NO SPARK PROBLEM KOHLER Courage twin cylinder Wont START , How To FIX and UPDATE the IGNITION SYSTEM
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- เผยแพร่เมื่อ 20 ส.ค. 2024
- What's wrong with my mower ? NO SPARK! A 26 horsepower KOHLER Courage twin two 2 cylinder engine that WONT START won't RUN or backfires. How To FIX a NO SPARK problem and change back to MAGNETO style ignition . Must use Kohler UPDATE KIT to REPAIR . REPLACE both coils , rewire and also had to replace the STARTER MOTOR. Craftsman DGS 6500 model riding lawnmower. Common problem. Procedure , specs and part number. Slightly GROUCHY old fart mechanic. How to fixing and repair common problem problems. Review thoughts tips advice troubleshoot wont won't why carb carburetor clean piston valves spec specification capacity much gas fuel belt motor model choke fuel spark capacity oil why when where what shows whats diagnose service inspect check tank watch replace start hard starting tell dont advance change gap procedure can whats wrong
does can dies stalls magneto rewire compression parts diagram Craftsman Poulan adjust adjustment Yard Machines koler kohler tecumseh briggs and stratton straten stratten John Jon Deere Deer Scott's Scotts Cub Cadet Toro troy-bilt troybilt Troybuilt troy built bilt Ariens rider tool tools Jonsered ohv intek single twin Gravely Snapper Hayter Lawnboy Mountfield lowes home depot walmart seafoam grip tools will it run work rebuild turbo cool lawn mower repair small service oil gas spark compression how to
Same as John Deere Husqvarna Poulan Troy-bilt Toro Gravely Ariens Cub Cadet MTD Honda Bosch
Music by BonzaiRod ~song "staging lane"
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PLEASE KEEP IN MIND when you are watching my videos: I am showing you the least expensive, quickest "backyard" methods for repairing or servicing your lawnmower. Replacing all components such as gaskets and fuel lines is always recommended when rebuilding or repairing equipment. With these videos I hope you are able to fix and repair your lawnmower yourself with minimal parts, knowledge and tools. Thank you for watching!
Been running my Kohler 26hp for 13 years. Can't be that bad.
Just found your video and your top secret information did the trick. The conversion kit for the coils totally worked. I just doubled the price of my mower as I was going to offload it. The mower works (almost) like new. Thanks Brother. Be well.
glad it helped
Just a tip, loosen the coil bolts, slide coil(s) back, rotate the crank until the magnet lines up with the coil , insert a business card, let the magnet suck the coil in, tighten bolts, rotate crank, pull out card, done....WAY easier than the way you were doing it......have used that method forever, and never had an issue....the way your doing it was what I used to do, and had the same issue as you did.
Bit of a lout- aint he !! ?
@@mauricekeithjohnson2598 Except he is right and his way is so much less frustrating and more accurate.
I just did this business card trick and it worked perfectly for me. Did both in under 1-2 mins. Way easier.
I always use a business. Never anything else.
I do agree on some parts, the courage single cylinder is terrible, ive had good luck with the twin so far, the commands are great engines ive seen, its not unheard of to have them go to 2000hrs before needing a refresh.
Courage was the budget line for kohler. They had in the time this motor was made better quality motors available. People want low price and this is what you get. I have a 2008 courage 24hp twin with 500 hrs now, purchased new. It has had normal problems over the years but its been a good motor overall. I new when I purchased it was budget motor. Mine came with updated magneto system. Called kohler cs at the time inquiring how long its projected life was and was told 1000-1200 hours.
Hi Jeff,
Thanks very much for your videos. I've found them very helpful in performing repairs and service on my lawn gear.
Your comments regarding Kohler engines reflect your experience, no doubt, but I've had somewhat better luck. My Kohler Courage 25 hp engine powers a Troy Bilt Mustang zero turn mower. I bought it new in 2010 from Lowes, and this is my 11th season of use mowing a 0.9 acre lot, using the side discharge. I put about 53 hours a year on it, between May and November. I have 535 hours on it as of today. I do an lube/oil service every 25 hours with a full synthetic 10W-30 oil and Kohler filter. Each fall it gets a pre storage service - wash, full tuneup, blades, air filter, oil/filter. I fog the cylinders and carb prior to storage, and put the battery on a Sure-Charge unit all winter. To date, the only original part I've replaced is the starter due to early signs of a failing bearing. The original Gates belts are still going strong, as are the two hydro-static units. Compression on both cylinders is well within spec. So, I may be something of an outlier with respect to this engine, but I'm happy with it so far.
