Kawasaki FH580V-AS20 Head gasket problem

[rkesmodel]

I hope someone can give me a little Help.

First the short version:

GT235 Tractor, Prod ID No MOG235F095731, Kawasaki Engine 18hp, Code FH580V-AS04, E/NO FH580VA09890, about 350 on the hour meter. Engine apart for short block replacement. Gasket surfaces scraped. New head gaskets from JD dealer are the wrong size. JD dealer says they are the only ones listed. I cannot put the engine back together and the grass is getting high. BTW, gaskets from dealer won't fit the new short block either. Good thing since the old heads and everything else wouldn't have fit either. Help!
Update: Original gaskets tried were part of the 'Engine kit' purchased 5/28/16 (see below). The dealer ordered just the head gaskets themselves, which came in today. They are the same size as the ones in the kit ;-( Dealer asked me for the exact mower model and serial number and exact motor model and serial number for further investigation. I emailed him the info above tonight.

Parts from dealer:

Purchased 5/19/16
2.00 M135790 GASKET
1.00 M149281 SEAL
1.00 M149282 SEAL
2.00 M149305 GASKET
1.00 M149308 GASKET
2.00 M149309 GASKET
2.00 TY22029 TURF-GARD Oil 10W30 SN/GFS
1.00 AM107423 OIL FILTER
1.00 AM133230 Short Block Assembly

Purchased 5/28/16
1 .00 AM 133237 Engine Kit

Purchased 5/30/16
1.00 M45460 SHAFT KEY
1.00 M77843 SHAFT KEY
1.00 AM126100 CLUTCH


Now the complete, sad story:

I purchased a used GT235 2 years ago, hoping I would have a relatively trouble-free mower for a few years. My father-in-law had previously purchased a consummer grade Cub Cadet (new from a dealer) that was nothing but trouble from day 1. I and my children mow about 3 acres.
Recently the mower quit. I thought the motor had locked up as I could not turn the crankshaft (I was using a wrench on the flywheel bolt). I ordered what I was told would be a complete engine and the few exterior gaskets from a local JD dealer. While waiting for the new engine I began taking the exterior parts off of the current engine (electronics, shields, wiring, starter, etc.). I was having trouble getting the clutch off and left it for the next weekend. The motor arrived and I had a weekend to replace it. Imagine my surprise when I unpacked it to discover that I had purchased a short block. Now I had to wait again for a $149 gasket set. As I was waiting for the new gasket set I began taking the motor apart (removing exhaust manifold, heads, carb, intake manifold, and clutch). Over Memorial Day weekend I discovered that the problem was a frozen clutch, the motor spun fine. Dang! The motor is all apart, and all I have to do is replace the clutch. Back to the JD dealer. Purchased clutch, flywheel key, and clutch/drive sheave key. Now this past weekend I am ready. I decided to put the old motor back together. I would run it until it died. If I could get the JD dealer to take the new one back, great (I had unpacked it, but hadn't installed anything on it or filled it with oil). If they wouldn't, I would keep it as a spare. Scraped off all old gaskets. Prepared to install the heads and discovered that the head gaskets wouldn't work. No matter which way they were flipped or turned, only one hole would line up. It was like they were for a slightly larger engine. As above, JD dealer says they are the only ones listed.

What now??

Any assistance greatly appreciated.

Roy

 

[Rivets]

I've been trying to find your engine, but it is one where Kawasaki has allowed JD to block the exact engine with a non published engine code AS04. Not unusual for JD. Using the JD numbers all the parts seem to have the correct part numbers, but there is no way to cross-reference them to Kawasaki. If the original heads don't fit on the short block, then you know that someone at the dealership has screwed royally in looking up parts and you should be able to return all parts which do not fit. This is not the first time I have seen JD parts (part numbers) not matching the right Kawasaki parts (part numbers). You are going to have to work this out with the people you ordered from, if they are good they will work with you, as I hope they looked up the parts you needed.

 

[BlazNT]

FH580V-AS20
Use that number. I found it but am very sick and can not concentrate.

 

[rkesmodel]

I've been trying to find your engine, but it is one where Kawasaki has allowed JD to block the exact engine with a non published engine code AS04. Not unusual for JD. Using the JD numbers all the parts seem to have the correct part numbers, but there is no way to cross-reference them to Kawasaki. If the original heads don't fit on the short block, then you know that someone at the dealership has screwed royally in looking up parts and you should be able to return all parts which do not fit. This is not the first time I have seen JD parts (part numbers) not matching the right Kawasaki parts (part numbers). You are going to have to work this out with the people you ordered from, if they are good they will work with you, as I hope they looked up the parts you needed.

Thanks, Rivets. I guess I didn't state the problem very well. The short block seems to match. I cannot state that for sure as I didn't try to install the heads. The problem is that the head gaskets don't fit the original engine OR the short block.

If anyone out there has contact information for a reliable source for Kawasaki engine parts (other than JD) I would appreciate it.

Roy

 

[BlazNT]

jackssmallengines.com/jacks-parts-lookup/manufacturer/kawasaki/4-stroke-engine/fh580v/fh580v-as20-4-stroke-engine-fh580v

 

[rkesmodel]

jackssmallengines.com/jacks-parts-lookup/manufacturer/kawasaki/4-stroke-engine/fh580v/fh580v-as20-4-stroke-engine-fh580v

Thanks. I am hoping that someone who has encountered this same problem (ordered gaskets too large) in the past will contact me with a solution. I am leery of ordering any more until I can find out why the ones I have gotten so far won't work. Surely I am not the only one this has happened to.

Thanks.

Roy