Kohler problems

[Medic Man]

Hey guys, another question that may have an easy answer (or not):

My Kohler (on a DC) turns over but won't fire up. Took the plugs out, doesn't look like they are firing. I used the machine for four hours straight yesterday, no problems. My question, how can I troubleshoot this? Is there another safety switch besides the seat that I can bypass to see if that's the problem? It was doing this the other day but I had a leaking fuel bushing, fixed that and it started. Now I don't know what I did.

I looked at the service manual that someone had posted, but I don't think I was looking at the right thing. I'd just like to be able to check before I take it to the shop in case it's something small.


Thanks

[Guzman Properties]

what type of machine is it? Check to see if it has a parking brake safety switch, and neutral switches on the handles (if it's a ztr). Check if the blade switch is on as well. Check for spark from the wires, it could be the coils.

[Medic Man]

It will start (not right now) with the PTO enaged, park brake off, etc. I don't know how to check the coils, but i would think it odd that both would go bad exactly the same time?. I don't have fire to either plug.

[Medic Man]

Sorry, I forgot to say the model # - CV745 on a 2003 Dixie Chopper XT3000. I'm hoping something is just grounding out but I don't know what to check.

[Restrorob]

Medic Man,

Unplug the seat switch relay and just leave the plug dangling then check for spark again, This will eliminate the seat switch. If still no spark unplug the unit harness back at the engine. Remove the white wire (coil kill lead) from the connector then plug the connector back into the engine and check for spark again, This will eliminate a bad ignition switch.

If you still have no spark with the white wire disconnected the wire could be shorted under the flywheel cover or both coils took a dump.

Your unit only has a seat switch no others that's why you can start it with the blades on or joysticks pulled together.


Good Luck

[Medic Man]

Thanks for the input. Now about that unit harness...I don't know what that is. That's where I had problems with the service manual. I haven't found a white wire....sorry I sound helpless. Is there a post or site that might show that harness?

[White Gardens]

Dixie Chopper uses a fuse for the ignition system, it should be in line somewhere near the wiring harness near the motor. The harness connects the iginition switch to the motor. Check that first. Tell me how that goes.

If you disconect the seat switch, you must use a jumper to complete the circut. I use a short piece of wire pushed into the plug for the seat switch.

Check the tipover saftey switch too. It's the little bullet shaped item on the side of the engine near the wiring harness. This is a mercury switch that is clamped onto the engine cover, if it is turned or malfuctioning, you won't get any spark.

[White Gardens]

Also, how was it stored over the winter. I've seen mice get around the coils and chew the wires. Once they ground out you won't get any spark.

Dixie uses a safety switch that must have a circut, unlike a lot of other mowers where you can just disconect it. It was a warranty thing, they didn't want their customers just disconecting it.

There shouldn't be any saftey switch for the PTO, which is a manual lever, the steering bars, or even the parking brake.

[Restrorob]

Dixie Chopper uses a fuse for the ignition system


Not for the ignition system but in-line to the ignition switch for starting.


If you disconect the seat switch, you must use a jumper to complete the circut


Not if the relay is un-plugged as I mentioned.


Check the tipover saftey switch too


This unit does not have one.


http://i107.photobucket.com/albums/m314/Restrorob/Dixie%20Chopper/DixieChopperXT3000WireDiagram.jpg



Good Luck

[Sharpcut 1]

Rob,
XT3000 will have a tip over switch. Remember, this must be a repower as this machine originally had a Generac:cry:

[White Gardens]

Restrorob,

Your right about the fuse, I thought about it last night.

Dixie did put a mercury switch for the Kohler, It's not on a Kohler diagram, or a Generac diagram as Dixie had done it themselves.

I don't know what you mean by unplugging the relay. I always used a jumper when I disconnected it from the seat in order to get it started.

Sharpcut- Dixie did put the mercury switch on the Kohler. Some models did come from the factory with the Kohler engine, but they primarily used the Generac. I asked them about that, and they said that there were too many customers out there that were accustomed to the Kohler, so Dixie never completly dropped them.

[Restrorob]

Rob,
XT3000 will have a tip over switch.


Not ALL units have the tip switch and this XT3000 did come with a Kohler.




Dixie did put a mercury switch for the Kohler, It's not on a Kohler diagram, or a Generac diagram as Dixie had done it themselves.



The diagram I posted is not from Kohler or Generac but from Dixie's Dealer Only website under the model number posted, Yes I'm a Dixie Dealer/Service Tech.


I don't know what you mean by unplugging the relay. I always used a jumper when I disconnected it from the seat in order to get it started.



That's fine as well. But, You see....The only function the relay has is to operate the seat switch, Unplugging the seat switch and installing a jumper will keep the relay activated all the time. If the unit is left with the seat switch wires jumped for a couple days you will find a dead battery when returning to start it up.

Unplugging the relay bypasses the seat switch and stops the battery drain. Now which is easier, Unplug one connector or two connectors and installing a jumper ?

[greenscapestx]

The kohler on my dixie has oil sentry protection (i think that's what it's called), which I believe is a switch that will ground out the ignition if the engine is low on oil. Maybe that switch went bad, or the unit is low on oil.

[White Gardens]

Not ALL units have the tip switch and this XT3000 did come with a Kohler.





The diagram I posted is not from Kohler or Generac but from Dixie's Dealer Only website under the model number posted, Yes I'm a Dixie Dealer/Service Tech.





That's fine as well. But, You see....The only function the relay has is to operate the seat switch, Unplugging the seat switch and installing a jumper will keep the relay activated all the time. If the unit is left with the seat switch wires jumped for a couple days you will find a dead battery when returning to start it up.

Unplugging the relay bypasses the seat switch and stops the battery drain. Now which is easier, Unplug one connector or two connectors and installing a jumper ?

Thanks for the info, I did look at the diagram better and seen what your talking about. I just can't figure why there isn't a mercury switch on that mower. When I used to work on them, they all had that switch.

[Medic Man]

Thanks to all, still can't figure it out. I wondered about that oil sentry, but has plenty oil. I'll take it to the dealer and let the pros do their thing. THe labor charge is probably cheaper in the long run than anything I might mess up trying to fix myself.

[Sharpcut 1]

Whenyou say you had leaking fuel bushing, do you mean on tank?? Take plugs out and have them touch metal and crank over mower. See if you got nice blue spark, If you do, reinstall, take off air cleaner, shoot a little gas down carb throat (or carb cleaner, NOT starting fluid) and see if she fires. Then you will know if it's spark or fuel. Your assiming it's spark without really telling us if it is.