Kawasaki 4 Stroke Engine Breakdown - Piston Ring Removal Part 1
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- Опубліковано 14 жов 2024
- Today we removed the piston rings from my kawasaki FH580V. This motor is off my exmark turf tracer. The mower started running at half power and had a consistent puff of white smoke coming out of the exhaust. This is a good indication of oil burning. We started taking things apart and ended up removing and dismantling the entire engine. I learned a lot from Hunter and Zack during this process. We ordered the piston rings and will have part 2 of this installing the rings and putting the mower back together.
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When he pointed at the casting mark on the cylinder saying thats where the case splits I laughed so hard. Dudes have no idea what going on in that motor.
Compression won't "leak off"..There's a check valve in all compression gauges..Only a cylinder leakdown/differential pressure tester will tell you if the cylinder is leaking. Try reading the instructions that came with the compression gauge.
I've been working on mowers all my life. I rebuilt my minibike when I was 3. Hey, but at least you have some guys there with some knowledge. The best way to learn, is to do it.
Carburetor linkage issue resolved today. After looking at your video over and over from beginning before you removed the plate on front that holds throttle cable and choke cable I noticed that the plate was raised higher on the one side than the other, so positioned mine in that same way and Bingo problem solved. Thanks for sharing your video.
good video. own a lawn business too. i have a kawasaki FX730 off my ferris im working on. except i did opposite. mine locked up. torn whole engine down to find nothing broke inside or nothing wrong. after watching your video i am now wondering if something got jacked up under the fly wheel. its tough being a lawn guy. i work on my own equipment as well. its videos like yours that help our lawn guy community out. Thank you.
Nice video (and work) you guys.
Finally getting rain here in northern California.....but the grass is growing a couple of inches a day. Just now got over a pretty tough cold, and felt good enough yesterday to try cutting some. 15 minutes into a 2 day job I get a whole bunch of blue smoke....and a sinking feeling. There goes my chance to stay ahead of the growth.
God bless UA-cam. Looks like a blown head gasket. Only 13 phone calls and 100 miles later and I have the gasket. Tearing down the engine and I quickly find the Kawasaki 4 stroke V twin is a little different.
THANK YOU for a video on the Kawasaki......and I was able to get the Service Manual online, like you did.
I appreciate the cyber help!
That's awesome. It's nice to have some knowledgeable team members.
what a great video. these are things I always wanted to know about my 19hp kaw. if I had of seen this a few years ago I probably wouldn't have trashed my 10 hp Briggs on my leaf blower when it seized up on me. you have helped a lot of people thanks bro.
Wow! Valuable employees my friend...Beyond changing oil and filters and belts, im up a creek! Awesome video, thanks for sharing
Grassroots Lawn Care Thank you!!
Great video, I have to break apart a 24 hp K soon and this will come in handy!
Great video. Going to fix my Kawasaki 590v engine myself. I've been inspired.
+Jeff Putman Make sure you watch some other videos also because I know we prob didn't do things the perfect way. Good luck sir.
The exhaust valve is hung up in there. Probably seized to the guide. That head at least needs rebuilt. That is the reason the push rod fell out. That should have never happened if things were right. It would have had spring pressure on it. Chances are the rings are fine. But when the exhaust valve hung open and you kept running the motor the fuel was not all being burnt and thinned the oil down. Then the oil just pushed past the rings. JMO
I believe oil also came in thru the exhaust valve into the cylinder. Engine oil that lubes the valve guide/spring ran into the cylinder with the valve staying open.
HappyScrappy47, you are right. You can see the stuck exhaust valve as clear as day at about 9:15 in the video.
My 27 hp Kawasaki hydro floated one of the rockers off because the engine was stuck running on a extreme angle. We simply reinstalled the rocker arm and run it for 11 more years.
at what point in the video do you see the valve open, I'm learning as well
I was looking in the comments for someone to notice this, that head is done lol
You are brave a would have never attempted that. Those are some great guys you got working for you. You could build a nice business with that crew.
Marathon Watching 6/26/22 Thanks for showing others how to do this!
Excellent video guys thank you very much for that in teaching
Guy's I need part 2 of this, I'm in the middle of my tear down, hadn't planned on messing with the timing. But now it looks like I'll be doing just that, finding oil seeping past the cylinder. So your vid would help...
they already posted part 2 six years ago ua-cam.com/video/IuIzUQhN_tA/v-deo.html&ab_channel=TopNotchLawnCare
I would be freaking out if it was happening to me. Holly crap! Those boys seem that they know their stuff. Hope you get your mower running again.
