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26 HP Kohler Courage on Craftsman DGS 6500, intermittent surging

#1

G

GPB

I recently bought this tractor used and since getting it home it has surged or lost power (with a gas smell when it loses power) and then surged back to full power. It happens both when mower is engaged and not. What I've looked at so far:
-tested the solenoid under the carb and it worked well.
-removed the existing fuel and put fresh ethanol free unleaded in.
-sea foam soak in the carb (while still installed, I did not yet tear it down)
Plugs look equal and dry. I have heard the fuel cap can form a vaccum, but mine seems fine.

Today I took the solenoid off and removed the plunger, magnet and spring and reinstalled the solenoid body along with an in line fuel shutoff valve. I was thinking it was possibly working intermittently. I drove it while mowing for 45 minutes after that with no issues. Hooked up my leaf vacuum and pulled that around for another hour with no problems. This whole time the hood was still sitting in my garage, so while unloading one of the last loads of leaves, I put the hood back on. Surging returned. Took it off and it went away, almost like a switch.

Any ideas on this one? I'd like the hood on when the snow starts flying as it came with a snow blade.


#2

M

mechanic mark

Searching Model For Search Your Way 91728745 | 2 | SearsPartsDirect Check air filter for replacement.

Free Kohler Service Manual Downloads : Kohler Engines and Kohler Engine Parts Store, Genuine Kohler Engine Parts scroll down to locate SV735

Read fuel system in your manual, specifically carburetor, remove, clean, inspect per manual instructions, you may need to purchase overhaul kit.
Regarding coil or ignition module you have 2, testing procedure page 37. Purchase an inexpensive multi-meter to test, it will serve you well in years to come.


#3

G

GPB

Thanks for the reply mechanic Mark. I forgot to add that to the list of things done. That was actually the first replacement I did on this new mower (new to me anyway). In other threads I have seen some recommend new coil/ignition modules. Given this issue comes and goes, I don't know that I can really give that a good test. Any credence to looking at the coils or ideas how to assess it?

Thanks again Mark, I will try the carb this weekend and have ordered the multimeter.


#4

Fish

Fish

You need another digit in your craftsman number, just wanted to see if there was any safety switches on your attachments.


#5

Fish

Fish

Your ignition system looks to be getting into new, expensive territory........

http://www.smallenginesuppliers.com/html/engine-specs/kohler/PB-259_DSAI_MDI_IGNITION.pdf


#6

Fish

Fish

But my "kneejerk" opinion on your problem, makes me think that you have some moisture/dirty water slinking around in your fuel system. I would run some fuel dry and
mow until something serious may happen, otherwise, just burn that moisture through the system.


#7

C

cambre

GPB said:
I recently bought this tractor used and since getting it home it has surged or lost power (with a gas smell when it loses power) and then surged back to full power. It happens both when mower is engaged and not. What I've looked at so far:
-tested the solenoid under the carb and it worked well.
-removed the existing fuel and put fresh ethanol free unleaded in.
-sea foam soak in the carb (while still installed, I did not yet tear it down)
Plugs look equal and dry. I have heard the fuel cap can form a vaccum, but mine seems fine.

Today I took the solenoid off and removed the plunger, magnet and spring and reinstalled the solenoid body along with an in line fuel shutoff valve. I was thinking it was possibly working intermittently. I drove it while mowing for 45 minutes after that with no issues. Hooked up my leaf vacuum and pulled that around for another hour with no problems. This whole time the hood was still sitting in my garage, so while unloading one of the last loads of leaves, I put the hood back on. Surging returned. Took it off and it went away, almost like a switch.

Any ideas on this one? I'd like the hood on when the snow starts flying as it came with a snow blade.
Click to expand...

I have same engine as you do on my Craftsman. I don,t have an answer for your hood problem but was the hood causing your problem? I cannot get my governor adjusted the way it should be but it runs good other wise. Cambre


#8

M

mechanic mark

cambre said:
I have same engine as you do on my Craftsman. I don,t have an answer for your hood problem but was the hood causing your problem? I cannot get my governor adjusted the way it should be but it runs good other wise. Cambre
Click to expand...

cambre, page 28 in Kohler manual above #2 shows governor adjustment for SV735 engine.


#9

C

cambre

mechanic mark said:
cambre, page 28 in Kohler manual above #2 shows governor adjustment for SV735 engine.
Click to expand...

Thanks m. mark


#10

G

GPB

Fish said:
You need another digit in your craftsman number, just wanted to see if there was any safety switches on your attachments.
Click to expand...

That should be 917.287451, thanks.


#11

G

GPB

Fish said:
But my "kneejerk" opinion on your problem, makes me think that you have some moisture/dirty water slinking around in your fuel system. I would run some fuel dry and
mow until something serious may happen, otherwise, just burn that moisture through the system.
Click to expand...

I think you are correct with this being a fuel issue. I ran it near empty on fuel at the end of the week, drained the rest out and purged some fresh gas through the lines up to the carb. Then refueled and ran it for 6+ hours this weekend (with hood on), and had only one short episode of power loss right at the start. Maybe getting that first few gallons of new fuel thorugh it and/or seafoam purged the 'funk' out of the fuel system. I think I am going to put the guts back into the solenoid and keep running. Plenty of leaves/pine needles to pick up with the lawn vac pull behind attachment.

Also replaced the brake pucks so no more roller coaster rides down the hill!

Thanks all for the advice and Fish for the info on the ignition update.


#12

Fish

Fish

Yeah, those little pockets of water/moisture can haunt for quite a while. I usually add the gas dry liberally, and just mow, and hit the choke when the thing starts running "squirrelly"... After a few mowings of doing that, all of the moisture is burned through, and the mower runs good for the rest of the year.....


#13

C

cambre

Fish said:
Yeah, those little pockets of water/moisture can haunt for quite a while. I usually add the gas dry liberally, and just mow, and hit the choke when the thing starts running "squirrelly"... After a few mowings of doing that, all of the moisture is burned through, and the mower runs good for the rest of the year.....
Click to expand...

Not my thread Fish:Cambre


#14

Fish

Fish

Fish said:
But my "kneejerk" opinion on your problem, makes me think that you have some moisture/dirty water slinking around in your fuel system. I would run some fuel dry and
mow until something serious may happen, otherwise, just burn that moisture through the system.
Click to expand...

Yeah, but it was "our" thread...


#15

Fish

Fish

For better results, start your own thread. Makes more sense, and a whole lot less confusing, eh?


#16

C

cambre

Fish said:
Yeah, but it was "our" thread...
Click to expand...

OK, my mistake, sorry:Cambre


#17

Fish

Fish

No problem, This site is so huge and dozens of nooks and crannies to make posts, I find it hard to keep up with them all. Way too many different categories. and way too
much overlapping.


#18

G

GPB

Fish said:
Your ignition system looks to be getting into new, expensive territory........

http://www.smallenginesuppliers.com/html/engine-specs/kohler/PB-259_DSAI_MDI_IGNITION.pdf
Click to expand...



Well, the surging came back after a good while of working fine. Now its just low power and I see The right side has no spark. I've cleaned the leads/contacts on the ignition and nothing. Upon closer look, the sealant on the top of the failed ignition is cracked a bit. That's enough of a cause to me. Looks like I should convert to the MDI ignition at this point unless anyone has other direction.


#19

G

GPB

Well the MDI conversion kit came yesterday, installed in a few minutes and its running like a charm. Looking at the DSMI that I removed on the side that was firing intermittently, it was more cracked than it appeared and the coating material would actually flap open so quite exposed. I have the other side DSMI that is working if anyone doesn't want to convert quite yet, let me know:smile:


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