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FLC2000
02-10-2012, 05:51 PM
I have an Encore 36 walk behind with a Kawasaki FC420V. Its probably got a good 2500 hrs on it. Unfortunately its run its course and I need to replace it.

Basically I noticed small amounts of oil on my shop floor where it was parked and as time went by the amounts of oil got larger. One day while mowing I stopped to pick up some trash and looked at the front of the motor. I noticed oil spraying out where it attaches to the deck. I thought it might be a gasket so I took it up to my mechanic. He told me what he thought it was ( I dont remember) and quoted me $1300.00 to rebuild the motor.

After some research I found some online distributors that have motors in the $700-950 range.

My questions are this:

I see that the FC420 is no longer available. What is a comprable replacement from Kawasaki for it?

As far as replacing. Im a halfway decent mechanic. I can replace the belts and adjust the hydros, stuff like that. How does one go about doing this?

I noticed it has 4 bolts. Do I just remove those bolts, lift the motor off and put the new on?

Im pretty tight with my money so I would rather do this myself.

Thanks.

Lefet
02-10-2012, 06:08 PM
Subscribing, interesting thread.

I have an older Bobcat WB with the same motor. Still running strong though, one pull.

FLC2000
02-10-2012, 06:14 PM
It starts great. It just requires a quart of oil every other day...

pugs
02-10-2012, 06:46 PM
I dont understand why he would even quote you a rebuild if he wants more than what a new 15HP Kawasaki would sell for.

If it isnt burning oil, I would look into finding the leak and fixing it. An oil leak doesnt need a rebuild. Now if there is a hole or crack in a major part of the engine then it isnt worth it.

A good replacement would be a 13HP or 15HP Kawasaki V-twin. You will need a longer throttle/choke cable since they route to the front of the machine instead of hooking right on the back of the engine.

dutch1
02-10-2012, 06:46 PM
As long as you choose and engine with the same crank diameter and length that will fit in the confines of your mower you should be OK, as long as you don't have electric clutch/electric start, in which case you may have other considerations.

In the past I have ordered several engines from Tulsa Engine Warehouse. They used to have an 800 number for engine replacement questions--I didn't see one any longer. Parts orders are internet only now. The do have a message line and a chat feature that you could use to check what they advise for a favorable replacement. Mounting patterns are pretty standard among manufacturers.

http://tulsaenginewarehouse.com/

The big boys may be around later with additional suggestions but they're probably busy right now with their steak and shrimp.

FLC2000
02-10-2012, 07:06 PM
I dont understand why he would even quote you a rebuild if he wants more than what a new 15HP Kawasaki would sell for.

If it isnt burning oil, I would look into finding the leak and fixing it. An oil leak doesnt need a rebuild. Now if there is a hole or crack in a major part of the engine then it isnt worth it.

A good replacement would be a 13HP or 15HP Kawasaki V-twin. You will need a longer throttle/choke cable since they route to the front of the machine instead of hooking right on the back of the engine.




Im going to assume there is much more labor in rebuilding a motor then slapping a new one on and thats why it is so expensive.

piston slapper
02-10-2012, 07:28 PM
The only cheap labor is your own.....
I would replace the base gasket, pto seal, and governor seal on the FC420,

And use it for another 5 years...Those engines are bulletproof, and don't care how you treat them.
Dutch.....on Friday's ....its Lobster and Cracked Crab......
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dutch1
02-10-2012, 08:03 PM
You're right on the three likely leak sources, Slapper. It doesn't happen often, but I've seen a mounting boss crack develop over a period of time, so it doesn't hurt to check the integrity of the pan.

Sorry, Slapper, time passes so fast when I'm having fun, I thought it was Saturday. As a result, I was a day ahead on the menu.

FLC2000
02-10-2012, 08:05 PM
The only cheap labor is your own.....
I would replace the base gasket, pto seal, and governor seal on the FC420,

And use it for another 5 years...Those engines are bulletproof, and don't care how you treat them.
Dutch.....on Friday's ....its Lobster and Cracked Crab......
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Is this something a guy with relatively no small engine experience could do easily?

piston slapper
02-10-2012, 08:13 PM
Saturdays are good too....Ahh...if everyday were Saturday.
A full bank account.....and Daisy Maes as far as Restrorobs eyes can see....

Sorry FLC...didn't mean to get off topic....
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FLC2000
02-10-2012, 08:22 PM
Saturdays are good too....Ahh...if everyday were Saturday.
A full bank account.....and Daisy Maes as far as Restrorobs eyes can see....

Sorry FLC...didn't mean to get off topic....
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I dont mind at all.

Im worried. Im one of those guys that doesnt pay attention when taking things apart which makes it hard for me to fix things.

I dont suppose there is some sort of book or online literature I could read that would point out where all these things are at?

dutch1
02-10-2012, 08:41 PM
Sorry about the side show, FLC, I got carried away with Slapper.

You can buy a manual fairly reasonably from a Kaw dealer or you could use the search function on this site--someone posted a link to Kaw online service manuals a short time ago.

