Kawasaki FE290D Not running wide open without half choke

[allseasons]

Hello folks, I've just stumbled my way over from the PERR. I'm working on a Kawi. FE290D-AS24 single cyl. It is in a Snapper utility side-by-side. The problem I'm having is to run above idle, it requires the choke to be half closed, as if its not getting enough fuel for the air supplied. I cleaned the carb in my ultra sonic and had the same problem. I also changed the plug and set the valves. No change. So after looking at the cost of parts, still thinking carburetor, I ordered a whole new carb. Got the new one installed, same problem. Now I'm thinking air leak behind the throttle plate on the carb. While running, I sprayed carb cleaner around all of the gaskets and had no change. Fuel supply is sufficient as well. Any suggestions from this point?

Thanks
Chad

[KE4AVB]

The problem is usually a fuel delivery problem but see you have already replaced the carburetor and adjusted the valves.
I would do a leak down test to see if you have a valve or head gasket related problem.

I would also double check the fuel pump (IPL indicated it has one) to see if it is actually pumping enough fuel.

[allseasons]

Here is an update on this Kawi motor. I really hope I can get some help here because I have exhausted every option I can think of.
This is what the current symptoms are:
Starts and idles great, cold or warm starts
at full throttle it chokes out and will die if I don't let off the gas, cold or warm, it doesn't matter.
While trying to run, it is more noticeable with the air filter installed and results in heavy carbon on the plug.
With the filter off, it will run on it's own but still burns really rich and very choppy with very little power.( I originally thought I had a lean condition until now)

What I have done so far:
Compression check good
<2% leak down
adjusted valves
cleaned carb in US cleaner
replaced plug
(At this point I reinstalled the carb and tried again. No change.)
Bought new carb
installed new carb with new gaskets behind carb and behind spacer.
(No change in symptoms)
Pulled shroud, checked for head gasket leak or any other leaking gaskets. No leaks found.
Pulled new carb off to check Main jet size. #95. Checked old carburetor jet size #86 (I am in Oklahoma so no need for high altitude jet)
Looked online for other jet sizes, only #95 listed.

This is where I'm at. The ONLY other thing I can think of is a weak coil. However, I don't want to just go throwing more high dollar parts at this thing.

I could use any help here possible
Thanks, Chad

[motorhead64]

Have you tried without the muffler connected? Could be obstructed exhaust. You have a spark arrestor in the exhaust that could be clogged. MH

[RoyM]

I'm thinking you still have a fuel delivery problem. Check the fuel pickup in the tank. Is it clean? Also look for a pin hole in the fuel line or loose fitting. The choke will have no effect if the ignition is weak, usually it would refuse to rev up or backfire.

[allseasons]

I'm thinking you still have a fuel delivery problem. Check the fuel pickup in the tank. Is it clean? Also look for a pin hole in the fuel line or loose fitting. The choke will have no effect if the ignition is weak, usually it would refuse to rev up or backfire.

Thats basically what it's doing. When you open the throttle wide open, it won't rev, it just falls on its face and tries to die. You let off the throttle and it returns to a nice smooth idle. It occasionally will backfire lightly through the carb at full throttle, but very random.

[okie]

Hi Chad from another Okie (Ardmore)

Have you looked at the key on the crankshaft?
It sounds like the timing is a little off maybe a little bit partially sheared condition

Continue to keep us up dated Please.

Okie

[JandL]

I had something very similar to this problem last week. Turned out, it was the fuel line between the fuel tank and the filter. The inside of the fuel line had decomposed due to I suspect, ethanol. For troubleshooting:

I ran a fuel supply from a shop tank I have directly to the carb input,
engine ran great,
then put the original fuel hose back on the carb and took off the input side of the fuel filter,
I put my shop fuel supply on the input side of the fuel filter,
engine ran great,
I put the original fuel line on the fuel filter input side and engine ran bad (like you are seeing),
I then changed the fuel line from the tank to the fuel filter, engine ran great.

You might try and put a known good fuel supply to the carb direct and see what happens...

[KE4AVB]

If you plan on changing the coil the following might of interest.

The following depends on the type of low oil alert this engine has. Diagrams indicate this is an electric starter model so the following is also base of that.

Engines that has the low oil alert that kills the ignition then you should try replacing the ignitor first before replacing the coil pack. On engines with low oil alert that just lights a light then it can still have an ignitor but there is also a version of the coil pack that the ignitor is built-in so you would need determine which you have.

Link to the service manual
http://www.google.com/url?sa=t&rct=j&q=&esrc=s&source=web&cd=2&cad=rja&ved=0CDQQFjAB&url=http%3A%2F%2Fedoqs.com%2Fdownload%2Ffc9927414611f3b5aa0443c7c9adb73a&ei=5FmuUqz_IaewsQSBs4DoDQ&usg=AFQjCNFXu6eedkb5ZTLZ1VcP-JWEK2VGqA&sig2=ZlaZSRs06sno9KzKZLlH2w&bvm=bv.57967247,d.cWc

[allseasons]

Thanks for the help guys! It just occurred to me. Why not make a video? So I did. and here it is. It's been a couple weeks but I think I had it running off of my transfer pump with good hose the other day with the same problem. But I'll go change the hose and see what happens. As far as the crankshaft key, it crossed my mind briefly but it idles just too darn good. However, even though it will be extremely difficult to check it in the cart, I'll give it a shot. Watch the video and tell me what you think. I'm not thinking spark anymore. Also this is with the spark arrestor removed and air filter removed. At about 45sec. you will see I half choke it and get it to wind up to full rpm, then open the choke and it kills it.
http://www.youtube.com/watch?v=P_oLWkW_Aqc