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Kawasaki FR691v Replacement/Repair

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danthemanx07

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Discussion starter · #1 · (Edited)
I just picked up a Gravely ZT 52HD with a Kawasaki FR691v. The engine has a nickel or so size hole in the block on the lower, forward side of the engine. Otherwise, the engine is clean and unmolested.

So, I need to either repair or replace the current engine. I plan on doing this myself as I have the tools and a fair amount of mechanical experience - none on mowers though.
I mow 1 acre once a week maybe 10 months a year. So, my annual usage, on the high side, is probably 80 hours a year.

Given my usage, I am not inclined to pony up $1200-$1600 for a new Kawa, and frankly, my budget just won't allow for it.

I have been cruising ebay, CL, and others for a used, low-hour Kawa replacement - or a suitable B&S or Kohler. I have also looked at new options on small engine warehouse. Looks like I could get into a new B&S or Kohler for $600-$700.

I have also considered picking up a parts mower with a suitable engine. The FR691vs pop up frequently on cub cadet mowers with low hours that are sold cheap when a deck or hydro goes out. There are two in my area now for under $500.

Also - is the engine repairable after that kind of damage?

Any suggestions (other than get a bigger budget)?
 
#2 ·
The engine may be clean and unmolested from the outside, but there could be considerable damage inside. Have you determined what caused the hole in the block? What is the condition of the rest of the mower? Post pictures, if you can, so the members can provide better assistance as far as whether you should go used or new on a replacement engine.
 
Discussion starter · #3 ·
Walker56 said:
The engine may be clean and unmolested from the outside, but there could be considerable damage inside. Have you determined what caused the hole in the block? What is the condition of the rest of the mower? Post pictures, if you can, so the members can provide better assistance as far as whether you should go used or new on a replacement engine.
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I don't doubt that there is considerable internal damage. The rebuild option might just be indeterminable before popping the thing open. No idea on the cause. Owner couldn't attribute it to anything and did not have anyone look at it. You can see the part of the motor that blew out in one of the pictures below. He considered replacing the engine, but was itching for something bigger anyway. He had a shiny new SCAG in his garage.

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#4 ·
Maybe short block it? How much would that set you back?
 
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#5 ·
I would not waste your time attempting to determine the cause or if it is rebuildable. I would be inclined to go the used route as long as you can check the engine out. Others may offer differing opinions. With a replacement engine other than a Kawasaki, you have to be sure that the crankshaft diameter and length are the same as well as the mounting. It just makes for an easier install. Anything can be made to work, but at what cost?
 
#7 ·
OP, if you decide to go the short block route, there is only a one year warranty, vs three years for new engine. In addition, a short block would require you to utilize the heads from your existing engine. Since you know nothing about the engine, I would be cautious about the heads. They may be good and then again, they may have damage.
 
Discussion starter · #8 ·
hal said:
Maybe short block it? How much would that set you back?
Click to expand...
That was my first thought. New short block may be the close to the cost of a good used engine, maybe even a new one. Will have to look into the pricing on that.

Walker56 said:
I would not waste your time attempting to determine the cause or if it is rebuildable. I would be inclined to go the used route as long as you can check the engine out. Others may offer differing opinions. With a replacement engine other than a Kawasaki, you have to be sure that the crankshaft diameter and length are the same as well as the mounting. It just makes for an easier install. Anything can be made to work, but at what cost?
Click to expand...
I have mostly been looking at complete mowers that can still be run so checking out the engine should be an option in those instances.

mKp7Tn1 said:
Take a look here for a complete replacement or a short block and parts:

http://www.psep.biz/store/kawasaki_fr691v_engines.htm
Click to expand...
Thanks for the link!

Walker56 said:
OP, if you decide to go the short block route, there is only a one year warranty, vs three years for new engine. In addition, a short block would require you to utilize the heads from your existing engine. Since you know nothing about the engine, I would be cautious about the heads. They may be good and then again, they may have damage.
Click to expand...
Good thoughts. I figure there may be additional damage beyond the block. The parts costs may quickly reach the cost of a good used/alternate new engine.

Anyone know if dealers ever pull and sell used engines off trade in machines that are toast for some other reason?
 
Discussion starter · #10 ·
I pulled the 691v off tonight. Was much easier than I anticipated. The main wiring plug, the starter wires, PTO clutch wires, muffler guard, PTO clutch bolt, and 4 mounting bolts. Here is the damage. I have no idea what would have caused this. So - I am moving on to a new engine. Guy locally has one of these brand new in box for $600. http://www.smallenginewarehouse.com/44T977-0015.html Same shaft length and diameter. Mounting pattern is the same.

Only things to figure out will be the wiring and the muffler. The wiring should not be too bad. I have the Gravely wiring diagram. Just need one for the Briggs.

Anyone know if the muffler from the Kawa will work on the Briggs? May be able to have it cut and welded if not or possibly find some type of replacement online somewhere. I dont think this part should be too hard either, but I could be wrong.

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danthemanx07
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