FR691V can I reuse this scored cylinder?

[pete cutting]

I started a small engine repair business and still have a long way to go to build up my knowledge and skills. I could use some experienced advice. One of my knowledge gaps is internal engine repairs.

A customer brought me a Huster Rapter 54" zero turn with a Kawasaki FR691V engine. He said that she was smoking a lot and that he had taken her to the local repair place that had said... Looks like something broke inside the engine, we recommend replacing the entire motor, it will cost at least $3000. The customer brought it to me hoping I would be willing to be a little more thorough and be willing to do the necessary internal engine repairs. I told him I would take a look.

Fast forward to today. I have the engine in my shop dissassembled and cleaned. The 2nd cylinder was jammed at an angle midway in the cylinder. The rod was broken and the there is a lot of aluminum transfer on the crankshaft.

I did my best to remove the jammed piston without doing additional damage. I ended up having to cut the piston out with a hand saw and a drill. The drill slipped once and did some additional damage.

In an attempt to quote my customer the lowest price, I would like to reuse the cylinder.

Questions:
Do you all think I can sand down the nicks, rehone it, replace the other damaged parts (pistons, rings, rods, crankshaft, etc.)? Or do I need a new cylinder?
Are there ways for me to be more quantatative about wether a cylindar is saveable, specifically in regard to nicks?View attachment 73721

I started a small engine repair business and still have a long way to go to build up my knowledge and skills. I could use some experienced advice. One of my knowledge gaps is internal engine repairs.

A customer brought me a Huster Rapter 54" zero turn with a Kawasaki FR691V engine. He said that she was smoking a lot and that he had taken her to the local repair place that had said... Looks like something broke inside the engine, we recommend replacing the entire motor, it will cost at least $3000. The customer brought it to me hoping I would be willing to be a little more thorough and be willing to do the necessary internal engine repairs. I told him I would take a look.

Fast forward to today. I have the engine in my shop dissassembled and cleaned. The 2nd cylinder was jammed at an angle midway in the cylinder. The rod was broken and the there is a lot of aluminum transfer on the crankshaft.

I did my best to remove the jammed piston without doing additional damage. I ended up having to cut the piston out with a hand saw and a drill. The drill slipped once and did some additional damage.

In an attempt to quote my customer the lowest price, I would like to reuse the cylinder.

Questions:
Do you all think I can sand down the nicks, rehone it, replace the other damaged parts (pistons, rings, rods, crankshaft, etc.)? Or do I need a new cylinder?
Are there ways for me to be more quantatative about wether a cylindar is saveable, specifically in regard to nicks?View attachment 73721

 

[packy51]

Real nice honing job though. If you come in at $1,500 and it runs fine, I'd be happy with that over the $3,000. The customer has to learn to take care of the engine oil and maint.

 

[gossamer]

I'd love to hear a follow-up once you get this going and a summary of how it went.

 

[mmoffitt]

Fair point. $2250 (engine + labor) versus $1500 - $2000. This math is one of the things I am struggling to sort out. This is a hard lesson for me to learn.

Makes me want to do what I can to keep the final bill to $1500. I don't like the idea of failing to give the customer a good value for the money they spent.

Also, I need to improve my ability to determine the internal failure before I crack into the crankcase. There were a couple of things I could have done differently during diagnostics.

I'm sure this fellow expects "some kind" of warranty to many variables what was cause of failure in the first place??

 

[RevB]

no. You might see if oversize pistons are available, and a machine shop near you can bore it oversize. The cost will probably be as much or more than a new engine from HF

No.

 

[RevB]

slomo,

It is a aluminum crankcase with a steel sleeve.

And they are cast in place. New engine.

 

[RevB]

I started a small engine repair business and still have a long way to go to build up my knowledge and skills. I could use some experienced advice. One of my knowledge gaps is internal engine repairs.

A customer brought me a Huster Rapter 54" zero turn with a Kawasaki FR691V engine. He said that she was smoking a lot and that he had taken her to the local repair place that had said... Looks like something broke inside the engine, we recommend replacing the entire motor, it will cost at least $3000. The customer brought it to me hoping I would be willing to be a little more thorough and be willing to do the necessary internal engine repairs. I told him I would take a look.

Fast forward to today. I have the engine in my shop dissassembled and cleaned. The 2nd cylinder was jammed at an angle midway in the cylinder. The rod was broken and the there is a lot of aluminum transfer on the crankshaft.

I did my best to remove the jammed piston without doing additional damage. I ended up having to cut the piston out with a hand saw and a drill. The drill slipped once and did some additional damage.

In an attempt to quote my customer the lowest price, I would like to reuse the cylinder.

Questions:
Do you all think I can sand down the nicks, rehone it, replace the other damaged parts (pistons, rings, rods, crankshaft, etc.)? Or do I need a new cylinder?
Are there ways for me to be more quantatative about wether a cylindar is saveable, specifically in regard to nicks?View attachment 73721

"The rod was broken and the there is a lot of aluminum transfer on the crankshaft.". He ran it out of oil. YOU are not responsible for the stupidity of others. This should be an object lesson to them....one that involves $$$$$

 

[Tdj2591]

The FR691V on my son’s 3 yr old Ariens zero turn exploded while mowing. Something internal blew a sizeable hole in side of the crankcase. He had recently changed the oil and filter and said that clean oil was pouring out the hole. He couldn‘t afford a new engine and parked it. I’m not a small engine mechanic but have built V-8s from a bare block. I was unaware that one could purchase a short block for a Kawasaki engine. Is a short block replacement worth it or would it be better to replace the entire engine? I realize that without dismantling it we have no idea of the extent of the damage.

 

[Tiger Small Engine]

The FR691V on my son’s 3 yr old Ariens zero turn exploded while mowing. Something internal blew a sizeable hole in side of the crankcase. He had recently changed the oil and filter and said that clean oil was pouring out the hole. He couldn‘t afford a new engine and parked it. I’m not a small engine mechanic but have built V-8s from a bare block. I was unaware that one could purchase a short block for a Kawasaki engine. Is a short block replacement worth it or would it be better to replace the entire engine? I realize that without dismantling it we have no idea of the extent of the damage.

Short block is worth it if the remainder of engine is in good shape and not all scored up.

 

[Moz-a-lot]

I started a small engine repair business and still have a long way to go to build up my knowledge and skills. I could use some experienced advice. One of my knowledge gaps is internal engine repairs.

A customer brought me a Huster Rapter 54" zero turn with a Kawasaki FR691V engine. He said that she was smoking a lot and that he had taken her to the local repair place that had said... Looks like something broke inside the engine, we recommend replacing the entire motor, it will cost at least $3000. The customer brought it to me hoping I would be willing to be a little more thorough and be willing to do the necessary internal engine repairs. I told him I would take a look.

Fast forward to today. I have the engine in my shop dissassembled and cleaned. The 2nd cylinder was jammed at an angle midway in the cylinder. The rod was broken and the there is a lot of aluminum transfer on the crankshaft.

I did my best to remove the jammed piston without doing additional damage. I ended up having to cut the piston out with a hand saw and a drill. The drill slipped once and did some additional damage.

In an attempt to quote my customer the lowest price, I would like to reuse the cylinder.

Questions:
Do you all think I can sand down the nicks, rehone it, replace the other damaged parts (pistons, rings, rods, crankshaft, etc.)? Or do I need a new cylinder?
Are there ways for me to be more quantatative about wether a cylindar is saveable, specifically in regard to nicks?View attachment 73721

Time for a new short block or like others have said, bore it oversized. Putting new rings in this is just asking for reputational troubles and will tear up the new rings. Live, Learn, fix it right and move on.