• Replacing starter on kohler engine

    Replacing starter on kohler engine

    Click here to learn more. Log in or Sign up. Sign up now! Read the timely article from Turf addressing this question. Kohler starter motor problem Discussion in ' Mechanic and Repair ' started by peterdeeAug 25, Messages: Suddenly refused to start, starter not engaging with the fly wheel.

    Checked wiring, A OK, fitted slave solenoid. Starter now runs fine but still does not engage with fly wheel. There was a thread on here in about this problem with the Kohler starter, and Kohler's refusal to recognise the fact, apart from publishing an alternate wiring diagram to prevent the starter motor running on.

    What was not discussed was a solution to the situation. Is there a solution? I'm thinking of touching up the teeth on the starter dog; doing the same to the fly wheel, machining the fly wheel and rotating it??

    But they don't seem badly damaged. With this starter motor doing what it is supposed to do, apart from engaging, I can't see any benefit in fitting a new starter. Any thoughts from you guys out there would be appreciated. Messages: 11, Can you perform a test? Put a multimeter black lead to ground and red lead on the small solenoid activation wire, Turn the key and post the voltage on this wire while trying to crank RestrorobAug 25, At rest battery gives John Deere for one of a couple other equipment makers had starter engagement problems, They came out with a starter relay kit that solved the issue.

    Why Kohler?

    You can install a relay which would give the solenoid full battery voltage You can pick up a 30 amp relay at any auto parts store and wire as below and see if that solves your issue, I've done it on a few machines Mount the relay to the frame near the starter RestrorobAug 30, I will try that.

    Let you know. But what is the problem with existing set up?

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    Is there some resistance somewhere? I've put in a slave relay, which is essentially the same thing as a relay. The wiring is the same. That has not cured the problem. I wonder if the resistance lies in the braided wire between the starter solenoid and the motor?

    replacing starter on kohler engine

    I need the full engine model AND spec numbers to go any further at this point RestrorobAug 31, When you turn the ignition key to the start position, the starter solenoid sends current to the starter.

    With the insulating cover positioned on the cable, reconnect the positive battery cable to the positive battery terminal. If the engine is hard to start or if the spark plug electrode is burnt or cracked, take 15 minutes to replace it. If the engine of your lawn tractor surges or is hard to start, the carburetor could be the problem.

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    Follow these steps to install a new one. Use the advice and tips in these articles and videos to get the most out of your riding mower or lawn tractor. March 1, Quick links. Replacing a starter solenoid on a riding lawn mower. This video explains how to replace the starter solenoid on a riding lawn mower. Remove the battery. Wear work gloves to protect your hands.

    Turn the ignition switch off and remove the key. Lift the seat. Remove the bolt connecting the negative cable to the battery. Lift the insulating cover and remove the bolt connecting the positive cable to the battery. Lift the battery out of the battery box. Remove the battery box.

    Release the seat switch wire harness clip from the seat bracket to create slack in the harness. Release retaining tabs and lift the battery box out of the mower body. Set the box on the fender. Remove the starter solenoid.

    Note the location of wires connected to the starter solenoid. Remove the mounting nuts from the terminal posts and pull the wires from the posts. Pull the wires from the coil spades. Remove the starter solenoid mounting bolt from the mower frame. Rotate the starter solenoid forward and pull it out of the mower. Tip: Take a photo of the connections to help you reconnect them correctly. Install the new starter solenoid.

    Transfer the mounting clip from the old starter solenoid to the new one. Position the new starter solenoid on the frame and install the mounting bolt.

    Connect the wires to the coil spades. Install the wires on the terminal posts, connecting them with the mounting nuts. Reinstall the battery box. Position the battery box in the opening and align the wire harness and battery cables. Lower the battery box into the mower body and engage the retaining tabs. Reconnect the seat switch wire harness clip to the seat bracket. Reinstall the battery.Since Tracy Underwood has been fulfilling a lifelong dream of writing professionally. He has written articles for Possumliving.

    He received an Electronic Technician certificate from the U. The Kohler Command 20 horsepower V-twin engine is relatively simple to wire to your existing garden tractor or other equipment. The only wiring the engine really requires to run is 12 volts to the ignition system, which also energizes a fuel cut-off solenoid.

