Discussion for the Kawasaki FC540V-AS13 4 Stroke Engine
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Question: Flywheel Assembly
something is rattling below the flywheel assembly. We cannot remove the flywheel after all the obvious parts have been removed.
Can anyone help us?
Reply: Flywheel Assembly
Loosen the nut that secures the flywheel to the crankshaft. Unthread the nut so that it is sitting just higher than the crankshaft threads. The flywheel sits on a taper on the crankshaft. The taper seats the flywheel securely to the crankshaft. Have a helper put two pry bars under the flywheel, 180 degrees apart, and apply moderate upward force to the flywheel. At the same time strike the nut on the crankshaft with a hammer. The force of the pry bars with the vibration caused by striking the nut will pop the flywheel free from the crankshaft.
I hope this helps,
Question: Electric Starter -cold Problem
When my mower sits for some time (over 6 hrs), the electric starter has a hard time cranking. It will only start with a 40 amp charger boost. The problem is gradually getting worse. Once the mower starts and runs a bit it starts right up as long as it hasn't sat for more than about an hour. Connections are good and the battery is new. I have two FC540V's that are old (over 3000 hrs) and they both do it. Is there a compression release or are the starters just worn out and require the boost with the charger? Where can I buy a new starter to try on on machine?
Reply: Electric Starter -cold Problem
The starter is getting worn, you can bring it to the shop or buy an amp meter to see how many amps are being drawn. The starter wire getting hot is a sure sign the starter is worn. You can rebuild them if you're a bit of a handy man. God bless you with wisdom to tackle this task. Johnny
Review: Kawasaki - FC540V FC540V
Very strong mower engine and very reliable. Easy to get at anything. I have two with over 3000 hrs. Make sure that you keep the air cooling fins clean since if they get hot the mower will slip a rod. Looking to replace a starter. Both engine starters drag and will only start with a 40 amp boost with a charger. Once it starts, no problem starting when the mower has been idle for over one hour. Both doing it?
Reply: Kawasaki - FC540V FC540V
I'd like to suggest checking the automatic compression release valve in the cylinder head, acturated by the camshaft. Remove the valve cover, adjust the valves cold at .006 both intake and exhaust then observe the movement of the exhaust valve with a dial indicator. If the exhaust valve DOES NOT open more than 0.01 in. (0.25mm) briefly just after the intake valve closes, the ACR mechanism on the camshaft is faulty. Obtain a copy of this engine's work shop manual P/N 99924-2015 for additional information on trouble shooting. I have had starter bell housings explode during hot starting events because of this faulty ACR valve. Good luck Danny, OB1.