Romero lawn care Thanks Romero!
I haven't read all the comments yet, so I don't know if this has been mentioned - but it wasn't the cylinder holding steady pressure. It was the gauge. The gauge will peak and hold, by virtue of a check valve. You could remove the tester from the engine, and it will still read 90# (or whatever).
The only way to check pressure drop accurately is with a leak-down tester.
Thank you for posting this. I thought I was the only one that caught that.
I have this same engine tore apart at the moment, Actually the same exmark..The engine I'm working on I took it completely off the body to disassemble ,
It turned out to be a broken valve which destroyed the head when it compressed at high speed against the piston which knocked a hole in that also and bent 2 valve stems..I'm going to order a new head,valves,piston,Yamabond ,clean it up and throw it back together and hope for the best..My damage is obvious from catastrophic failure..The reason for all this was low oil..So always keep an eye on oil levels,Not all have a low pressure warning light.,Or sometimes they don't even work at all and you don't know it..Good vid guys wish I could have been there to help out!
Also if the rocker has come off of the intake valve when the piston come down it will create a vacuum and pull the oil past the rings because it cannot pull vacuum through intake valve therefore using oil through the rings, had you re installed the push rod and checked the movement as to what caused the push rod to fall out you wouldn’t have to check rings and the engine would seat the rings when running properly!
My dealer is exactly the reason I replaced heads my self. I took it in to diagnose the the reason why it was dying on me off and on occasionally. When I took it in it was dying on me at time. I ask them to have mechanic to come out to see mower while it was failing and mechanic made comment that it was probably caves and the would look at valves the next day. Instead of checking compression some guy spent day eating and drinking coffee letting engine run to see engine fail like day I brought it in. I went in that day and told them that is why I had mechanic come out to see it fail when I dropped it off. When I went in I saw that one of hydro pumps leaking from the top cover and told them that thing was not leaking when I took it in. Anyway they finally pulled valve cover and showed me that the valve guide, which oil seal sets on was pushed all the way through the other side, so was advised to replace both heads. The mower was eight years old, so decided to buy new mower and take old mower and replace heads myself and replace hydro seals also. Since this was first time like your self of attempting this work. Every bolt on that mower sump pan was less than hand tight, I ended up replacing every seal and gasket on motor. Me biggest fear was that I would still have leaks in engine and hydro pump, but did not have any leaks. Now I have been meticulously taking off and adjusting the L shaped arm that sets on governor. I try to do all my work to avoid having someone else do work. Can you ask the people what they did to correct you problem and get back to me?
I would have guessed moved valve guide from overheating due to dirt on the cooling fins and not bad rings. The rings would have worn equally. I think engine overheated, guide moved, held valve open, and then piston fouled. I don’t think it’s a bad ring case. Kawasaki’s are great but notorious for guide problems if you let the engine overheat due to dirt.
I know this is off topic but I found out and started to use fram oil filters instead of the Kawasaki. saves money and time I get them from Walmart. Fram PH4967 Extra Guard
Why because so many videos say to stay away from fram? Do you work for fram by chance?
@OUTTA TIME I have never ran anything but fram filters never had a problem one
Man I would love to have some helpers that knew that much. Keep those guys as long as you can.
Doug Duncan They come in handy. If you guys don't stop praising them I will have to give them a raise. LOL
Just bought a 36" walk behind with a Kawasaki, really neat to see how the engine works.
SYCK Outlaw It will be up shortly my friend.
I have an EXMARK mower exactly like this one. I had to replace both heads and got everything back together and am having carburetor issues. You indicated that you also were having issues. I think its a linkage problem. How did you correct your problem?
Your ring were not bad..the exhaust valve was stuck open which is why you had no compression. No need to tear down engine in this case. Push rod fell out when the cam lobe went down and the spring didn't reseat the valve
How did you break the flywheel from the shaft, because I know it didn't just left off.
Have the same mower, just checking to see how the rebuild is holding up, mine is just now starting to use a little oil.
got balls to get that far into a motor. I would have never done that. Nice work. hope it works out. great vid
The Lawn Ranger that's right I would screw it up so bad no one could put it back together.
