I have a 2007 exmark turf tracer hp with a 17 hp kawasaki motor. Has maybe 400 hours. Engine has been surging from idle to nearly full throttle. Doesn't surge at wot but engine doesn't sound smooth. I have done research and tried all the secrets and tricks on here. I've had the carburetor off 8 times cleaning it and pretty much dissecting the thing cleaning every port and hole there is hoping that every time I bolt it back on that i knocked some microscopic piece out and it's going to run like a top, but that wasn't the case. I've replaced fuel filter, air filter. I've called dealers and they mention its the carb with my symptoms. One thing is while its idling and surging I can pull the choke up a bit and it smooths out and that's why I'm assuming they say its carburetor. I'm about to give up! Is it a governor issue? Or should I just buy a new carburetor and try that? Any advice or info is appreciated!
Kawasaki fh541v 17hp motor issues on exmark tthp
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TDM713
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I have a 2007 exmark turf tracer hp with a 17 hp kawasaki motor. Has maybe 400 hours. Engine has been surging from idle to nearly full throttle. Doesn't surge at wot but engine doesn't sound smooth. I have done research and tried all the secrets and tricks on here. I've had the carburetor off 8 times cleaning it and pretty much dissecting the thing cleaning every port and hole there is hoping that every time I bolt it back on that i knocked some microscopic piece out and it's going to run like a top, but that wasn't the case. I've replaced fuel filter, air filter. I've called dealers and they mention its the carb with my symptoms. One thing is while its idling and surging I can pull the choke up a bit and it smooths out and that's why I'm assuming they say its carburetor. I'm about to give up! Is it a governor issue? Or should I just buy a new carburetor and try that? Any advice or info is appreciated!
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12,480 Posts
No vane governor and new carb bad idea for now.......
TDM713,
Start the engine cold and set throttle to where it surges, Spray carb & choke cleaner around the intake manifold and carb mount gaskets and see if surge changes.......
Have you checked/adjusted the valves yet ?
I have sprayed around all the intakes where gaskets are and nothing changes. Havent had the valves adjusted though. I took it to the local small engine guy this morning and I told him what all I have done. He seems to think I may have got the governor out of adjustment or that it may be something worn out with the governor internally which I hope not!
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12,480 Posts
I hate to say it but....... I've never in my 30+ years had a engine do the above with blown head gaskets, In fact..... I don't recall ever seeing a blown head gasket cause surging......
Me thinks your being take'n for a ride......
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4,378 Posts
Me too.....
You either have a sucked in intake gasket or a piece of trash the size of a junebug in the carb...
Wouldnt hurt to adjust the valves...
First time for everything! I took the shroud off and you could feel air blowing big time and no it wasn't air off the flywheel. The engine makes a popping sound as well which is sucking air. I'm pretty confident that replacing all the top end gaskets are going to fix it. I have done everything else but that!
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614 Posts
good luck Thumbs Up
Back in business! Problem solved and runs like a top now. Although before i mentioned cleaning out the carb several times and still surging. We found that one head gasket was blown so we replaced both head gaskets, both valve cover gaskets and exhaust gaskets. That didn't completely fix the surging so it had to be the carb. I found a brand new one on eBay that had the throttle shaft missing for $40 so I couldn't pass up that offer. Better than paying nearly $300 for a new one! So upon getting the new one, I notice a factory seal on top that covers a jet was missing on mine and right then I knew that was where the air was getting sucked in therefore causing the surging. I took the throttle shaft out of the old one and put it in the new one and bolted it on! Ran smooth as silk! Thanks to all the help! You guys were right, the head gasket didn't fix it but it wasn't a waste because they were nearly blowed out!
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614 Posts
congrats
![Image]()
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378 Posts
Wow, this thread save me $$, I was minutes away from ordering a new carb, missing welch plug was my problem,
thanks
thanks
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4 Posts
Do you have a picture of the factory seal? I have looked for a replacement part but can not find one. I believe I have this same issue on my fs600v
I have similar problem with deere x475 Kawasaki FD671 (23Hp?) with ~700 hours. It surges when idling, but runs smooth for about 3-5 minutes after initial startup. Also after mowing for about 1hr it will start loosing power and try to die. I can keep it running by feathering the choke or disengaging the blades. If it does die, it always starts right back up, but soon repeats the issue. I have tried the following:
New fuel pump, all hoses and filter (even short piece of hose in tank)
Cleaned gas tank
Cleaned carb, but it was practically spotless
Checked to be sure gas cap vent wasn't an issue
Checked fuel pressure and flow - meets spec
Sprayed lube around carb gaskets and throttle shaft - no change in idle
New plugs and one new coil (#1)
New ignition control module
Disconnected or jumped seat & reverse switch
Also ran hot wire straight to the fuel pump
Adjusted valves to spec (.006")
The dealer said may need to go with new carburetor, but I'm not convince this will fix the problem. It does have some play in the butterfly throttle shaft. Also, may have a bad #2 coil but, the #2 coil tests good 128,000 and 17,000 ohms (essentially the same readings as the new #1 coil & within deere specs). I understand the coil could break down under load, but I'm not sure if I should spend another ~$70 guessing. Any thoughts would be appreciated.
New fuel pump, all hoses and filter (even short piece of hose in tank)
Cleaned gas tank
Cleaned carb, but it was practically spotless
Checked to be sure gas cap vent wasn't an issue
Checked fuel pressure and flow - meets spec
Sprayed lube around carb gaskets and throttle shaft - no change in idle
New plugs and one new coil (#1)
New ignition control module
Disconnected or jumped seat & reverse switch
Also ran hot wire straight to the fuel pump
Adjusted valves to spec (.006")
The dealer said may need to go with new carburetor, but I'm not convince this will fix the problem. It does have some play in the butterfly throttle shaft. Also, may have a bad #2 coil but, the #2 coil tests good 128,000 and 17,000 ohms (essentially the same readings as the new #1 coil & within deere specs). I understand the coil could break down under load, but I'm not sure if I should spend another ~$70 guessing. Any thoughts would be appreciated.
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2 Posts
Sounds like a flogged governer cog or shaft think might be nylon cogs on governer id look at that first
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2 Posts
Id also look at governer springs inside also the vane springs could cause this as time goes by springs loose tension might look ok but loose springyness
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