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Question
Hello Eric:  I have a John Deere 445 from 1997 with Electronic Fuel Injection.  This model uses the Kawasaki FD620D, John Deere is the only one that used this engine with EFI.

Over the years I have done many repairs such as replacing the polymer cam gear, piston rings, engine overhauls, etc.

I am not very knowledgeable about EFI.  The fuel pump works well.  The EFI module works correctly, the machine cycles correctly for the 2 seconds at start to pressurize the injector.  The coils and plugs have good spark and voltage.  The cylinders have excellent compression.

The machine does not start.  I notice when the plugs are off, that both cylinders have excess fuel spraying out of them.  They must flood the cylinders immediately at start so there is no combustion.

My question would be:  if the fuel regulator is the issue of malfunction, then the excess fuel is being sent to the manifold rather than back the the fuel return hose?

Is there a way to test the regulator? or I just have to replace it?

Thanks,

Vince

Answer
Checked the Kawasaki manuals we have...no FI.  Additional research yielded what you know...JD only uses the FI model.

Have you read the info at the URL below?

http://forums2.gardenweb.com/forums/load/tractor/msg0520311630705.html?

or this URL?

http://www.perr.com/phpBB3/viewtopic.php?f=14&t=9332

Did you try brand new spark plugs?

From what I found on the net is appears fuel pressure is critical to have 25-27 PSI of pressure. You can get a fuel pressure tester at Harbor Freight.

If low or suspect:
Check for loose or damaged pressure hose from pump to sender assembly inside fuel tank.
Check for plugged fuel filter or bad wire connection (internal and external) at pump/sender assembly.
Check spark- normal blue crisp spark. If fouling then install AM101194 (BMR4A) plugs gapped at .035.  ALSO read .025 gap with Champion plugs worked.
Clean and check ground. - Use remote ground from engine to frame to insure ground is good.
Spray WD-40 around manifold and other gaskets.- checks for air leaks

Please let me know if this helps and what you find so I can add to the net.
Eric

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Eric A. Jones

Expertise

Lawnmower Repair . Certified Master Service Technician from B&S. Have 23 years experience on B&S, Lawn Chief, Weed Eater, Echo, Peerless, Wheel Horse, Snapper, Atlas, MTD, McCulloch, Homelite and many other numerous brands. Specialize in electrical repair.

Experience

Born and raised in the midwest. Started tinkering with engines when I was about 14 on my Suzuki RM-80. I began lawn mower repair at a small hardware store. I knew absolutely nothing. I read lots of repair manuals and met an older fellow who taught me many lessons. I continued working on small engines through high school and paid my way through college working on mowers at the same hardware store. Decided to get away from the midwest and mower repair so I joined the Air Force. I repaired air traffic control electronic equipment and ended up in Hawaii where I got a part time job at Small Engine Clinic. I gained a lot of experience from the Small Engine Clinic and had a blast repairing small engines. I then took the Briggs and Stratton Master Service Technician test and earned my MST. I then traveled to Wisconsin where I attended the factory update training seminar and received formal training. Continued working on mowers part time as I completed 20 years of military. Retired from the military on a Friday and continued in the lawn and garden industry the next Monday.

Education/Credentials
MAS Aerospace Operations BA Mathematics AAS Electronic Communications AAS Electronic Technology

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