Kohler Courage, leaking oil

[arch252]

I agree that the engine is toast, getting the block machined would not be worth the cost. I'm hoping to find another engine, preferably a Kohler Command that I can just replace it with. As for the bearing thing, I think a "thrust bearing" is what I think of as a traditional bearing with some type of rollers, I don't consider one piece of metal sitting on top of another piece of metal a bearing just because it is moveable, but that's why I'm no expert. As for a thrust bearing in that Kohler Courage engine, I'd really have to argue that there is not one, at least not one associated with the crankshaft anyway. Again though, I'm just a guy who owns a set of wrenches.

Well, the part I was worried most about, the crankshaft and counterweight, are in excellent condition. I guess I'll take that engine completely apart and Ebay it, maybe absorb some of the cost of a replacement engine. Hoepfully the Command engine will be a suitable replacement and will swap out easily on that mower.

 

[reynoldston]

The odds of finding a shop that would want to tackle that job would be about the same as me being able to baptize a cat with bare hands.

If we could find one to take the job we no doubt wouldn't like the cost . Give it up and sell the aluminum, it's trashed.

I agree with the cost and trashing the old block, but I don't agree with the shortage of any machine shops. I have never had any problem having any machine work done, but don't be in a hurry.

 

[arch252]

Re: Kohler Courage, leaking oil UPDATE: Kudos to Kohler

I contacted Kohler directly about the engine by email. I was really hoping to sound sad enough to get a decent price on a short block. They were quick to get back to me by email and they were quick to address the problem. I had a service tech contact me directly and he seemed to have the right level of authority to approve the service I needed, which was nice, not a bunch of runaround. They did not come out and directly admit that there are flaws with the design of the Courage engine, but it was apparent that I was not the first person with this problem. He had me send some pictures of the block, bearing and camshaft. Even though the engine was well out of warranty, they agreed to replace the short block free of charge. The work had to be done by a certified mechanic but they let me pick the repair center of my choice. I was responsible for the shipping and labor. When I paid the bill I discovered that they had not even charged for the shipping. The short block came with a new carb also. Labor cost me a little over $200 but all in all I couldn't be happier. Way to go Kohler, way to stand behind your equipment. The service tech who helped me was top notch. Still not crazy about the Courage engine, and I doubt I'll buy another piece of equipment with that engine, but I definitely think highly of the Command and others.

 

[bertsmobile1]

As I said earlier just why can't a machine shop bore the case and install a bushing. Also look on E-Bay for a good used engine case. Not worth spending too much money on that engine because you can buy a new one for around 600 dollars.

It is a lot bigger job than it looks.
Both the top & bottom cases will require fitting a sleeve bush then reaming out to size.
Briggs make bushes, Kohler don't so they will have to be custom made.
The crank will most likely need a touch up as well.
About 30 to 45 minutes of machining and 4+ hours of setting up.
An hour to remove the engine
an hour to replace the engine
another 1 to 2 hours to strip clean & reassemble the engine
+ parts

It is an uneconomic repair

A 1/2 honest workshop would do a replacement engine for 2 hours lablor & offer a discount for retaining the old engine which is either kept for parts or dragged out mid winter as a loss limiter for the boys to do when they have nothing else happening.

I have two lathes, two mills & shaper but I would not even think of attempting the job on a Courage.

OTOH if you know a backyard, hobby - semi commercial machinist they they will most likely take on the job, just like you, to see if they can do it and charge a fraction of the actual commercial cost.