Based on your experience, about how many hours should I expect to get, ultimately? Would you consider going to an E Go electric zero turn as an alternative replacement? I've seen them for $4600 on line, so not a huge difference vs the big box price for another Troy Bilt.
At 5:34- You don't have to remove that plastic leaf-guard. It does not conflict with the engine cover.
Put one of these conversion kits on mine about 2 years ago. Hasn't missed a beat since.
I love it when you rag on Kohler ! Should get a better deal for a replacement !
Kolher used to be the engine to buy. I bought a 8hp Kolher tiller (Troybuilt) in 1991 and it still runs like new. Starts up every spring. Just change the oil yearly and sparkplug every 3 years.The newer engines are crap and even though B&S moved to Mexico and I hate to buy them, they are still much better than Kolher.
Hey Jeff thanks for this video! It really helped me and my father figure out the issue with his Kohler!
I've been checking reviews on which best used riding mower to look for and learned pretty quick to stay away from ones with that brand of engine. Seems to be a lot of failures. Thanks for the Vids! :)
Good choice!
have this one with the old style coils / was popping the 20a breaker after 10 min. of diagnosis it was part no 532-193-350 ignition switch (the key ) had dirt sand down it took it apart cleaned it it works. breaker not popping but ordered a new one $15.00 IDk why does every one dislike this engine just change the oil and filter blow out the air cleaner fresh gas store your mover inside. it is not a car water will damage your stuff happy cutting
thanks for the comment!
Awesome video and awesome fix. I have been wondering where you were. Now it all makes sense, working on a Kohler. Lol
I think this guy is a Briggs-Stratin dude, worst under powered and loud engine I ever had, hell, I love my Kohler and would buy another one if I needed to.
I stumbled upon this video a few weeks ago while my wife's Craftsman was having issues and intermittently running on one cylinder. It has a '07 26hp Kohler. I never thought to look for a service bulletin, just thought the thing was toast. Bought and installed the kit you showed and now it runs like new again. Easy fix...just shouldn't be hard to find the SBs or any other info from the company. Thanks for the video!
Just use a standard business card to set the coil gap. It's easier.
Used that trick a million times on solid state and points motors, definitely the easiest way to do it.
Just finished installing this kit about 30 mins. Ago set the business card in loosened the bolts coil pulled up tight. Tightened the bolts and vroom vroom. Perfect gap.
Wow.. Kohler's are known to never die in my neck of the woods..
Briggs.. is known for being not so good.. anymore
Run your feeler gauge across both sides of the coil and magnet you get it done in one shot
not all kohlers are bad every engine manufaturers have some bad models older engines and some newers are good too. if i wasthe customer i would replace the ring gear starter and anything else wrong or broken i do not just replace i repair a real mechanic can repair like you jeff thanks for sharing
thanks for watching
DYS4500 Minus the coil update needed our 26hp Kohler has been trouble free since 2008 and over 600hrs. !
Nice video. The customer really should replace the flywheel or the teeth will break
I agree, I told him that but couldn't persuade him
@@JeffsLittleEngineService Well he will be sorry
Been running my 25HP Kohler engine for 10+ years and no issues. Not sure why you hate them so much.
My Kohler V-Twin has been running trouble free for of 24 years, one before it was still perfect after a decade…had to turn you off!!!
You have been lucky.
I hope this helps with my 27HP Kohler Courage. It went from running to not starting back up in the same day. I didn’t realize that the coils required 12v! I unhooked the wiring harness and tried starting it in case I had a ground or ignition issue. No wonder that it still wouldn’t start. But it did show spark on the plugs… maybe without the 12V it doesn’t have strong enough spark. I may try the conversion kit because nothing else seems wrong to be causing the no start.
It is a common failure on a a bad design
The old wiring harness was suppose to be taken off for the coils. Not wire tied down to the intake. You have to make sure the Fuel Cut off solenoid has power to it when the ignition switch is turned on..