The Lawn Ranger that why i would tape it so i know how it came off.
Why? Its not that hard
@@wnytrashtrucks your only gonna screw shit up if thats your mindset.
@@Busdude97 this comment is 7 years old and still stands. I know nothing about motors and have no interest.
Great video! How'd you get the crank pulley off? Did you use a pulley puller or did it just come off?
Hang in there Brian. You got this covered. Good job.
Tim The Pool And Lawn Guy Time will tell. Thanks!
The big problem is look at the cylinder head the exhaust valve is hung open . That's why the push rod came off .
Hello nice video How did it work out is engine still in service ? Did you ever get a quote on repair work before you started.
Great video! I love to tinker with my mowers even if they don't need it. Lol. Also, if u have a minute what was your oppinion on the Wright stander. I was considering picking one up that needs some work as a project.
Nathan Levin I will have my opinion in the next video.
TopNotchLawns Ok. Thanks a lot Brian. Love the videos.
Just question,why didn't you make it easier for yourselves and wash it down first?
That looks intimidating, I tried to do some work on a cbr I had once I ended up having to get it towed with a box of parts to the dealer. Way to step up and take on the challenge the more you can do in house the more money saved. I hope it all works out for you guys in the end.
Zone 5(EH!) I figure its the only way I will learn and I want to learn. Thanks
I'd have just used a breaker bar at the 5:39 / 5:54 point. There's really very little substitute for the right tool and the right technique. Also, you DO know that every so often you need to remove the top end external items and clean all that grunge out of the fins and from under the flywheel don't you? Especially on commercially used equipment. This grunge traps heat, distorts the aluminum block and causes several problems, two of which you found. You also have to remove the heads every 200 hours or so and remove the carbon build up on the piston, valves and combustion chamber. Proper maintenance would have saved you several days of down time.
hey guys I saw all the dirt on top of your motor it made it overheat and made the exhaust valve get stuck if you look again at the head you'll see the exhaust stuck open
where? at what point in the video?
enjoyed this very much. Learned alot in the process. Thanks for the Video!
brianlabarre1 Thanks!
TopNotchLawns How many hours did you get out of the motor before you had problems?
brianlabarre1 Not sure, I bought it used and it doesn't have a meter.
You guys are smart I would be at the mower shop
Moe's Lawn. Care. LLC It's not fixed yet Moe. The hard part is coming up.
How about the compression release , makes it hard to preform a compression test.
"im gonna go ahead and say this sides low" lmao that was gold. loved the vid, educational waiting for pt 2. looks likeya gonna have to give zac more time on the exmark now lol.
ForFUKSake67 Yea, he might deserve a little more riding time now. LOL
I would've put the pushrod back in and adjusted the valves would've likely solved the compression problem
You also should have checked and adjusted the valve guides before putting the valve covers back on. There are UA-cam videos on how to do that. Just make sure you have the appropriate gap. It should run much smoother after that.
I got a 20 hp Kawasaki engine on my 2010 52 gravely pro walk with 390 hours, its starting to leak a little oil about 1/2 quart in 2 weeks, im afraid its gonna need some work soon, cant tell were it leaking from but its on both sides, hope it will wait til late fall.
Good luck hope it works out for you in the end handy the two lads know about small engines,been in this situation my self when a machine you rely on breaks down,i have also borrowed machines but don't like doing it worry about breaking a friends machine,anyway all the best...
I've been very impressed with Kawasaki engines mine is starting to give me a few problems now but I've put the mower thru total hell
Does the piston cylinder not have to be machined ?
Just wondering.
Thank goodness the cameraman was breathing heavily into the microphone for the ENTIRE video. Jeez!
I set a stihl trimmer down to talk to a homeowner, picked it up and it wouldn't start after 20 pulls... Equipment trouble is a pain in the cheeks. I'm still tinkering with the thing. Bought an ignition module and after working it in for days I'm thinking it's the spark advance that's built into the module. Long story short, good luck TopNotch
Hollier and Son Lawn Care You too!! Thanks!
A compression tester doesn’t bleed down it holds till u bleed it off 😂😂
You looked real worried as more was taken apart, dont worry they will do a fine job getting it back together , lucky to have them, do you know how many hours is on that mower? have the pumps ever been replaced? that stater was really dirty try to keep an air cooled engine clean so it does not get so hot...hurry and get back to mowing and truck talk..
