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Discussion Starter · #1 ·
My 25hp Kohler has run great since the headgaskets were done about 2 months ago,but today it feels like it lost about 5-8hp all the sudden.There is no smoke like last time,I will do a compression check tomorrow am,is there anything else that'll make it weak?Its only got 125hrs on it,I checked the air filters,they are like new yet,i popped a new fuel filter in it,the decks clean,any other tips would be appreciated(besides trading it in)I still have 30 months of payments I hope it lasts that long.Its on a 2000 DC XW2500,my governor is set at 3760 with blades on.It drops to 3500 easily now and i have to slow down or bog.
 

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Discussion Starter · #3 ·
Dealer did it,they put sae30 in it too,I doubt they planed the head because it was done in under 2 hrs.I really regret buying this engine.The original gaskets that blew were the updated ones thatwere supposed to fix the problems,they just put in another set of the same ones that came off,im not sure if they used new bolts too.

[Edited by John DiMartino on 09-11-2000 at 01:25 AM]
 

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90% of the lawn companys up here run Walker mowers due to Maine has thick grass and looks like crap when its discharged and Fall cleanups, any ways the kohler engines up here range from 1hr to 3000hrs no rebuilds but talking to the Walker distruter he says that his dealer average around 2000hrs up here on those kohlers. We also use them in winter to plow and throw snow
 

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Discussion Starter · #5 ·
With the chunk of headgasket in my oil for 9hrs,i dont expect it to last nearly that long.There was a piece of gasket about 1" in lenth and about 2/3" wide that got blown into the exhaust pushrod passage,that goes to the oil pan,so im sure tha if i tore doen the engine the bearings are scuffed and scored,then kohler would try to deny it,so im not even bothering,when it pukes out of warranty ill put a kawi in or whatevers better by then.I dont expect it to last more than 500hrs
 

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i would have the bolck and heads check for strainghtness,also might be a good idea to change the head bolts since there prob tourqe to yeild anyway,springs,locks.rockers,valves,lifters,never hurts to look.
 

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Discussion Starter · #8 ·
I wasnt there when he did the work,i doubt anything was checked,i think it was a simple R&R gaskets.When i bought this new it didnt use a drop of oil for 66hrs,it popped the gaskets and used 1 1/2 quarts in the 9 hrs i used it before they did them,ever since i got it back its using some oil still,about 6 oz in 50 hrs,thats 6 more than it used before the gaskets blew,si i bet the cylinders got scored too.
 

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Man, this really sucks that so many people are having problems with these engines even after the supposed fix. On one hand you have mower manufacturers who can't control Kohler, but rely on them heavily to supply power. On the other hand you have Kohler who would rather fix your problem than replace an engine, even if it takes multiple trips to the dealer to do so. And then you have the end user, who has countless payments left on a machine with an engine that is completely unreliable. Paying this much for these machines, you would think, would give you years of service without failure.

I truly believe the problem with these Kohler engines is their 9:1 compression ratio, teamed with only air and oil cooling and a lot of times only 87 octane gas. They must truly be running on the ragged edge of detonation constantly. I only run synthetic oil in mine in an effort to get the operating temperture down...even if it is just a few degrees.
 

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I agree. Kohler may make some engines that run for many hours but the 25hp that I had was made in hell.
My gaskets went like yours John at 120hrs. It was a great mosquito fogger. From there I had constant problems from coils to wires to sending units to intake gaskets. I finally got it fixed and sold the unit at about 650 hrs.

Kohlers policy on not replacing these anchors really sucks.

I can see trying to fix it at problem #1 but to continue to try and try gets to be a big mess. I think some of it was my mechanic. He was a Kohler certified mechanic but it didn't seem like he had a good handle on what was happening.
Basic fixes are like band-aids on a bleeding artery.

I am a small operation and yes, when I replaced the 25 Kohler I bought a 26EFI (it takes me a while) but I do have the warranty and so far so good. But in the future it will be diesel. Good Luck
 

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John, I don;t see where the piece of gasket in your oil pan would ahve much to do with engine damage. Everything goes through the filer before it gets to the bearings. I had the head gaskets done on my 25 at around 100 hours. No problems internally since then. I am having coil problems and I have the new parts here to swap out. If they are the old series coil Kohloer will reimburse me for them. 700 hours on the machine now, virtually no oil consumption, I've had to add twice in just over 200 hours. I do run synthetic, with yearly changes, filter change at the mid point. If it matters, I'm running 89 octane all the time.
 

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John,

I have a machine just like yours -- same motor -- same head gasket problems (done twice) -- same loss of power. I have about 200 hours on it. I changed the Donaldson air filter and that seemed to help some, but it still loses power going up steep hills and in thick grass. Today it quit on me, dropping under 1800 RPM.

I have a friend with a '98 DC XW2500 (25 Kohler) and it runs very strong. My dealer doesn't have a clue as to what's wrong. Kohler suggested that the dealer do a "lead-down" test and I think I'll drop it off on Wednesday for him try that.
 

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I think that would be a "leakdown" test, but with Kohler manning the control board who knows

"Hello, Thanks For Calling The Kohler Tech Line. How May I Route Your Call...Engines Or Toilets?"



[Edited by Keith on 09-12-2000 at 03:17 AM]
 

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Discussion Starter · #15 ·
Thank you to everyone who replied,I did a compression test tonight,it has 168 in left side,167 in right.this thing hasd a alot of cranking pressure for such a slug.I stopped at the dealer today on my way to my first job,he has 3 brand new CV25's on the shelf,that isnt a good sign,but he said no matter what happens we will have you running in a matter of hrs,that is good to know.They also have at least 5 sets of gaskets on the shelf and the new coils,so they are well stocked and have done plenty of these.Its still a dog,they want me to run it a few more hrs and let them check it if it doesnt get better.
 

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We have had problems with our valves and valve seats in those engines. Real quick spot to lose horsepower fast. Check for a bent push rod.

First off, several issues have been raised about the compression ratios on these motors. The lower compression raitos are a direct result of all engine manufactuers having to build engines that will meet the CARB standards. If you can't sell it in CA, it's not worth having as a manufactuer's product..

The overhead valves, streachs out the combustion chamber, longer stroke, hotter burn, all equals a cleaner emmission. Also equals an engine that operates on the weak side of structural tolerances.Keith addressed that in his post on the detonation issue. Detonation combined with poor metalurgical process's and poor tolerance's and pot metal for crankshafts and every other metal part, it dosn't take much to push one of these engine over the edge.

I feel that is the sole cause of these engine failures. Most of these engines are also detuned down about 20% mmore than they need to be. Think how much sooner the Kohler's would fail then.

Kohler has won all the hearts of the manufactuers in the last several years. Think how low they had to cut the price to make deals with all the iron dealers. It will take 3 years for some to change over engines. Some can do it in a year, it the stuff really hits the fan.

Not real encouraging.
 
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