FLC2000
02-10-2012, 08:44 PM
Sorry about the side show, FLC, I got carried away with Slapper.

You can buy a manual fairly reasonably from a Kaw dealer or you could use the search function on this site--someone posted a link to Kaw online service manuals a short time ago.



No big deal.

I actually found a couple online that are pretty well diagrammed. I think the first thing I need to do is get the motor off the mower and take a look at it.

I assume the base seal is the seal between the bottom of the motor and the mower itself?

Im also going to assume it does not need to be rebuilt. Its not knocking at all. It doesnt burn oil or smoke. It runs fine. It just has oil coming out of it.

beats me...

piston slapper
02-10-2012, 08:57 PM
I've probably done 50 or more. You have to pay attention to everything.
Its not important to be fast....speed comes from practice. Its not an easy job or a hard one.
Its easier to get it apart than back together. You have to make sure that the oil pump shaft,
As well as the governor gear mesh correctly when reinstalling the sump. You also have to make
Sure that you don't damage the crank seal.
Getting the engine off can be a chore...some times the engine pulleys don't want to come off.
Not trying to discourage you...just want you to have your eyes open going into this job..
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FLC2000
02-10-2012, 09:00 PM
I've probably done 50 or more. You have to pay attention to everything.
Its not important to be fast....speed comes from practice. Its not an easy job or a hard one.
Its easier to get it apart than back together. You have to make sure that the oil pump shaft,
As well as the governor gear mesh correctly when reinstalling the sump. You also have to make
Sure that you don't damage the crank seal.
Getting the engine off can be a chore...some times the engine pulleys don't want to come off.
Not trying to discourage you...just want you to have your eyes open going into this job..
Posted via Mobile Device


This is pretty much why Im wondering if I shouldnt just spring for a new one instead of trying to tear the old apart and replace a few seals.

If I did replace it with a new one is just a matter of taking the old one off and bolting the new one on and connecting the throttle cable?

dutch1
02-10-2012, 09:06 PM
FLC, you didn't post a spec number but following is a link, if you haven't searched one out yet, to a typical FC420.

Don't get in a hurry and if you have a camera, taking a shot at each step-- may help in reassembly.

FLC2000
02-10-2012, 09:40 PM
FLC, you didn't post a spec number but following is a link, if you haven't searched one out yet, to a typical FC420.

Don't get in a hurry and if you have a camera, taking a shot at each step-- may help in reassembly.



Thanks Ill try that also.

dutch1
02-10-2012, 09:53 PM
Late night and old age don't mix. Here's the link I forgot to post:

http://kmcb2c.econnect.partsandwarranty.com/kmcb2c/Menu?action=CATALOGB2B&chID=324690&elementType=1&historyDepth=2&CHANGENUMBEROFITEMS=63

I MOW ALONE
02-11-2012, 12:58 AM
This is pretty much why Im wondering if I shouldnt just spring for a new one instead of trying to tear the old apart and replace a few seals.

If I did replace it with a new one is just a matter of taking the old one off and bolting the new one on and connecting the throttle cable?

you still have to remove pulley's to remove engine from mower. and even if your lucky and the pulley's are small enough to fit through the hole on the mower you still have to remove them from engine to use on the new engine. one more thing is you will have to spend another $100 on a muffler if you go with a new engine since 90% are sold without them. easiest way to remove pulley's is to use a puller.

I MOW ALONE
02-11-2012, 01:00 AM
also where abouts are you located?

FLC2000
02-11-2012, 08:32 AM
also where abouts are you located?



Kansas City area.

pugs
02-11-2012, 01:08 PM
Im going to assume there is much more labor in rebuilding a motor then slapping a new one on and thats why it is so expensive.

Oh there is...but thats the point. Why bother quoting it? Quote an engine and be done with it.

One other thing I forgot, you will need a new bolt for the end of the crankshaft. The FB460V and FC420V had a metric thread down there. All the air cooled V-twins have standard threads.

piston slapper
02-11-2012, 02:26 PM
FLC.....Pugs is probably right....a new engine is probably the way to go....
With your inexperience and probable lack of proper tools, You'll probably be money ahead,
(And maybe a few knuckles) just replacing it. At 2500 hrs it doesn't owe you a dime.
The new V twins start so easy , its impressive. The first one I installed almost scared me.
I got half the rope pulled out and it was already running.
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FLC2000
02-11-2012, 03:05 PM
FLC.....Pugs is probably right....a new engine is probably the way to go....
With your inexperience and probable lack of proper tools, You'll probably be money ahead,
(And maybe a few knuckles) just replacing it. At 2500 hrs it doesn't owe you a dime.
The new V twins start so easy , its impressive. The first one I installed almost scared me.
I got half the rope pulled out and it was already running.
Posted via Mobile Device



yeah, Im thinking new is the way to go. less of a headache. thanks for all the advice folks.

I MOW ALONE
02-12-2012, 01:03 AM
if you do replace with new i would be interested in buying the muffler from your 420.