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Old 04-25-2012, 09:13 AM
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JimQ JimQ is offline
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Location: Beatrice, NE
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Kohler Command 22hp Hard Start

OK Guys. Looking for some thoughts from you more experenced techs.

I've got one that's giving me trouble.

It's an older eXmark 3 wheel Turf Ranger. 22hp Kohler Command.

The engine tag is so weather faded I can't come up with any numbers.

1300 hours, Hard start...

Got her going with a snort of starting fluid. Seemed to run fine but then lost spark on one cylinder. I changed out the ignition system the the DSAI stuff and fresh plugs.

Still hard start...

Engine will not start unless the choke is on even when hot.
Once its running, it seems OK. OK power. No miss.

Removed, disassembled, cleaned carb.

Still hard start. When I say hard start, I mean it will crank for 30 -45 seconds with the choke on. Start firing slowly around 45seconds then slowly take off.

Leak down test showed about 15% leakage, most through intake valves.

Removed the flywheel bolt to check the key, it looks OK.

Am I missing something here? Seems like the leakage is on the high side but is that enough to cause the issue?

Thanks fellas.

Q

Last edited by JimQ; 04-25-2012 at 09:15 AM. Reason: added info
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Old 04-25-2012, 10:31 AM
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piston slapper piston slapper is offline
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The 22 came with the analog SAM module and coils..
Did you replace the flywheel? Kohler uses different flywheels for different ignitions. Sounds like you have mismatched ignition parts.
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Old 04-25-2012, 12:55 PM
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JimQ JimQ is offline
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Location: Beatrice, NE
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Quote:
Originally Posted by piston slapper View Post
The 22 came with the analog SAM module and coils..
Did you replace the flywheel? Kohler uses different flywheels for different ignitions. Sounds like you have mismatched ignition parts.
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Interesting thought.

I've upgraded several other machine in the past from the SAM to the DSAI and never had to change out the flywheel. Is there something that might make this one different?

Thanks for your thoughs. I apreciate it.

Q
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Old 04-25-2012, 01:17 PM
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piston slapper piston slapper is offline
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Ignition timing is built into the flywheel....
I've seen a few hodge podge setups that actually ran...but were never quite right.
Which parts did you use?
If you look at the flat area near the flywheel bolt....it will either have ...
No marks.....regular coils
A drillbit indent....analog SAM and coils
Drilled thru hole DSAM. And coils
DSAI coils have built in SAM and require the flywheel with ventilation slots on top.
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