Flywheel stuck

robro1102 · Aug 21, 2011

Several of you have tried to help me with what I thought was a starter problem. I have removed the starter and now discover that the flywheel itself seems to be stuck. This is a Toro Z5000 Kohler engine.

My previous thread, Starter Just Clicks, has gotten me to this point. I have removed the plastic blade cover and the flywheel will not budge.

I am attaching a picture of the flywheel. The mower has been working great up until last week when all this happened. It seems that I am an idiot. I have washed my entire mower over the past couple of years and it appears to have rusted the flywheel some, but I don't think that is the issue. It is just surface rust.

I would like to investigate further but afraid to. I can't see why the wheel will not move. Is it bolted down? Any suggestions would be appreciated. Thanks.

robro1102 · Aug 21, 2011

just testing this thread

robro1102 · Aug 21, 2011

I can't move the flywheel at all. I know the oil level was fine. I read somewhere on here that a bearing can "melt to the shaft". Is that possible? I don't see any oil in this thing now. Would the oil leak into the engine somewhere but not out onto the garage floor? I have never seen a leak?

Restrorob · Aug 21, 2011

You need a puller such as this to get the flywheel popped loose, Some chain auto parts stores have them in their loan-a-tool program.

And, There was no need in starting another thread.....

ed2hess · Aug 21, 2011

Could t his be a clutch that melted down?

Restrorob · Aug 21, 2011

ed2hess said:
Could t his be a clutch that melted down?

In most cases you would still be able to rock the flywheel back and forth the distance between the clutch and clutch stop bracket/bolt. The way I've read, The flywheel doesn't move AT ALL ?

rwaters · Aug 22, 2011

robro1102 said:
I can't move the flywheel at all. I know the oil level was fine. I read somewhere on here that a bearing can "melt to the shaft". Is that possible? I don't see any oil in this thing now. Would the oil leak into the engine somewhere but not out onto the garage floor? I have never seen a leak?

i could be a lot of things, but restro is taking you threw steps that will be less intrusive for you. I could be a long way to the answer but if you follow his steps you have a chance of repair. Remember we are trying to troubleshoot over what you have told us, it is much easier to troubleshoot and engine when we can see and touch it.

topsites · Aug 22, 2011

I think we have a misunderstanding, from what I gather the operator is not
trying to remove the flywheel, he is trying to get it to turn over the engine.

If such is the case, try removing the spark plug(s),
doing that will relieve any internal engine compression.

Could be a gasoline-filled cylinder keeping the engine from turning, for example.
Removing the spark plug(s) should let you turn the engine over via the flywheel.

If, however, you are trying to physically separate the flywheel from the engine, then you should follow Restrorob's instructions.

piston slapper · Aug 22, 2011

topsites said:
I think we have a misunderstanding, from what I gather the operator is not
trying to remove the flywheel, he is trying to get it to turn over the engine.

If such is the case, try removing the spark plug(s),
doing that will relieve any internal engine compression.

Could be a gasoline-filled cylinder keeping the engine from turning, for example.
Removing the spark plug(s) should let you turn the engine over via the flywheel.

If, however, you are trying to physically separate the flywheel from the engine, then you should follow Restrorob's instructions.

MISUNDERSTANDING???????

Now there's an Understatement.....
How about some engine #'s
How about checking the engine oil before starting a thread ?
I think we're looking at the wrong end of the horse.

TOPPER....TOPPER...TOPPER.... Its monday again:hammerhead:

robro1102 · Aug 22, 2011

How about checking the engine oil before starting a thread ?
I think we're looking at the wrong end of the horse.

I certainy deserve that comment. I just can't believe I ran it without oil. I never had any sign of it running hot or leaking or anything. That being said, I must face reality.

This is a Kohler Courage 21 HP SV610-0020. If I locked it up, please answer probably this last question. Do people rebuild these types of engines, or is it just not feasible to mess with? If I got one of those "pullers" mentioned above, I think it is obvious I would not know what to do with it.

Can the community "small engine repair guy" do this type of work, or are we talking a true ENGINE SHOP?

Thanks for all of you help.

piston slapper · Aug 22, 2011

The courage engines are a low end engine.....Pretty inexpensive to replace ( compared to the Command Engines $1200-$2000)

Put a pipewrench or breakerbar on the crankshaft, and see if you can get the engine to free up. If it does, put oil in it and see if it runs.

