26 hp Kohler Pro Courage

wirespider

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First off, Hi to Everyone...

I have a couple year old Craftsman with a 26 hp Kohler Pro Courage. Last year I let my son, who's now old enough take over the lawn mowing, cut our yards. Even though I changed plugs, oil, filter and blades with him toward the end of mowing season last year to show how to maintenance it, I somehow forgot to tell him about draining the gas and a few other things before he put it away for the winter. Completely my fault as hes just being taught these things.

Well, he told me he wanted to start mowing so he got the tractor out of where we store it and started it. I was in the house but I could here the mower looping (surging) after he had it warmed up. Went out and stopped him and realized what a dumb ***** I was.

I drained all the gas, put fresh in with some antifreeze (for moisture) some good carb injection cleaner and still it surged. Now its only really bad (Idle go's low then high) at mid and low idle. I can hear it some on high idle but as soon as you engage the deck and the governor kicks it up another notch it clears out, so it mows great.

Last night I tore it down to the carb. I cleaned out the top jet, took off the top and sprayed it out good with carb cleaner and unscrewed the solenoid and let the bowl drain. I sprayed carb cleaner it the choke opening and let it drain out the bowl. I fired it up and it still surges.

I tried while it was running two different brands of carburetor cleaner in the carb but two half used cans of carb cleaner later still no luck.

Any ideas? Could the bowl or jets and ports be varnished so bad all that cleaner wouldn't get it? Could it be the float sticking? Any ideas would be GREATLY appreciated as I'm also aware of the fact that maybe something else like a coil could've went bad over the winter?

Oh, I pulled the plugs, they still look almost new. Was going to check the voltage but it would fluctuate with the idle.

Thanks ahead of time.

Wade, in PA...
 

ILENGINE

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From a dealer standpoint welcome to the world of emissions carb. The biggest nightmare for engine repair. Some of the new carbs have passages that are so small and have restricted access that they are not cleanable in some cases. Any ethanol/water sitting in the carb will corrode these passages to the point that the carb is unservicable and may need to be replaced to repair the engine.
 

wirespider

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Thanks for the heads up. I think your right, it looks like it does have on of those carbs made in Japan. I've owned 4 wheelers with those carbs and always had problems with them. Kind of reminds me of the ones that sit on the early 2000's Yamaha Wolverines. More than likely all those Yamaha warriors had them too...Guess I'll need to tear it down and take a good look... Do you know where I can get rebuild kit if I can salvage it?
 

Rivets

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If you have a small engine repair you can trust I would take the carb to them and have them dip it and then rebuild it. May be cheaper than buying a new carb.
 

wirespider

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Ya that would definitely be cheaper. If it has the carb on it I think it does the price is going to be about 300 for a new one...

So are you guys in agreeance that you think its definitely the carb? Do these have any kind of CDI module's?
 

Rivets

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The CDI module is built into the coil. From your original post I feel that it is definitely the carb.
 

wirespider

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The CDI module is built into the coil. From your original post I feel that it is definitely the carb.

Thats what it was Rivets...On advise from KennV an ILENGINE I tore it apart and used carb cleaner and air...Runs great now...Thanks for responding... :smile:
 
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