Exhaust Valve spring retainer model FC401V-CS03 FC401

[Cfs]

I am attempting to repair an old Ferris 36 inch walk behind. It has a Kawasaki FC401v engine. I removed the head and found both push rods not in contact with the rocker arms, and that the exhaust valve was stuck. I removed the head and removed the exhaust valve cleaned up the valve shaft and lapped the valve into the seat on the head. However when I removed the exhaust valve the spring keeper went flying and was lost. I ordered a new keeper part number 12009-2058 and it does not seem to fit. The keeper has the key hole type of attachment to the valve...a larger hole and a smaller ho!e. The outside diameter seems correct and the overall configuration of the keeper seems correct but I cannot get the valve to fit ino the smaller ho!e. The tip of the valve fits into the larger hole but it cannot slide into the center of the smaller. The hole seems too small. I checked the diameter of the valve at the long where the keeper attaches and it measures 4.8mm. I checked the diameter of the smaller hole and it measures 4.8 mm but because of the way the small hole connect to the larger hole the valve shaft cannot fit into the hole.

I will post some photos later tonight. I have checked the part number with two dealers and A couple of websites Jacks Small Engines being one and the part number seems correct. The metal on the keeper is so thick I do not see anyway to make this work. I am reluctant to dremel away any metal to make it fit. Has anyone else had a issue like this and know what I should do. I am going over to a John Deere dealer tomorrow with the parts to see of they have any ideas I sure wish I could find the keeper that flew off!

Any comments greatly appreciated

Spit

 

[Auto Doc's]

Hello Cfs,

While out of the head, can you slip the tip of the valve through the large hole down to where the groove is and then slip it on to the groove area?

If it fits correctly, then it is a matter of compressing the spring with the keeper offset far enough for the keeper to slip into the groove when compressed far enough.

 

[txmowman]

I am attempting to repair an old Ferris 36 inch walk behind. It has a Kawasaki FC401v engine. I removed the head and found both push rods not in contact with the rocker arms, and that the exhaust valve was stuck. I removed the head and removed the exhaust valve cleaned up the valve shaft and lapped the valve into the seat on the head. However when I removed the exhaust valve the spring keeper went flying and was lost. I ordered a new keeper part number 12009-2058 and it does not seem to fit. The keeper has the key hole type of attachment to the valve...a larger hole and a smaller ho!e. The outside diameter seems correct and the overall configuration of the keeper seems correct but I cannot get the valve to fit ino the smaller ho!e. The tip of the valve fits into the larger hole but it cannot slide into the center of the smaller. The hole seems too small. I checked the diameter of the valve at the long where the keeper attaches and it measures 4.8mm. I checked the diameter of the smaller hole and it measures 4.8 mm but because of the way the small hole connect to the larger hole the valve shaft cannot fit into the hole.

I will post some photos later tonight. I have checked the part number with two dealers and A couple of websites Jacks Small Engines being one and the part number seems correct. The metal on the keeper is so thick I do not see anyway to make this work. I am reluctant to dremel away any metal to make it fit. Has anyone else had a issue like this and know what I should do. I am going over to a John Deere dealer tomorrow with the parts to see of they have any ideas I sure wish I could find the keeper that flew off!

Any comments greatly appreciated

SpitView attachment 71940View attachment 71941View attachment 71942

The part number is correct.
The overall width at the top is 25mm,
The overall height is 7.3mm,
The center hole is 5.1mm.
Was the part in an original Kawasaki package?
Where did you obtain the part?

 

[Cfs]

Hello Cfs,

While out of the head, can you slip the tip of the valve through the large hole down to where the groove is and then slip it on to the groove area?

If it fits correctly, then it is a matter of compressing the spring with the keeper offset far enough for the keeper to slip into the groove when compressed far enough.

No it will not fit into the smaller hole outside of the head…it is just too small of an opening. If you see the photo the placement of the smaller hole on the keeper it is not allowing the full 4.8 mm circumference valve to pass into it.
I do not know who I could check with at Kawasaki to review the specs/ measurements of the keeper

The part number is correct.
The overall width at the top is 25mm,
The overall height is 7.3mm,
The center hole is 5.1mm.
Was the part in an original Kawasaki package?
Where did you obtain the part?