Restrorob · Aug 22, 2011

Maybe you should have followed this advice;

rwaters said:
if you can not move the flywheel, that is bad you might want to take it to a mechanic

And I should have.......

......and......

piston slapper · Aug 22, 2011

robro1102 said:
How about checking the engine oil before starting a thread ?
I think we're looking at the wrong end of the horse.

I certainy deserve that comment. I just can't believe I ran it without oil. I never had any sign of it running hot or leaking or anything. That being said, I must face reality.

This is a Kohler Courage 21 HP SV610-0020. If I locked it up, please answer probably this last question. Do people rebuild these types of engines, or is it just not feasible to mess with? If I got one of those "pullers" mentioned above, I think it is obvious I would not know what to do with it.

Can the community "small engine repair guy" do this type of work, or are we talking a true ENGINE SHOP?

Thanks for all of you help.

Robro....Sorry about the "Slap".....You didnt deserve it.....:waving:
Guess Im just like all the other mower techs on Monday mornings in the middle of August.:wall

I realize if you were a mechanic, we probably wouldnt be having this conversation. If you can get the engine freed up, it might go back to work. Unfortunately, it would probably be cheaper to replace than rebuild.

Good Luck,

SLAPPER

robro1102 · Aug 22, 2011

Thanks to all of you for your help and encouragement. I have tough skin, so no problems here. I think it is great that you guys are willing to steer someone in the right direction.

It is now in the hands of someone who works on these types of things and I should get some kind of report later this afternoon, and I want to go on record saying that i think there is still hope. I shut the engine off (it did not die on its own), so even if there was no oil, I just don't think it could have gotten hot enough to totally blow the engine.

I promise to report either way. Thanks again.

Floridalandcare · Aug 22, 2011

Id venture to say that a magnet came off the fly-wheel and is lodged between the stator . I had this happen on a pressure washer of mine.

rwaters · Aug 22, 2011

Floridalandcare said:
Id venture to say that a magnet came off the fly-wheel and is lodged between the stator . I had this happen on a pressure washer of mine.

thats what restro was shooting for, still a shot that that is the problem. I had one come in without oil that the safety system was not allowing the engine to start, poured oil in fixed the safety and the engine is doing just fine 5 years later. He is better about getting it serviced now though:laugh:

ed2hess · Aug 22, 2011

Short blocks works in this situaton if the heads are okay. Might get that down as low as $900 if you do the work. I did mine this winter not real bad. You do have to get that flywheel off.

IRRITECH · Aug 23, 2011

Like Topsites said, pull the plugs and try to turn it. If that doesn't work then just start pulling the whole thing apart. At this point what's it going to hurt and it wil give you a better understanding of the internals of an engine.

Snyder's Lawn Inc · Aug 23, 2011

robro1102 said:
Thanks to all of you for your help and encouragement. I have tough skin, so no problems here. I think it is great that you guys are willing to steer someone in the right direction.

It is now in the hands of someone who works on these types of things and I should get some kind of report later this afternoon, and I want to go on record saying that i think there is still hope. I shut the engine off (it did not die on its own), so even if there was no oil, I just don't think it could have gotten hot enough to totally blow the engine.

I promise to report either way. Thanks again.

You learn hard way I know you will be checking oil everyday from now on

topsites · Aug 23, 2011

Here's your problem, now you have to pray because unfortunately when an engine runs low on oil it doesn't seize immediately,
matter of fact if there was any oil in the engine it can run for some hours, be shut down, have the oil changed....
Then seize three days later yet run good up to that point.

That's been my experience.
But it's still worth a shot, because you don't know until all is truly lost.

Generally speaking rebuilds are only worth it for the experienced mechanics who have a lot of time on their hands.
The short answer is replacing it costs about as much and now you have a brand new engine with a warranty.

Flywheel stuck

robro1102

robro1102

robro1102

Restrorob

ed2hess

Restrorob

rwaters

topsites

piston slapper

robro1102

piston slapper

Restrorob

piston slapper

robro1102

Floridalandcare

rwaters

ed2hess

IRRITECH

Snyder's Lawn Inc

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