Hustler Z - Kawasaki engine very hard starting

[dschell]

Hi - I have an older Hustler Z (circa 2002) with a Kawasaiki FH680V engine. I bought the mower used last fall and replaced many of the normal wear and tear parts, such as spark plugs, fuel filter, and fuel pump. I also cleaned the carb and serviced the oil. It ran like a champ last fall. This spring, it has been very difficult to start. I've put in fresh gas (high octane) but it will just not fire until after several minutes of trying. It usually backfires once or twice during the process before it starts. It's getting gas to the cylinders - I pulled a plug yesterday and it had gas on it. Once it does start, it runs ok (although it does surge a bit when the mower is not engaged). Any suggestions on what I should look at? Thanks.

[mowerconsultant]

With something 7 or 8 years old it could be about anything...
But... from what your describing I would first check a couple things.
Throttle cable / choke adjustments.
Compression checks need to be done on the cylinders, along with valve adjustment checks, have the heads ever been off to be de-carboned?
And you mention surging... surging is a sign of debris in the jets of the carburetor, this needs to be checked also.

Pj

[dschell]

Thanks for the information. I checked the valves last night and they were horribly out of adjustment. Where the spec is .07 mm, one measured .50 and another .27. I have them adjusted right now but then my starter motor went out so was not able to see how well that solved the problem.

On a different note, I opened the bypass valves on the pumps to move the mower but lost track of how many turns I opened it. To set back to the right position for normal operation, should these valves just fully closed? Or is there adjustment in there? Thanks.

[mowerconsultant]

Once you get the starter replaced get it started up and let me know how you make out.
The by pass valves need to be turned all the way in, but DO NOT over tighten them, I would turn them in until you feel resistance and snug them up slightly.

Pj

[dschell]

Wow! The valve adjustment was definately the problem. Once I got the new starter on there, and everything back together, I turned the key and the motor started before I even got the key all the way turned! The thing absolutely purrs now. Where the starter really struggled and strained to crank it before, it now easily and smoothly turns it over. Such a difference. Thanks for the great advice.

I wish all the products I owned had such great support!

[mowerconsultant]

Wow! The valve adjustment was definately the problem. Once I got the new starter on there, and everything back together, I turned the key and the motor started before I even got the key all the way turned! The thing absolutely purrs now. Where the starter really struggled and strained to crank it before, it now easily and smoothly turns it over. Such a difference. Thanks for the great advice.

I wish all the products I owned had such great support!

Great to hear.
On a side note... you may want to get those heads off and de-carbon them.

Pj