    If the equipment is more than five years old, it would be a good idea to replace the switches and other electrical components at the same time that you install the new engine. This will reduce the likelihood of electrical problems. Connect a battery cable from the positive terminal of the battery to one of the studs on the starter relay.

    Connect the other battery cable from the other stud on the starter relay to the stud on the starter, which is on the engine. Connect a fused gauge wire from the positive terminal of the battery to the "Bat" terminal on the ignition switch. Connect the red ignition and violet regulator wires from the engine to the "Ign" terminal of the ignition switch.

    Connect the white kill wire from the engine to the "Off" terminal of the ignition switch. Connect an gauge wire from the "St" terminal of the ignition switch to the small terminal of the starter relay.

    Connect the ground cable from the negative side of the battery to one of the mounting bolts on the base of the engine. Pin Share Tweet Share Email. Things You'll Need volt starting battery 6-gauge battery ground cable 2 battery starter cables, 6 gauge starter relay Ignition switch amp fused gauge insulated wire gauge insulated wire Wiring tool and terminal set Wrench set Screwdriver set.

    Step 1. Step 2. Step 3. Step 4. Step 5.

    replacing starter on kohler engine

    Step 6. Warning Do not connect the ground cable to the battery until you have checked your wiring. Show Comments.Part Number: S. Part Number: 24 S. Part Number: MS. Part Number: 25 S. Part Number: 52 S. Part Number: 12 S. Part Number: XS. Part Number: S1. Part Number: 32 S. This video will help you replace the spark plug on a small engine which will help get your gas powered equipment up and running again. This video explains the steps necessary to repair a small gas engine's recoil starter.

    A broken recoil starter can prevent you from starting the equipment you need, but with a quick and easy repair, This repair video will instruct you how to repair a dirty or damaged spark arrestor on your small engine. Shopping Cart. Submit Search. Sign in Sign in with Password.

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    Cart Shopping Cart 0 item s in your cart. Restore a saved shopping cart. We're open and continuing to ship packages. Continue Shopping Proceed to Checkout. Find Part by Symptom. Won't start Leaks gas Leaks oil Hard to start Engine lacks power Engine RPM's surge up and down Only runs with the choke on Starts, runs for a while, then dies Starts but immediately dies Blows black smoke from exhaust Runs for a while then dies Engine misfires Engine will idle but dies at full thro.

    Search within model. Page A. Screw, Flg M6x1.

    replacing starter on kohler engine

    Page B. Screw, Hvy Flg M5x.Most large Kohler engines on riding lawn mowers use an electric starting system. Part of that system is a starter solenoid. The cylindrical solenoid is a low-amperage relay that safely completes the high-amperage electrical connection between the battery and starter motor when the ignition key is turned.

    A bad solenoid can deny electricity to the starter motor and prevent engine startup. But other basic problems may also exist. Check the charge level of the mower battery by touching the red lead of your voltmeter to the positive post of the battery and the black lead to the negative post.

    If the meter reads less than Check all electrical connections between the battery, solenoid and starter motor to see if they are tight and free of corrosion. The starter motor is a vertical metal cylinder about 6 inches long mounted on the side of the engine. Attached to the solenoid are two thick red wires, one from the battery and the other to the starter motor. You also may see a separate small grounding wire. Clean any visibly corroded connections in the starter system.

    First, disconnect the battery. Undo the corroded connection with the appropriate wrench or screwdriver. Remove corrosion from the connecting pieces by sanding them with medium-grit sandpaper until they are bright, then reconnect them.

    Tighten any loose connections. Check that the gearshift is in neutral, the mower deck is disengaged and the parking brake is set. Reconnect the battery and try to start the engine again.

    Test the solenoid if the engine still fails to turn over. Look for the large terminal posts on the solenoid where the thick red wires connect to the solenoid. Touch the metal shaft of a screwdriver to both of the large terminals at the same time.

    If the engine turns over and starts, the solenoid is bad and should be replaced. If the starter motor does not run, the motor itself is probably defective. On some solenoids, the large terminals are on opposite sides of the solenoid.

    In such a case, use a jumper cable to connect the two large terminals. Some Kohler engine models use a type of starter where the solenoid and starter motor are an integrated unit and cannot be separately replaced.

    Herb Kirchhoff has more than three decades of hands-on experience as an avid garden hobbyist and home handyman. Since retiring from the news business inKirchhoff takes care of a acre rural Michigan lakefront property and applies his experience to his vegetable and flower gardens and home repair and renovation projects.

