnboy. But these 4 strokes are easier then your regular fourstroke timeing chain engines being they are gear ran. There fun but 2 strokes you can damn near rebuild on site lol.
Hey where you got the rebuilt kit I need one
I'm searching for the same thing my friend. Let me know if you found it.
What’s the model of that engine?
Nothing is better than it firing up
Hello I have the same mower and this got mix gas in the oil
I need Help. I get it to the shop and they tell me was the carburetor but I already replaces it and I got the same problem. So what will can be the problem??? Thanks
I am not an expert. I just did some research and it seems that bad piston rings or running to rich can cause this. If air filter is to dirty can also cause to run rich, make sure choke fully closes on carb and is not stuck leaving the choke partially on. Maybe new NGK spark plugs that run hotter to avoid flooding. Just a few things to rule out.
Was that another exmark walk behind I saw in the background towards the end?
Kevin Jag Yea, I borrowed it from a friend for a couple of days.
Cool video man. You put new oil in?
Gregs Mowing Yea, LOL. I actually should have shown that.
No engine assembly lube???
Super cheap insurance for initial startup as oil pump will take a few seconds to prime and build pressure.
I would have like to seen Loctite