Kohler engine troubleshooting guide

KOHLER ENGINE TROUBLESHOOTING
Engine Will Not Crank
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Battery lead connections loose
Battery charge low or discharged
Battery amperage too low
Starting leads reversed
Fuse in wiring harness blown
Key switch wired wrong
Safety switch malfunctioning
Wiring harness wired wrong
Wiring harness incorrect
Starting cable connectors loose
Connectors corroded or worn
Starter/solenoid malfunctioning
Electric clutch air gap wrong
Drive pulley against engine power take-off (PTO) face
Drive belt wedged between idler pulley
Drive belt wedged between belt guide
Drive belt tension adjusted too tight
Starting torque too high for starter
Automatic compression release inoperative
Combustion chamber flooded with oil/gas
No oil in crankcase causing seized rod
Drive shaft coupling forcing engine shaft against internal thrust face eliminating crankshaft end play
Transmission brakes too tight
Cranks - Will Not Start
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Fuel tank empty
Fuel hose kinked, pinched
Fuel filter clogged
Fuel valve shut off
Fuel solenoid inoperative
LPG regulator not opening
Water in fuel, stale fuel
Wrong type fuel (diesel)
Throttle control in stop position
Choke not fully closed
Choke on, flooding hot engine
Power take-off (PTO) clutch on
Safety interlocks inoperative
Spark plug wire disconnected
Spark plug improperly gapped
Wrong type of spark plug
Wiring harness not connected
Wiring broken, loose or wrong
Transmission not in neutral
Electrical clutch not adjusted
Cranking speed too slow to start
Spark plug loose
Low or no compression
KOHLER ENGINE TROUBLESHOOTING
Runs Rough on Low & Will Not Accelerate
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Spark plug gap incorrect
Engine not properly warmed up
Running out of fuel
Low idle set too low (below 1000 RPM)
Low idle fuel setting too lean
Electric clutch dragging
Parasitic load on power take-off (PTO) shafts
Crankshaft end play zeroed by drive
Backfires on Full Throttle
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Water-contaminated fuel
Low on fuel
Fuel mixture too rich or too lean
Carburetor fuel solenoid shorting
Throttle or choke improperly set
Dirty carburetor needs cleaning
Kill switch contacting intermittently
Key switch malfunctioning
Safety interlock(s) malfunctioning
Faulty fuse in unit control box
Leaking, worn valves in engine
Electrical System Problems
Charges and Gradually Discharges
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Improper ground causing battery to lose charge when accessories activated
Faulty battery will not hold charge
Will Not Charge
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Rectifier-regulator failed
Rectifier-regulator not grounded
Flywheel magnet not charged
Fuse blown or circuit breaker open
Blowing Fuses
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Rectifier-regulator burned out
Leads pinched causing shorting
Alternator stator shorted
Electric Clutch Will Not Engage
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Wrong rectifier-regulator used
Wiring wrong or not grounded
Engine Runs on When Switched Off
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Ignition grounding terminal or ground lead not connected at ignition module
Faulty switch
KOHLER ENGINE TROUBLESHOOTING
Engine Not Running (After Hot Test)
Smoke rises out of top of horizontal-shaft engine or flywheel screen on vertical-shaft engine.
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Paint or oil burn off
Battery cables reversed causing charging stator to short out
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Running out of fuel
Defective rectifier-regulator causing charging stator to short out
Electric clutch - no running clearance
Back to top
Stops on High Idle
Running out of oil in crankcase
Carburetor solenoid malfunctioning
Key switch malfunctioning
Safety interlocks malfunctioning
Spark plug lead loose
Fuse blown in control box
Carburetor out of adjustment
LPG regulator malfunctioning
Loss of vacuum to LPG regulator
Tight drive belt causing crankshaft bearing to seize
Hot - Will Not Restart
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Overheated - clogged cooling fins
Overheated - blocked shrouding
Closed choke flooding engine
Throttle not in midway position
Throttle left in stop position
Carburetor solenoid malfunctioning
Fouled spark plug
Kill lead shorting out
Ran out of fuel
Lost compression
LPG regulator not functioning
Vacuum too low to open LPG regulator
Cannot Reach High Idle RPM (No Load)
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Choke not completely opened
Throttle control cable clip loose
Throttle control improperly installed
Fuel filter or line clogged
Fuel inlet line too small
Fuel running low
Fuel tank too far from engine
Fuel pump malfunctioning
Gravity feed tank below carburetor
Foreign material in carburetor
Carburetor out of adjustment
Spark plug gapped wrong causing intermittent firing
Drive system binding
KOHLER ENGINE TROUBLESHOOTING
Starting Hints - Command Retractable Start Engine
Dual Control Cable Instructions
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Close choke
Set throttle to full
Pull starter rope to set engine on compression
Return starter rope, then give a full, steady pull
When engine starts, return choke to full open immediately
Position throttle control to desired setting
Single Control Cable Instructions
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Move throttle/choke lever to choke position
Pull starter rope to set engine on compression
Return starter rope, then give a full, steady pull
When engine starts, move the control lever to the desired setting
If troubles persist after checking all possible causes listed in the foregoing categories or you are unable to detect the
cause, call the Kohler Co. (920-457-4441) and ask for Engine Customer Service.
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