I just checked the keeper. It is 25.2 km overall width. The height is 7.3 mm the center hole is 4.8 mm
I bought it from a reputable dealer here in the Columbus OH area, they ordered from their supplier who I assume was Kawasaki but it maybe through another distributor. The valve itself measures 7 mm at the top of the valve stem, and stands 92 mm tall, the diameter of groove that the keeper locks onto is 3.1 mm tall and the diameter is 4.8 mm.
The part was is a small zip lock bag and had a sticker with the part number on it. As you can see in the photos. The 2 holes in the keeper are stacked on each other like a snowman and the center hole (smaller one) has an opening that is maybe 5.1 mm. Its pretty hard to measure even using an electronic caliper.

I think it has to be a bad part wether it was made wrong or a bad substitution. I am going to visit the dealer tomorrow with the keeper, spring, valve and head and hopefully they can talk to their distributor and get me the right part.
I have looked all over my garage and side yard looking for the original keeper. I could kick myself for letting it fly off into the ether

Spit

 

[Cfs]

No it will not fit into the smaller hole outside of the head…it is just too small of an opening. If you see the photo the placement of the smaller hole on the keeper it is not allowing the full 4.8 mm circumference valve to pass into it.
I do not know who I could check with at Kawasaki to review the specs/ measurements of the keeper

I just checked the keeper. It is 25.2 km overall width. The height is 7.3 mm the center hole is 4.8 mm
I bought it from a reputable dealer here in the Columbus OH area, they ordered from their supplier who I assume was Kawasaki but it maybe through another distributor. The valve itself measures 7 mm at the top of the valve stem, and stands 92 mm tall, the diameter of groove that the keeper locks onto is 3.1 mm tall and the diameter is 4.8 mm.
The part was is a small zip lock bag and had a sticker with the part number on it. As you can see in the photos. The 2 holes in the keeper are stacked on each other like a snowman and the center hole (smaller one) has an opening that is maybe 5.1 mm. Its pretty hard to measure even using an electronic caliper.

I think it has to be a bad part wether it was made wrong or a bad substitution. I am going to visit the dealer tomorrow with the keeper, spring, valve and head and hopefully they can talk to their distributor and get me the right part.
I have looked all over my garage and side yard looking for the original keeper. I could kick myself for letting it fly off into the ether

Spit

Correction: the most narrow part (the gate way between the larger outside hole and the center hole)
of the center hole is 4.1 mm not 5.1... If it was 5.1_it would fit in I think

 

[StarTech]

I think I see the problem

yours

And an image from eBay

Note the two sharp points on the part you receive that is not there on the eBay image. Yours might just need the points file off a little so the keyhole is straight and not indented.

What do you think txmowman ?

 

[txmowman]

I think I see the problem

yours
View attachment 71943
And an image from eBay
View attachment 71944
Note the two sharp points on the part you receive that is not there on the eBay image. Yours might just need the points file off a little so the keyhole is straight and not indented.

What do you think txmowman ?

I believe you are spot on, @StarTech . The part @Cfs received is not a Kawasaki part. I’ve never known Kawasaki to use ziploc bags.

 

[StarTech]

I would like to see the part package label.

Here lately many of the aftermarket parts have been made wrong like the BB pulleys that I had shave off an eight of an inch just get them to clear the safety covers. Or the Toro dampers that had 5 mm on the ends instead 3.2 mm. Another thing that took nearly an hour to get the four down to 3.2 mm with a die grinder.

 

[Cfs]

Hello Cfs,

While out of the head, can you slip the tip of the valve through the large hole down to where the groove is and then slip it on to the groove area?

If it fits correctly, then it is a matter of compressing the spring with the keeper offset far enough for the keeper to slip into the groove when compressed far enough.

No it will not fit into the smaller hole outside of the head…it is just too small of an opening. If you see the photo the placement of the smaller hole on the keeper it is not allowing the full 4.8 mm circumference valve to pass into it.
I do not know who I could check with at Kawasaki to review the specs/ measurements of the keeper

 

[Cfs]

I redoubled my efforts and searched the area where the keeper flew into..and I found the original keeper. It fits the valve perfectly. The original does not have the projections, whoever suggested that those needed to be filed or dremel-ed away was correct. I am going to use the original and I will see if the dealer will take the new defective on back. It was under $15 so it’s not the end of the world if they won’t take it back.

Another question. The head gasket that I found in the engine seems to be little more than a very thin stamped sheet of aluminum? Not at all like other head gaskets that I have seen on Briggs Tecumseh and Honda am I missing something here. I still need to reassemble the head to the crankcase and I am concerned that I have a good seal on the head. If this paper thin metal sheet is the head gasket is it reusable? Is there a good way for me to test the head when installed for an air tight seal?
Thanks to everyone for the help!!
Spit