Thanks again for sharing your videos...maybe to a total engine rebuild while its apart?
BrianLeeUSA73 I'm a little worried but I figure worse case scenario is I buy a new motor. Things could be worse!!
if you think the mower dont have alot of hours on it then i would use new motor but if the pumps have over 1,000 hours then its close to having bad pumps. did you find out why that one push rod was just loose? when you took of the valve cover? make sure to look that head over good look and make sure the hole for the push rod is round and NOT oval, if its oval then the head is bad . Do you have any idea about how many hours on the machine?
TopNotchLawns I think your exactly right with this comment. That's the worse case...and in the meantime, your gaining valuable experience. Your not out much money, just man hours when trying to fix this motor, so why not give it a shot. Hope you get it running, but new engine or repair of this one, it will work out one way or the other. Hope you put together a re-assembly video as well. Take it easy.
Thanks bro!!
G'day I know that this was a long drawn out process, but it's the only way to learn so good on ya. If I could offer some advice which no doubt you know, invest in some good tools and anti seize for bolts ect
Regards John Kinnane Tasmania Australia
John Kinnane Yea I definitely need some new tools man, thanks!
Excellent diagnosis except that compression tester has a valve in it. You cannot tell if rings are leaking with a compression tester
I think your exhaust valve may be stuck open causing the no compression condition.
Ken Heller I'm going to check on that. Thanks
You can see the stuck exhaust valve at 24:00 nice diagnostics...
A lot of those vertical shaft Kawasakis's lose the oil seal on the exhaust valve, the valve wont push open, the pushrod will bend. Should've looked at the valve guides before pulling the engine.
Great Video Guys!
just got a mower off a guy and i just had to do the same thing. everything cost me in mower and parts $300. for a 52" deck and mower cant beat it.
Brandon Sparks Cool, glad it worked out for you!
not sure but it looked like the exhaust valve was open without the rocker arm installed
sure was. couldn't tell if the seat was protruding out or not with the shadow and all the black carbon. looked like a stuck exhaust valve, possible valve guide protruding out some of the head, maybe even a bent valve. i saw that right away.
Mechanic tip, always have a deadblow or rubber mallet. It makes taking/breaking shit appart way easier.
I learned about a dead blow hammer on taking a crankcase over off a motorcycle. I hit on it for an hour with a rubber mallet. Then read a forum and they said use a deadblow hammer. One hit and it popped free. I think it was called a crank case cover. it covered the stator windings and magnets. I had a little fun putting it back on with the magnets working against me.
There is no such thing as 90 and holding, the. Schroeder valve in the compression gauge is what holds the pressure as soon as you quit cranking cylander drops to zero!
90 and holding ? It’s a compression gauge. It’s suppose to hold the air u til u release the Schrader valve
any news yet about your motor? i have a few pics of the wright stander and other mowers we use now..did you find out why the push rod was loose?
Brian Lee Yea, the pushrod was loose because the exhaust valve was stuck open. We got that fixed so now just waiting on the other parts to come in.
thats great news, i hope everything goes well for you.
Thanks buddy!!
I think the valve guides . one of the pushrods are bent. Valve lash. Did you readjust the valve lash after every season. If you did not that's why that's why the Rocker come loose and that it's probably all the problem is.
what is a valve lash?
TOP NOTCH MECHANICS
Why didn't you put the pushrods back in and adjust valves on both sides and recheck compression. Change oil 50 hours, a just valves every 250 hours.
I thought the same thing!
Howd you git the flywheel off?
How do you know the rings are bad
Or the oil gallery through the head leaks past head gasket and fills up cylinder especially when parked for a while
Those kawasaki engines stored in a garage are perfect place for mouse to build nest on top of piston. Sounds funny but mechanic said it has happened several times
Oil leaking bad from the crankcase breather plate, did u replace that gasket, you should have to stop that oil leaking all over the engine. Just fyi
Does zach and hunter work on engines on the side?
SRK LandScaping Not professionally, they just like tinkering with stuff.