To much for him.. cause.. it's a big piece of poopy crap.. to him..
Also known as more technology.
Best way to get gap for coil it squeeze business card works everytime
Dad has a command seems to never have any issues
Nice fix, I actually have turned away some Kohler's lately. Takes to long to fix and customers don't want to pay for the hrs. needed to do them correctly. They used to be a great engine, don't know why they let the engineers ruin the company.
Kohler parts are more expensive too
Jeff: Very true, Have you seen the price of the EFI fuel pumps that are failing? Kohler does not back up their stuff very well.
I got so pissed off at the Kohler Courage my last mower had I sold it and went and baught a BadBoy Zero Turn and made damn sure it had the Kawasaki Engine! 6 years later the Kawasaki starts 1st time every time and has never broke down 1 time. I will never buy another Kohler POS again!
some times you just have to cut the lose. Nice job
I use 2 feeler gauges to set the coils. I've never had any problems doing it that way
A tip, run a marine battery terminal and run a ground to motor, frame and harness.
You can use a business card between the coil and flywheel perfect gap
The old Kohler engines are great engines i have an 18hp in my 78 homelight Jacobson it went through 5 foot grass and did not even bog down but the pully broke off of the dech so i dont use that for mowing anymore
It is always nice to hear good stories about Kohler products
Hi. Glad I found this video. I did the same upgrade and gaped ar 10 but I’m not getting any spark at all. I doubt both coils are bad out of the box. You ever come across this? Thanks
no, I would check all safety switches, maybe disconnect the coil kill/stop/ground wires and see if that changes anything
They are called courage cause it takes a lot of courage to wrk on them!
No every engine is a simple design don't let a few electronics baffle your brain....
Actually because it takes courage to buy one. The single cylinders are wayyy worse tho......
Courage in french means shit!
Takes Courage to own one!!!
Haha!
First to take the engine cover off you don't need to remove the fan cover to change the coils.and then i think if you look at the video and look at the starter i would say if you would look at the 2 bolts that hold the starter together and tighten the two small screws that go bottom to top you could have saved you customer a good amount. With the new fan cover and the starter he or she might of been able to pay for the new coil kit.
Good tips but It was not the long bolts on the bottom of the starter, they were tight. The bushings were toast.
@@JeffsLittleEngineService I'am sorry but the bushing have nothing to do with the outside cover for the fields moving around . and the power lug moving. Please look at 6:58 min into the film.and tell me how the outside was moving around ,and the mounting bracket stayed still.
Thank you
Bob
Yes I learned what the issue was with my Courage twin... but cmon man... who the heck gaps each arm of the armature separately. Tighten screws with coil at widest... rotate till magnets cover coil... put business card in between magnet and flywheel. Loosen bolts let it snap to flywheel tighten bolts and walla perfect gap every time... rotate flywheel and pull business card out.
Hey man! I’ve got the same POS engine. Kohler SV735s. Twin OHV Courage 26hp. Except it’s on a Cub.
And my name is Jeff so I’m gonna watch this video lol
These engines are so damn finicky and sensitive. You’ll hurt it’s feelings just by looking at it wrong and it won’t start.
Biggest headache I’ve ever owned.
After cycling through endless troubleshooting options, I’m about to yank the flywheel and see if I have a sheared key or something.
I’ll try ignition coils if it’s not the key or a compression issue.
Nice to know that it’s not just me having issues on this pile of crap engine
LOL! thanks for the comment. Yes the coils are a common problem on this piece of crap.
@@JeffsLittleEngineService yet that one mightve been slightly more pile of crappy!
I only have 1 wire going to each coil.
4??? 🤷🏼♂️
That’s right just put a business card in between there and you have done that’s a wrap
Thank u very very much for the video you solved my problem yessss yesssss thanks
Happy to help
Great video...
My Toro Zero turn has a Koehler, sounds like I’m just waiting for it to go out!!
25 hp kohler command
19 years old , never had a problem.
Good to hear!
Thank you so much, ill try it
My coil burnt out so I tried the conversion coils like you showed now engine not firing
make sure to wire them correctly, no power wire should be going to the coils now. Just the ground wires/kill wires.
