New 25 hp Kawi not running right

Discussion in 'Mechanic and Repair' started by lzrj, Jun 10, 2007.

  1. lzrj

    lzrj LawnSite Member
    Posts: 245

    I bought a everride warrior last fall with a 25 hp kawi and 54" deck. I only had 20 hours on it. Started mowing last night and after it warmed up, the engine stared "surging". At full throttle, RPM's will fall then go back up, fall and then go back up making it impossible to mow. If I throttle it down to idle it will die. It's still under warranty but I just got it back from another warranty repair with the pump belt. My main guess is that something is wrong with the carburator (needs cleaning, ect..). But with only 20 hours, I should not be having any of these problems. It's becoming very frustrating. Anyone have any ideas.
     
  2. Restrorob

    Restrorob LawnSite Fanatic
    Posts: 11,024

    It only takes one time putting fuel in to contaminate the carb. with trash/water. Unfortunately carb. cleanings are not covered under warranty for that very reason.

    Is the fuel thats in it from last fall ?
     
  3. lzrj

    lzrj LawnSite Member
    Posts: 245

    I just put brand new fuel in it just before I started to mow. Got it from the shell station so its not just cheap gasoline. I get all my gas there and never any problems. What's the cost of a carb cleaning or how hard is it to do it myself? I do minor repairs to my vehicles but never worked on a carb.
     
  4. lzrj

    lzrj LawnSite Member
    Posts: 245

    Also just looked at the warranty and it states nothing about the carb not being covered. It states only clutch, brake linings, light bulbs, filters, lubricants and coolants, spark plugs and injector nozzles.
     
  5. khouse

    khouse LawnSite Bronze Member
    Posts: 1,465

    I have installed sediment bowls in line on some mowers. Hopefully most of the water will drop to the bottom of the bowl. It's only successful if the owners regularly checks and clean the bowl out. But Restrorob is right on with the contaminated fuel problem and fix. I haven't seen a scientific report on performance issues but would guess that 75% of most engine issues result from contaminated fuel. "when in doubt- clean it out"
     
  6. Restrorob

    Restrorob LawnSite Fanatic
    Posts: 11,024

    From Kawasaki's web site Q/A section.

    A dirty/contaminated carb. is not a factory defect.

    Should you go into this carb and clean it make SURE not to get ref.#24 low speed jets and ref.#22 and 23 main jets mixed up, They have different size holes in the middle.

    [​IMG]
     
  7. lzrj

    lzrj LawnSite Member
    Posts: 245

    Thanks for all your help and the diagram Restrorob. I did drain all the gas and changed the spark plugs. After I tried it again, started doing it again after 10 minutes. I may tear down the carb and clean it and see what that does. If I do it, how will I know if I get all the adjustments back after its together again?

    I did run into another problem when I changed the plugs. The right one came right out but the left one I had to use the wrench to undo it all the way which worried me. When I got it out, it looked like the treads on the block were stripped a little (The end of the old plug thread was bad too so I was just hoping it was the plug and not the block). But I had to use the wrench to get the new one back in all the way again. I'm afraid what will happen to that thread over the years of changing the plug. Should not be dealing with all of this on a new $8000 mower. This I will talk to the dealing tomorrow.

    I'm starting to think this thing may be a lemon.
     
  8. Restrorob

    Restrorob LawnSite Fanatic
    Posts: 11,024

    Well, The only adjustment on this carb. (that you should mess with) is the idle speed and you don't have to mess with that just to clean it. Also you don't have to strip it down as shown above.

    Just remove the solenoid valve then the float bowl, Remove the low and high speed jets but label which hole they came out of to get them back in the same holes. Remove the float and float valve, Then spray carb & choke cleaner with the little straw through ALL ports and passages then follow with compressed air if available. Do the same cleaning on the top half of the carb, Then spray through each jet one at a time and re-install it (be careful not to blow it out of your fingers).

    Re-assemble the whole carb and re-install, Make sure there is no trash in the bottom of your tank then flush the fuel lines and replace the fuel filter.

    Also, If you have a camera snap a couple pics of the linkage before you start ripping, They could come in handy.
     
  9. khouse

    khouse LawnSite Bronze Member
    Posts: 1,465

    You may be treading on thin ice with the thread issue. If you happen to remove the plug in the future put some anti-seize compound on it. If it won't tighten up then you'll have to install a heli-coil.
     
  10. Bill Kapaun

    Bill Kapaun LawnSite Senior Member
    Posts: 917

    You might want to get a thread chasing tap and clean up the threads next time.
     

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