I think happyscrappy47 knows what he is talking about, dont think you needed rings. Hope you got it running.
yep. i questioned that too. valve train problems can lead to gas build up in engine making it look like more oil than needed in cylinder. when he did the compression test and it had 0 compression, didn't mean that the rings were bad, by looking at the exhaust valve hanging open being stuck for whatever reason, that is why he didn't have compression, the valve is open letting the compression out. he should've done a cylinder leak down test after the compression test before taking the heads off, therefore, he could've pinpointed the stuck exhaust valve without having to take the heads off, or should i say, before having to take the heads off, because after the detection of a leaking exhaust valve, he would "have" to take that particular head off, and he could also pinpoint any leaks in the other cylinder if there were any, limiting having to take the other head off and or breaking down only the top engine vs the whole engine. bottom line, he has great friends that are mechanically inclined to help him and not have to go to dealer, so kudos to them, that's what it's all about. good job anyways.
Good luck guys I love your mower!!!!
Drums
By Dee
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Please do yourself a favour,when you rebuild it make sure you(1)drop the valves out and re-cut(lap them in)it might take an extra 2 hours.....but i assure you it will be worth it in the long run eg missing(cause burnt valves)(2)you have done the hard work of,pulling it down,new rings and gaskets(so i would suggest de-glazing the bores)so the rings will bed properly........MOST important,everything needs to be spotlessly clean,degreaser,water,air compressor before you reassemble,,,,,,otherwise everything you have done will be for nothing and NEW oil on the bearing caps.I say this because i am in the same game as you.
mickycricket Thanks for the help!! I really appreciate it.
oil gets in the chamber around the rings or valve guides!
Rodney Carrington’s brother…..Am I right? Lol
How many hours do you have on the xmark
Empire Lawns Doesn't have an hour meter.
That valve was stuck open. That's why there was zero compression. Rings were definitely bad too.
You guys are awesome, jack of all trades I see
Way to go !!!
Nisvet Garibovic Don't give us that label yet. Wait until we get this mower back cutting some grass. LOL
the heavy breathing is real lol:D
does Zach and Hunter still working for you
I hope you run premium! That could be causing build up as well.
I would've shot that bad boy right up to the dealer and bought a bigger badder motor. It's only another write off :) Pretty cool video watching you guys get that motor off and apart. Probably saved a lot of money too.
Small Business & Fitness That's the thing, With it being so early into the season I really don't have $1600 for a new motor. Believe me, I thought about it.
You guy's should leave that engine alone.... Taking the head off and finding a valve still open HAS to tell you something. Your problems aren't where you're headed..............
why is finding part 2 so hard for me?
Hahaha I just noticed your exhaust valve is stuck open and that’s why you have no
Compression, and the fuel is washing the cylinder and creating thin oil And pushing it back past the rings, should have just done a valve job on that head and put it back together and run it for a few weeks and see if it clears up! Way more work then needed!
Mower medic one have you seen this video
Guy keeps on calling it a motor. It's an engine. Motors are electric.
Always gotta be that once douche in the comments with a smartass remark. Motors can be internal combustion too jackass. The actual definition of motor is “a machine, especially one powered by electricity or internal combustion, that supplies motive power for a vehicle or for some other device with moving parts”. Your trolling skills are like 2 out of 100. Step your game up before you make yourself look like a fool again 😂🤘
Not a ring problem those rings are fine
I'll never understand why people dont clean a engine before teardown. Your chances of contamination are much bigger. Pressure wash the darn thing. Drain the oil!! Look at that mess on the bench!.
Once you have done it you will realize its not that hard to do and have a greater understanding of how it works.
Maybe out of gas
Only one way to learn buddy tear into it and get it fixed. Way to stay positive about it and not blow a gasket you'll get it up and going again having a mower down is a bad feeling just think of the money your saving dealers labor rates are ridiculous.
Schut Lawn Service Yes they are a little pricey. I hope we can finish the job soon.
Did you ever figure out why the rocker was loose? While it's apart inspect the lifters to make sure they move freely get the torque specs and throw her back together be back out striping
Good luck worst feeling in the world to have a machine down time is money.
is no way that that engine Comes apart right there if you would've just took the engine off flipped it upside down took the bottom bolts out of the bottom casing of the engine you would've been able to see right down in there the guy knew a little but not enough to be doing that job
The dealer around here would just sell you a new motor.
Chet .Burke I know, that is what I'm trying to avoid. We will see!!
I thought inside an engine there was a hamster with a wheel.
Gregs Mowing I wish, then I could have just bought some new hamsters or a wheel.
it was just a blown head gasket due to oil over fill..
I would to that for only $150 and get that done in 2days