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I’m needing some help with a Kawasaki FD620D that’s in a John Deere 425 that was given to me.
I was told it needed a starter but that’s not whats wrong with it. To make a long story short the cylinders had water in them causing rust which had it locked up. The motor still had antifreeze in it and I don’t know where the water came from. The mower has be sitting for about 3 yrs in a shed and before I go and put much money in it I just want to see if I can get it running without completely rebuilding it if this makes sens. I ran a 3 arm cylinder hone in the cylinders which got out a lot of the mess but I’m wanting to get a ball hone and hone it with it. My question is what size and what material to ge. The bore size is 3”. I attached a pic and the cylinder which looks better than that now.

StarTech said:

You can't hone above the rings as you will produce a stepped area that rings will hang on. Also both ball and flex hones will just make any out of round and taper worst. And I would think you are already out of round beyond the below specs.

You need a rigid hone to don this work properly.

And you need mic the current bore to see if it is near spec. This not a guessing game as if it is already at 3.0000 then it is time to resize to next larger available pistons and rings.

View attachment 70427

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From the picture I would say he is already .010 or .25 mm over and will need .020 or .50mm to clean up.

ILENGINE said:

From the picture I would say he is already .010 or .25 mm over and will need .020 or .50mm to clean up.

Click to expand...

That cylinder does not look good from that one picture. Try to do a leak down and compression test if possible. If there was water inside engine there will probably be pitting, etc. that will possibly make the engine, for all practical purposes, unsalvageable.

StarTech said:

You can't hone above the rings as you will produce a stepped area that rings will hang on. Also both ball and flex hones will just make any out of round and taper worst. And I would think you are already out of round beyond the below specs.

You need a rigid hone to don this work properly.

And you need mic the current bore to see if it is near spec. This not a guessing game as if it is already at 3.0000 then it is time to resize to next larger available pistons and rings.

Click to expand...

Tiger Small Engine said:

That cylinder does not look good from that one picture. Try to do a leak down and compression test if possible. If there was water inside engine there will probably be pitting, etc. that will possibly make the engine, for all practical purposes, unsalvageable.

Click to expand...

I did a compression check after the first cylinder cleanup and it was around 60 on both cylinder. Then I did a leak down check but it was leaking around the valves so now I’m reworking the heads then I’ll check it agai. What should the compression be on the motor I believe I read around 160 to 170 I’m correc.

This manual might help. https://www.mymowerparts.com/pdf/Ka...20D-FD661D-KAWASAKI-SERVICE-REPAIR-MANUAL.pdf