The part I ordered from Amazon came with two electrical prongs. Any ideas?
They call them Courage because that’s what you need to depend on one! The old Commands were tanks, though!
lol!
He obviously thinks he knows different.. sorry brian
You don't have to take cover bolt all the way out all and before you pull the screen off you pull the outside cover off in the screen pops right off
Momma always said when thing aggravate daddy, he needs some; Mr. Jeff🙌😂😂😂😂😂😂😂😂😂😂 excellent fix sir 🙌💪💪💪💪💪👍👍👍👍👍👍👍👍👍👍👍
Lol!!!!! Hi Mikey
Haha!
I'm always aggravated
19:35 I got a laugh out of his amazement that the zip ties were in the Kohler box when he was running out of his own zippies. 10:10 The same ones that were in the box when he first opened the kit !!! Also, broke the fan screen when it wasn't even necessary to remove it in the first place.....SMDH.
lol!
im having troubles getting my ride on to run it just stopped it goes with the cylinders primed by hand and funnel and ive put on a new pump so ive ordered a twin plug wire coil
wish i knew what the trouble is its all we have to mow with
and im sure it would cost a fortune for an electric rideon
my 26hp Kohler has over a 1000 hrs on it driving a 72 cutting deck....been a Awesome Machine...
totally do not Think like this guy
it is always refreshing to hear good reviews about Kohler because I think they are crap!
Just curious: Why do you think the Kohler Courage is junk? I know that the SINGLE CYLINDER ones were indeed junk- but I haven't heard much bad about the twins, except by people who don't know what they're talking about. [
That is good news. In the past, kohler made it difficult to get parts . It is getting better now. They also commonly sell parts in "kits" so they can charge you more.
I agree! My '06 Kohler has been virtually trouble free for the 13 years I have owned it. Regular oil and filter changes is all it has needed. Piece of crap? Not on your life.
change my coils out just like you did and wired it the same way, but it won't run with ground wire hooked up, you can unhook the kill wire and it will run great. What could be the problem?
That means the kill wire/ground wire to the mag/coil is grounded all of the time. It should only be grounded when the key is turned to the off position.
What did you do about the red wire going to the fuel shut off solenoid
Nothing
if you have no spark with your riding mower there is a ground lead coming fromthe key switch the M lead when you turn the key to run or start that ground should be gone thats the lead that cuts the eng off when you turn the key off make sure if you can that lead dont stay grounded by a skined wire touching the mower body this ma save going into magnito
Anyone filming 5+ minutes of removing air shroud is not the guy I want advice from...
sorryman my bad
The Short Circuit is behind the screwdriver!!!!!
Like the command engines
Replacement coils are on eBay for 13$ each.
Stainless0521 replacement coils
myself personally id cut all that extra garbage wire off it
So POS, huh, so my 14 HP Kohler that I bought in 1994 and still runs great, only issue with it is I broke the governor, so I have to control the speed with the throttle, and this exact same engine I have, 11 years old, I believe, 600 hours on it, and until I JUST had this same issue 2 weeks ago has had no issues except Starters, is a POS? Wow you didn't try to take the cover off before you broke the guard, people actually pay you to work on things?
A reputable company would have admitted to their mistake and given the customer the parts to repair their engineering nightmare. BTW......did you mention that Kohler courage engines are a piece of crap?
Business card will work for gap
Never had any problems with my Briggs 😉
You broke the snap on plastic air screen cover by not using the screwdriver properly ! You should have placed the screwdriver under the plastic cover and used slight pressure up and it releases easily . I know because I have done this twice for cleaning.
good tip
The only problems I have is once a year have to replace a fuel pump power is great
Use a business card to set the gap....work smarter not harder. Every second you waste cost money and effort. Dont over think it, its not the space shuttle
.012 is usually the correct measurement not a business card. But in a pinch that will work
Jeff, would it be easier to use 2 feeler gauges, than one? That's the way I do it, but then I have a Briggs and Stratton engine on my craftsman mower
I have a problem with one of this, when it runs it smoks a lot and runs bad, if i pinch the hose coming from the valve cover to the fuel pump after a while it runs well, does somebody had the same problem?
