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  1. #11
    New Member
    Join Date
    Jul 2009
    Posts
    11
    Location
    Big Island, Hawaii
    Tractor
    n/a

    Default Re: Kohler Courage MYSTERY?

    Same problem here. Starter on a Courage 27 has been gradually getting weaker and weaker and now can't turn over engine to get it started. I pulled the starter; brushes look ok and spins great with no load on it. It just doesn't spin strong enough to turn over the engine. Maybe time for a new starter? Is there a relay that could be going bad?

  2. #12
    Platinum Member
    Join Date
    Mar 2008
    Posts
    670

    Default Re: Kohler Courage MYSTERY?

    Pull battery. Take to qualified shop that can perform a LOAD test. Today's small L&G batts are somewhat notorious for marginal life and for one or more cells going south. 3 yrs of service is typical - shorter depending on how machine is stored/maintained.

    M/W, disassemble and using sandpaper, clean every electrical connection mating surface in the start circuit to bright metal (don't just give it a quick visual - some corrosion can be colorless). Make sure you include batt ground wire to frame connection, starter solenoid to frame mounting. Re-asm all connections tightly. Also chk for corrosion buildup in copper wire strands back up under insulation of batt cables. Put new/good batt back in machine (watch for - to ground, + to harness.... some new batteries have post positions reversed).

    if still poor/no starter rotation, bypass ign switch and start solenoid by jumpering directly to starter post and chassis ground with jumper cables. If improvement is seen, replace solenoid first.

    If you have been using the garden hose or a pressure washer to wash/clean machine, lose 'em. L&G tractors are not designed/built to withstand soakings.
    Got yer manual ?

  3. #13
    Super Star Member J_J's Avatar
    Join Date
    Sep 2003
    Posts
    17,139
    Location
    JACKSONVILLE, FL
    Tractor
    Power-Trac 1445, KUBOTA B-9200HST

    Default Re: Kohler Courage MYSTERY?

    Turn ign on.

    Jump directly to starter bypassing all relays..
    J.J.

    When I works, I works hard. When I sits and thinks, I goes to sleep.

    Git er done.

  4. #14
    Super Star Member toppop52's Avatar
    Join Date
    Oct 2011
    Posts
    11,048
    Location
    Eastern Shore of Maryland
    Tractor
    Massey Ferguson 1855

    Default Re: Kohler Courage MYSTERY?

    Sounds to me like the valves are out of adjustment and not allowing compression release, I've seen this often on small ohv engines in particular.
    Randy
    Southern boy and proud to tell it! Live and let live...

  5. #15
    New Member
    Join Date
    Jul 2012
    Posts
    1
    Location
    Freeland, Md
    Tractor
    Kubota B7510

    Default Re: Kohler Courage MYSTERY?

    Same thing happened to my Cub Cadet Lt1045. Pulled the OHV cover off and walah! Found the one lifter nut had worked it's way loose. Retightened and on my way.!!!!!

  6. #16
    New Member
    Join Date
    Nov 2012
    Posts
    1
    Location
    joshua,tx
    Tractor
    troy bilt

    Default Re: Kohler Courage MYSTERY?

    I have the exact same issue. Was under two years old when it first occured. Engine would spin till it hit compression stroke than...eke...eke...eke...spin. At first it would do it a few times then suddenly spin normal speed and start. Got worst and worst so i took it to the local authorized Kholer dealer and he said there was water in the starter and rebuild it. No a warrantee repair because of measurements he took????no real explanation of voltage or current or what. Just out of range per the Kholer spec's. Anyway, Upon reinstalling it it did the exact same thing, not quite as bad. I can bypass the system and jump off a car to the starter but not that makes no difference. I think its the compression release. I think they use an undersize starter and take advantage of the lower torque needed with the compression release. As I recall it is open until the engine reachs 750 RPM(i think that is what I read). It is a small lever on the camshift that increases the clearence on the exhaust valve. Once the engine starts and gains speed it rotates out of the way so the valve operated normally. I think it sticks!

  7. #17
    Platinum Member Zork's Avatar
    Join Date
    Dec 2003
    Posts
    732
    Location
    Virginia
    Tractor
    '04 Branson 3520, '51 Fergy, '96 MTD 18/46, '02 Craftsman GT5000/48

    Default Re: Kohler Courage MYSTERY?

    I fixed one of these this past weekend. The Flywheel was about 95 degrees out of timing. The owner said it was always hard to start when the temperature dropped, shortly after purchasing, and finally quit when it backfired on shutdown.
    I replaced the key and adjusted the valves and cleaned the shmoots out of the carb and she ran better than new, so the owner says.
    He who is full loathes honey, but to the hungry even what is bitter tastes sweet.

  8. #18
    Platinum Member
    Join Date
    Mar 2008
    Posts
    670

    Default Re: Kohler Courage MYSTERY?

    Zork - to what specs/procedure did you you adjust the valves?
    Got yer manual ?

  9. #19
    Platinum Member Zork's Avatar
    Join Date
    Dec 2003
    Posts
    732
    Location
    Virginia
    Tractor
    '04 Branson 3520, '51 Fergy, '96 MTD 18/46, '02 Craftsman GT5000/48

    Default Re: Kohler Courage MYSTERY?

    Quote Originally Posted by rcbe View Post
    Zork - to what specs/procedure did you you adjust the valves?
    I don't exactly remember, SV590 19HP? Intake .005 in/ Exh .007 in, it wasn't much. Anyway you can get both manuals (owners and service) for free here on the Kohler site:

    Kohler Engines: Home
    He who is full loathes honey, but to the hungry even what is bitter tastes sweet.

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