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  #1  
Old 06-05-2014, 05:28 PM
swiller swiller is offline
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Mysterious Exmark engine problem

Hi, I have an exmark lazer Z hp with the kawasaki engine (FH580V) with 1800 hours. Recently I have been having some major issues with the mower that has been making business extremely difficult.

Symptoms:
1. Blade will not fully spool up, it seems like the load of the blades chokes out the engine.
2. The right gas tank pulls more fuel than the left and the mower has trouble running when the right tank is empty.
3. The engine is "hunting" when idling.... The RPMs go in and out.
4. There is a small oil leak (might be unrelated) behind the right side valves.
5. The engine backfires when the blade is turned off and then turned back on. The engine also backfires randomly while running and sometimes idling.

What has already been checked:
1. fuel filter and fuel pump have been replaced
2. valves have been adjusted
3. Engine runs the same when gas caps are off
4. starting the blades on choke does not help.
5. The right coil was bad and was replaced....but that didn't help
6. The starter, spark plugs and air filter have been replaced
7. Carb has been cleaned.

It would be greatly appreciated if anyone can provide me with some answers. My uncle who is a very good mechanic cannot figure out what is wrong and I have not been able to find anything on any forums. Thanks!

EDIT: I forgot to mention the Carb has been cleaned.

Last edited by swiller; 06-05-2014 at 05:37 PM.
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  #2  
Old 06-05-2014, 05:36 PM
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southerntide southerntide is offline
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#1-3 Carb most likely dirty usually the case of these FH motors, when they are hunting/surging also symptom #3

#2 have you looked at the fuel screens inside the tank for junk?

#4 Gasket going bad at least, my FH641V has governor seal leak a little more hours than you, did not start till after it came out of shop whole different story.

#5 I have no clue with all these symptoms happening all at once could be each isolated issues or a overall issue.


Rob or one of the other major league engine guys will chime in I am sure.
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Old 06-05-2014, 05:39 PM
swiller swiller is offline
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I have not checked the fuel screens but The carb has already been cleaned (I added that to the post). I will check that when I have time to work on it this saturday. Thanks for the quick response!
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Old 06-05-2014, 05:48 PM
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southerntide southerntide is offline
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How does the fuel filter look have you changed it lately?

My engine has always backfired after long use every now and then, when you stop to take a break and fire it back up.

With carb cleaned it could be something more major or little like filter and fuel screens.

That is as far I can go find restorob he knows it all on the engines it seems lol
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2014 JD 920M 7-Iron Pro 48" 23.5 hp Kawi
05' Gravely 148z 1700+ hours 21 hp Kawi
Echo Trimmers
5x10 (upgrading winter)

Alabama Group
http://www.lawnsite.com/group.php?groupid=108
John Deere Group
http://www.lawnsite.com/group.php?groupid=109

All truth passes through three stages. First, it is ridiculed. Second, it is violently opposed. Third, it is accepted as being self-evident.
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  #5  
Old 06-05-2014, 06:19 PM
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Restrorob Restrorob is offline
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Quote:
Originally Posted by southerntide View Post
find restorob he knows it all on the engines it seems

Ha ! I wouldn't say "all" but...... I've been around the block......


Sounds like you have multiple faults at the same time.

First,

Explain how and what you used to clean the carb ?

Did you remove the plastic limit cap from the low speed adjuster, Remove it and clean that passage as well ?

Is there any up/down play/slop in the choke or throttle shafts going through the carb body ?
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Old 06-05-2014, 07:04 PM
swiller swiller is offline
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Did not do low speed adjuster, carb bowl and main jet were spotless. I will redo carb clean and check . No noticeable throttle shaft play or choke shaft, someone mentioned governor shaft seal? Flywheel was removed last week to replace upper crank seal (have had this running issue long before that) stator coils were oily, some magnet chipping inside flywheel but nothing major. At that time the right plug was dry but black, left was light beige / normal. Replaced right coil, plug is now beige.
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  #7  
Old 06-05-2014, 07:07 PM
swiller swiller is offline
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Sorry, cleaned carb with carb clean spray, removed main jet, float, needle. Sprayed out all. Everything looked spotless.
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Old 06-05-2014, 08:06 PM
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Restrorob Restrorob is offline
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If you just done a quicky clean without removing the carb, Remove it from the engine. Pop the limit cap then screw the adjuster in counting the number of turns until LIGHTLY seated, Then spray carb cleaner (a brand beside Gumout) through every single jet-port and passageway visible. Watch for cleaner to exit other areas of the carb (end of passages) then follow with compressed air if possible, Reinstall adjuster LIGHTLY seated then back out the number of turns counted adding a extra turn out......

On the throttle link rod from the governor arm to the carb, Is the small spring intact not stretched and both ends hooked to the carb and arm ?

I'd rather go in steps and see each outcome before moving to other areas.....
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  #9  
Old 06-05-2014, 09:31 PM
swiller swiller is offline
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Carb was removed and cleaned. Thanks for your help so far, will check the carb out better this Saturday.
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Old 06-07-2014, 09:40 AM
swiller swiller is offline
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Have not dug back into it yet, but looked at Kaw manual, and upper screw ( pilot screw in manual) was removed and cleaned. Carb has the fuel shutoff solenoid on the bowl. Any chance that is partially failed or weak, or is it usually an all or nothing deal? Will check gov spring and seal in a couple of hours. Thanks again.
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