I'm curious why you think Kohler engines are crap? And is this all Kohlers or certain years or models. I have 3 craftsman mowers all with Kohler engines. My 20 plus year garden tractor 22hp is still running strong... my newer 8-9 year 26 hp Elite 747cc has had a few quirks. I didn't want the Briggs & Stratton models. What's your take?
Thanks😊
The Kohler Courage engine is faulty engineering with lots of problems and so are their push lawnmoer engines. Kohler often tries to reinvent the wheel with their engineering and they usually fail. Kohler also made it difficult to get parts but that issue has gotten better.
Got me a laugh when cutting that connector preventing you from finishing 😂
Well.kohler your mistake is going to cost people a lot money ☹️☹️ $100 plus labor ouch ☹️☹️ old school.coils are better great job on that fix jeff 👍👍would a business card be the same thickness as the metal.feeler gauge 🙄🙄?? Now starter motor price for the kohler one ouch ☹️☹️after market one nicw price 😃😃
I think a business card comes is 0.014 in thick.
@@jeffryblackmon4846 okay i say you have your A GAME on sir
@@robertmailhos8159 Thank you.
@@jeffryblackmon4846 you are most welcome 😃😎
Yes the bill was getting too high. When I found the broken ring gear teeth I almost declined to fix everything else. The final bill was $330.00
Where does the kill wire go is it on the key switch or where
Thanks Jeff! on the same engine I would like know how to get to the Carburetor? Like you did 1st you took the fitter out but it did not have Bolts have you got a video showing how to do this thanks brother 👍
That ring gear will break the new starter.
Just connect the white wires and run them to the spade fittings on each of the new coils, and connect the red ones, and jump them over to the carb. but I have a question. the old coils only need one wire, , , ,the white one, so just put on the new coils, and connect the multi-port-abortion that the engineers designed, putting the white female, to the male spade on the new coils. (I don't know if that would work, but I would try that before cutting anything).
sorry, I commented early in the video, before you did what you did.
Help. I replaced the ignition coils and the starter. It goes crŕrrrrrrr but wont crank.
this problem is not related to the coils
I have one that quitt running. Itll startup, smoke, and then quitt. Would that be the coils too? Thxs.
Would ignition System cause a Kohler 27 HP Courage to run for 15 minutes but then start running rough when it gets warm. Every once in a while, it will kick in and run okay for a few minutes only to do it again. Any ideas would be appreciated. Sometimes it will run rough and then backfire. Craftsman 54" Riding mower.
Similar here. Searching is telling me ignition coils get hot and hinky after a while. Not getting a tester. Just going to replace the pair at about $15 each. It's an '06 Courage that just turned 1,040 hrs. Only prob I've had was 10-gear starters were yearly replacements until getting 9-tooth and smooth sailing since. And I had dirt in the fuse holder clipped to the "firewall". Overall, it sounds like I got lucky considering the talk here.
Do you tell what after market parts companies to use in a video?
I only use Stens or Rotary aftermarket parts if possible. OEM is always best
What mower engine dosnt have a metric bolt or nut they all do ,and the Kohler 7000 series engine I have is a dam good engine I do perfer briggs but I have a craftsman 42" zero turn with a 7000 series Kohler twin 20hp it has about 700hours never had an issue with it at all ,I'm not sure where your misinformation is from but the newer Kohler engines are dam good yes I do like briggs but I've seen the newer kohlers out run briggs by far, you make it sound like every Kohler is bad but that just isnt the case it's the kohler prior to I believe 2000 I'm not sure of the exact date however after the later 2000s the kohler engines did end up getting made way better
First of all you didn 't need to take that off and then you break it...😢 and that's not how we set an air gap pull the coil all the way back..lightly tighten..use a brass feeler gauge or a piece of plastic..lay it sideways loosen coil.. moves into place automatically..😮... rotate the flywheel by hand so you know your clearance is good before you start it🎉
Good tips!
Use a business card to gap the coil. Does both sides at once!
Order the coils on eBay - 13$ each!!! not 89 for that 'kit'...
If you buy the eBay coils - DON'T CUT OFF THE HARNESS! Don't cut ANY wires.
Use the existing harness, and plug the connector WHITE part into the coil tab.
The green wires are grounded to the carbureator.