    Skip to main content. Tip Some Kohler engine models use a type of starter where the solenoid and starter motor are an integrated unit and cannot be separately replaced.

    replacing starter on kohler engine

    About the Author Herb Kirchhoff has more than three decades of hands-on experience as an avid garden hobbyist and home handyman. Kirchhoff, Herb. Home Guides SF Gate. Note: Depending on which text editor you're pasting into, you might have to add the italics to the site name. Customer Service Newsroom Contacts.Click here to learn more.

    Discussion in ' Mechanic and Repair ' started by CleveJun 13, Log in or Sign up.

    Kohler Engines Starters

    Sign up now! Read the timely article from Turf addressing this question. Male, from Rockmart, GA.

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    Messages: I have a Kohler Courage 20 HP with a odd starter problem. By the way the battery is new.

    How to Remove the Starter Gear From a Kohler Mower Engine

    Today it started just fine to mow but when I shut it off and after a few minutes I tried to start it, it sounded like it was trying to engage with the flywheel but just couldn't. If you held the key in it just "chattered". After a few more tries it finally connected and started fine. Does this sound like a failing starter or failing bendix?

    Mower only has a couple hundred hours so I just can't imagine the starter is failing. Thanks in advance. CleveJun 13, Messages: 2, Could the chatter be from the solenoid? If it is determined that you need a starter, these folks have great products and great prices. We use them for our Kohler starters with no issues. Sounds like an electrical connection issue, corroded or loose connection in the starter electrical circuit.

    It can energize the circuit but can't flow enough current to keep bendix engaged. Check, clean and tighten ALL of the connections in the starter circuit including the battery terminals and chassis ground. If it still happens it may be in the solenoid itself so you may need to replace it. The carbon disc in the solenoid arcs and burns and loses contact Always do the cheap, easy and free stuff first - no point in replacing a starter and having the same problem.

    HOW-TO Replace A Lawn Tractor Starter

    WGBJun 13, Many thanks for the notes. So far all the connections seem to be tight. Ericg, thanks for the link to the service manual and supplier. Yes, they do seem to have good prices too.You can identify your engine by the nameplate on the top of the engine cover.

    The starter gear, or starter motor, needs replacing when it will not spin the pulley fast enough to start the engine. You can replace the starter gear yourself at a fraction of the cost that a lawn mower repair shop would charge you. Park your Kohler riding mower on a flat, hard surface, such as a driveway or sidewalk. Turn the lawn mower off, remove the ignition key and engage the parking brake. Open the hood and allow the mower to cool completely. Remove the black, rubber spark plug boot on the side of the engine, or both boots on each side of the engine, if your model has two.

    Turn the wing nut on the black battery cable counterclockwise and remove it. Remove the battery cable from the battery.

    Remove the red battery cable in the same manner. Grasp the starter's bottom nut that holds the red battery cable onto it with a pair of pliers. Turn the nut counterclockwise to loosen it and remove it.

    Pull the red battery cable off the starter. Pull the starter solenoid wire off the starter. It is a small wire that connects to the starter top. Remove the bolts that secure the oil dipstick tube to the engine with an adjustable wrench.

    Rotate the tube away from the starter. Hold the starter with one hand at the bottom and remove the top two bolts that mount it to the engine with an adjustable wrench. Pull the old starter straight out from the engine. Align the boltholes on a new starter and replace the top two bolts with an adjustable wrench.

    Turn the dipstick tube back into position and fasten the bolts with an adjustable wrench in a clockwise direction. Plug the starter solenoid wire firmly onto the new starter. Replace the red battery cable and turn the nut clockwise to secure it to the starter. Replace the opposite end of the red battery cable onto the battery and fasten the wing nut clockwise.

    Replace the black battery cable in the same manner. Push the spark plug boot, or boots, firmly onto the spark plugs. Mary Lougee has been writing for over 10 years. She holds a Bachelor's Degree with a major in Management and a double minor in accounting and computer science.

    She loves writing about careers for busy families as well as family oriented planning, meals and activities for all ages. Skip to main content. Tips The Kohler Courage engine is available in a single cylinder style with one spark plug and the twin-cylinder style with two spark plugs.

    Check your battery and spark plug to rule out these starting problems that would not allow a good starter to work properly.


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