Kawasaki Mule 500 KAF300B1 with FE290D Engine Burnt Valve Repair Starter Removal and Testing -Part 4
In this video, we continue our work on the 1993 Kawasaki Mule Model KAF300 B1. We pulled the cylinder head to find excessively burnt / burned valves, which contributed to our low compression readings in a previous video. We sourced all of the parts for the valve job online via Babbitt's and were able to find a gentleman locally who was willing to do the machine work on the cylinder head and valve seats in his machine shop.
The list of replacement parts purchased is as follows:
(2) Valve Springs 49078-2060
(4) Valve Spring Collets 12011-2052
(2) Valve Spring Retainers 12009-2060
(2) Valve Spring Seats 16007-2052
(2) Valve Stem Seals 92049-2100
(1) Intake Valve 12004-2084
(1) Exhaust Valve 12005-2077
(1) Head Gasket 11004-2138
(1) Rocker Case Gasket 11009-2829
(2) Valve Guides 49002-2101 (Note that the Exhaust Guide is no longer available. The intake valve guide must be used for both intake and exhaust.)
(2) Valve Guide Snap Rings 92036-023
After testing the guides, my machine shop determined that replacing the valve guides was not necessary for me, so those parts will be returned, as well as the valve guide snap rings.
While waiting for the machine work to be done, we constructed a simple way to test the starter using a battery without going through the starter relay. When the cylinder head came back all clean and shiny, we installed it back in the engine and changed the oil/filter. Then, we performed a compression test to find that it had improved dramatically over the previous test, up to 75 psi from about 35 psi. After that, we reinstalled the starter and tested the starter in the motor using our test setup.
Music Credits: “Blue Mountains” by Gabriel Witcher
Пікірлер: 67
Just what I was looking for. Quality vid. Thanks for the parts list.
@budgetprojectsbydavid5263
3 жыл бұрын
No problem and thanks for commenting!
Awesome I’m going to do mines thanks
My mule 500 has the FE290D-AS04 I can find the piston and gasket kits, but not replacement valves. Your valves have the same part number. Are these cylinder heads the same?
What would cause the rod to come out of the groove of the rocker? On this engine. I just purchased a old John Deere AMT 626 and it will run fine, when you shut it off the rod falls out of the groove and you have to pull that cover off and put it back on.
@budgetprojectsbydavid5263
Жыл бұрын
Are you missing a spring somewhere on the rocker? Is the spring broken? Maybe I’m not visualizing what you’re talking about, but mine can’t move.
My j d gator with FE290D Kawasaki motor is acting up grinding when trying to start. I thought it was the starter. But from where you took your starter off, there isn't one and the big ring hole has a plate covering it. There is however a big (looks like a generator) motor on top. does that replace the motor? Will I have to buy that motor to correct the non start problem?
@budgetprojectsbydavid5263
Жыл бұрын
Hard to say. The only thing similar about our units is the motor. You might want to get on a parts website that sells john deer eparts and just look at the pictures / diagrams to see what you’ve got. I won’t be of much help. Sorry.
I'm looking to find out how to pull the drive pulley off of a 610 Mule 09 or 2009
@budgetprojectsbydavid5263
2 жыл бұрын
Sorry, but I don’t have any experience with that one. Maybe you can make a video when you figure it out! 😀
I'm trying to find out everywhere if my 03 John Deere Gator with the Fe290D has a compression release. My engine backfired and died after running perfectly now I have what looks to be good spark. I cleaned the carb it's clean and getting fuel. No pop at all. Maybe a bad plug that's old and not hot enough? And my compression is only 65 and 70 with oil in the cylinder.. That's why I'm hoping it has a compression release. Please anyone?
@budgetprojectsbydavid5263
2 жыл бұрын
Do you care to share the serial number with us for parts lookup?
@jaybourbon8608
2 жыл бұрын
@@budgetprojectsbydavid5263 Thank you for the quick response! I found a sticker on the engine there are 2 numbers.. The top one is.. Code. FE290D-DS08 The bottoms engine Serial number is. FE290D638731 Let me know if that helps.. Thank you in advance! The bottom
@budgetprojectsbydavid5263
2 жыл бұрын
I’m thinking that it does have a compression release. What about the john deere serial number under the passenger seat?
@budgetprojectsbydavid5263
2 жыл бұрын
I would for sure start with the spark plug. Culprits for bad compression could be valves, head gasket, or rings. In my case, the compression release was not the cause. My issues were both valves and rings. Double whammy.
@jaybourbon8608
2 жыл бұрын
@@budgetprojectsbydavid5263 When you said it might have a compression release I looked up the compression range with it not running. It was 70 to 70 right where mine was. I did the oil in the cylinder to check the rings and it only bumped it up 5 more psi. Put a plug in it and it started in 1 second.. 🤣✌️💩
I noticed the arrow on the piston is facing the clutch, it should be facing the fan side.
@budgetprojectsbydavid5263
6 ай бұрын
Don’t believe everything you read on the internet. The factory service manual clearly says converter side!
@budgetprojectsbydavid5263
6 ай бұрын
I believe there were two versions of the FE290 engine. One was clockwise and the other was counterclockwise. If your application is not specifically the Kawasaki Mule, you may want to check the factory manual for your specific piece of equipment.
how much was your compression before and after head job?
@budgetprojectsbydavid5263
3 жыл бұрын
My compression before the head job was 30. I feel like the lowish compression that you and I are seeing 60-70 may be related to the Automatic Compression Release (ACR) on the camshaft, that opens the exhaust valve just a little on the compression stroke at slow speeds. I’m glad to hear that yours runs so well with only 60 psi. What year model is yours?
@randy1ization
3 жыл бұрын
@@budgetprojectsbydavid5263 93.. it seems like the engine is governed down either by the governor or transmission. when I go up hills, it seems like the engine will rev higher, than on a straight away. once I get the starting situation sorted out, I will see what makes the throttle/transmission tick.
@randy1ization
3 жыл бұрын
@@budgetprojectsbydavid5263 I didnt know abt the compression release, there may be nothing wrong with mine.,., what is your compression now, ? my honda three wheeler has a compression release for starting it with the pull rope.
@budgetprojectsbydavid5263
3 жыл бұрын
Compression on mine was 30 with burnt valves up to 70, now. I’m not sure what rpm activates it to turn off, but it would have to be faster than the starter turns, otherwise, what would be the point of it?
ive put 2 new starters on mine and it still doesnt work right, might try to get OEM if I cant get it fixed right.
@budgetprojectsbydavid5263
3 жыл бұрын
What happens, specifically?
@randy1ization
3 жыл бұрын
@@budgetprojectsbydavid5263 sometimes it clicks, sometimes it starts. new battery, a strong one, checked cables, cleaned all connections,,
@budgetprojectsbydavid5263
3 жыл бұрын
Have you tested your starter relay? Part number 27002-1051? Look it up on ebay. It’s a module that plugs in to your wiring harness.
@randy1ization
3 жыл бұрын
@@budgetprojectsbydavid5263 I have not, I will check it. thanks
@budgetprojectsbydavid5263
3 жыл бұрын
I have a brand new one that I would let you try in yours as a test if you lived closer. My mule came with a bunch of parts missing and I had to buy one. We are in Arkansas. I assume from your name you are in Texas.