The little yellow wire of the coil plugs into the GREEN part of the connector!
good tips! Not sure i would trust a $13 coil though
@@JeffsLittleEngineService why not? And they have $11 coils at eBay item number 153356380528 but you have to use diodes so the coils don't short each other out so pick up a set of 10 1n4007 diodes on ebay for maybe $5,grab some spare wire and splice into the white wire on the harness and for under $30 you have new coils.
Can't anyone do a video starting with what happens when you try to start it or what it sounds like, etc then identify what the issue(s) might be?
I will next time
Very Good!
Thanks!
Have a Kohler 17hp. on a craftsman Lt 1000 Bought in 2000. I see the 26hp. Cranked right up. My 17hp turns over for about 10 seconds before it runs. Have to choke it. Even if it is hot. What causes this. What can I do to fix it?
My experience with warm start problems is that the carb needs cleaning and or rebuilding(needs new float needle valve). It is probably getting too much gas when restarting when warm.
Hhahahahah Your secret is safe with me!!!
Thanks, great job.
Thanks Jim
Hello hello sir will this also fit a Sv 840-0012 we love your videos
I am not sure about that. thanks for watching
i have a 1998 kohler twin 20hp on 46 in craftsman it purrs like kitten all it takes is TLC and a buchet full of new parts
Jeff...I have a question regarding my Kohler Engine I bought it used to remod a Bobcat Zero turn and the name plate is gone off of the shroud. Is there any other way to Identify those numbers
Fantastic thank you, but I h as to say I have a Kohler command for over 15 years and still going strong.. do you feel about all the Kohler engines ,? Also how about the Kawasaki engines as well as Briggs ?
Kawis aren't too bad. Some Kohlers are better than others
if you had to purchase one engine brand can you tell me which one you would pick ?
No one I ask that make mower repairs ever answer the question on which engine they would purchase if they had to choose one !
@@CHIBA280CRV no engine is good when it's time to work on it , but kawa is the better usually, vanguards are better tan intek on briggs and kohler has commands better than courage
On the gapping why didn't you just use a business card and slide it on both sides of the coil. And then turn the magnet around to the coil.
A business card is not a measuring device but will work if you do not have a measuring device
@@JeffsLittleEngineService Actually, It's a perfect "measuring device". Haven't had a single issue setting an air gap with one in well over 30 years. Takes no time at all to set the gap on both sides of the coil at one time rather than fiddle focking around with the wrong length feeler gauge and going back and forth from side to side.
What happened there at the end? Just before the video ended both the kill wires were disconnected?
Very good eye sir. There was an additional problem I encountered that I did not show in this video. The engine would start and run great but was stalling when I would set the park brake and try to get off the seat. Which is not right so I had to go back and troubleshoot one of the safety switches. One of the switches was too dirty and was short circuiting. I had to clean it is all to fix it. I did not include that part of the video beacuse of all the profanity I was using during the filming. lol!
Amazing video!!! Ordered the conversion kit and installed per your instructions without a hiccup....starts great! I do have a question...even after this conversions, my tractor is running slow and has a little black smoke coming out of the exhaust .....any suggestions? Should I take the carb off and clean it out or adjust?? Craftsman GT6000 with Koehler Courage 26hp engine. Thanks for the knowledge.
it could be the carburetor or loss of spark on one cylinder, or blown a head gasket
@@JeffsLittleEngineService it will start to idle faster and run faster with less smoke of I hold the choke halfway out. I took apart the carburetor and cleaned it all out. Is a head gasket repair major?
@@docroot462 I think the head gasket repair is about the easiest thing you can do. That is after you get everything apart out of your way.
I’m betting a head gasket
Comparing these with the smaller faulty Courage engines are plain stupid. It’s a great “Command” knock off
My opinion they aren't a bad command knock off either. There is a night day difference I feel like in a Courage twin verses the Courage Singles. My neighbor has a 2009 Craftsman bought new with the 26 hp Courage Twin likes about 7 hours turning over 700 hours and only thing they ever had a problem with was the coils. Sure now that its wore out its little tricky sometimes to start but, a valve adjustment would improve it greatly as in almost 700 hours its never had one.
It would be cause ur checking the gap on a round surface... The angle of arc takes up space