Kohler Courage - Intake Valve Leak FIX
Вставка
- Опубліковано 21 гру 2018
- How to!
In today's video, we'll be looking at a Kohler Courage (Model SV540S) with an Intake Valve Leak!
This machine has given my customer quite a few problems over the years, so if you'd like to get caught up, here's the previous videos down below:
How to Fix a Seized Engine - Kohler Courage P.1: • How to Fix a Seized En...
How to Fix a Seized Engine - Kohler Courage P.2: • How to Fix a Seized En...
Kohler Emission Compliant Carb Swap - EGR Removal: • Kohler Emission Compli...
After running into some issues with the Intake Valve not sealing up, (especially after lapping the valve myself, then sending it out & having another shop replace the valve & cut the seat) we finally sent it out to an actual machine shop.
Kohler recommends cutting the Valve Seat at 44.5° on either side (totaling 89°).
In combination with the Valve cut at 45° (totaling 90°), this 1° total difference is what seals the valve & seat under pressure.
Unknown to me, the previous shop I sent it to cut the seat at 45°, and also ground the old valve to 45° (which prevented it from sealing).
This lead to the valve leaking under pressure. (They didn't charge me for the work they did).
At the end of the day, we got this machine up & running again.
My customer even mentioned the engine ran better than it did when he bought it, which leads me to believe this engine has always had a slight valve leak.
_______________________________________________
If you enjoyed the video, hit LIKE & SUBSCRIBE!
New videos every week!
DONATE:
Bitcoin: 1NYgPvcvBWuhGRewsLE4Scy1cbzwndh5hZ
SOCIAL MEDIA:
/ eliminatorperformance
/ eliminatorperf
/ eliminatorperformance
GEAR:
Camera: amzn.to/2HVkW9o
Tripod: amzn.to/2HGWt4w
Microphone: amzn.to/2J7k9DA
Cheap Mic: amzn.to/2xCBn6z
Headphones: amzn.to/2JeHUG9
Editing Software: amzn.to/2JD7OTx
Photoshop: amzn.to/2HBY6Ez
MUSIC:
Intro/Outro Music: Burnt - Jingle Punks - Навчання та стиль
Dad taught me to grind valve and replace guides at 11 years old at his shop
I’m using the B/D machine 3/6 times a week
It still works and looks great
Great editing, to the point, educational! Great job.
Thanks for watching!
I enjoy your video because you get to point and fast
Organization is the key to any companies success nice to see you follow this simple rule. To you and all your Eliminators we at Double Action Consulting Inc. would like to wish you a Merry Christmas and Happy New Year . May 2019 be extremely prosperous for your Company and keep up the great videos we really enjoy watching and learning. We believe you are providing a service to your subscribers that has the potential to save them a lot of money they would otherwise spend on small engine repairs.
Thanks for the kind words, Merry Christmas and Happy New Year to you too!
Great video, thanks for this
Im working on a Courage V twin right now. It is running really rough. Its not fuel or air related because putting the choke on does nothing. Compression is nearly identical on both cylinders, healthy 180 psi. Spark is good and strong on both cylinders. Something I noticed was that the right cylinder has a very loud tick when I pull the plug boot off with the engine running. The other cylinder sounds ok for running on one cylinder. I think that this may be my issue, will have to take off the valve covers and check. I dont have a leak down tester so that may be my next step if I cant find anything wrong.
Got a 17hp. Sv530. is there a replacement motor I could install in my lawn tractor without too much hassle?
Great video!! Kohler sucks bad evidently!!! Great fix!
Thanks Bruce!
I got a kholer courage 149 with a blow by issue, changed head gasket, breather valve with original parts and nothing works
Your next project with this engine will be welding the crankcase crack[s] that develop on a lot of single cylinder Kohler Courage engines....
Yea they're not built to the highest standards. Surprisingly it's still running good!
Great video and editing. Straight to the point. Couple questions for someone uneducated. Why the leakdown test as opposed to a compression test? I saw where you said you had to do it but misunderstood why. 2nd, could you not do the water test after getting it back from the 1st machine shop after getting it back or did you assume it was good before putting it all back together?
The leak down test pressurizes the cylinder to not only test the seal of the piston rings, but also the both valves (since they're closed). A compression test only tests the piston rings, and you need to crank the engine over to do that. This engine (and many newer engines) have an auto compression release, which opens the exhaust valve slightly on the compression stroke to decrease compression and make starting the engine easier. This happens only when the engine is cranking below 750 rpm. Once you start the engine it doesn't engage this compression release. So basically you need to do a leak down test to test the valves, and piston rings on this engine. And yes I assumed it was good and bolted everything back together, this lead to me wondering if it was something else. Then I pulled it all apart again and did the water test the second time, making sure it sealed. Thanks for watching!
@@EliminatorPerformance Thanks! Subscribed
hi can you tell me if i set my cam timing marks on comp sroke piston up or down thanks
Tdc at compression stroke, so up
Koehler used to be the preferred engine to have, what happened to its quality?
My ferris was running really crappy. I couldnt figure it out. Mechanic said he fixed it and said leaking intake gaskets. Where is that located exactly
On the intake. The intake is what connects the carb to the head.
I have this Courage 19 on an LTX 1040 Cub Cadet. I have a weak start because it appears that the compression is not releasing. The start isn't strong enough to jump "over that hill of compression". I've double checked the ACR (automatic compression release) and its real sloppy so I am unsure if its opening all the time. I remove the spark plug and engine moves freely. I put the spark plug in and the compression doesn't release again. The cam that the ACR is on, if I pull the cam out and take out the ACR, there is a groove inside it and it appears to hook onto that groove and possibly not open properly. If I take out the plug and run the starter it spins beautifully.
If anyone has any info to help, I'd appreciate it. I'm at wits end.
First thing you do in this case is pull the valve cover and check the valve lash, probably out of adjustment.
Thanks. I adjusted the valves had same problem. I replaced the ACR with the new design and now it spins correctly. Thanks again!
My valve seat fell out. Do u have an idea what the price would cost me for valve seat replacement and valve job?. Just exhaust side
Google videos for how to fix that, you may be able to "peen" around it and reinstall it!
Its honestly better just to install a new head. There are ways to re seat the seat but its not gueranteed to last.
I have a Kohler Courage with 155 hours on it still going strong. Before the cover bolts backed out I removed them to apply locktite and re-torqued to spec so that avoided virtually all the issues on it (SV590S).
You couldn't pay me to own a Briggs & Stratton - cheap and lazy engineering on them with a focus on bleeding customers for replacement parts designed to fail. Their Vanguard line is made in Japan with honor by Daihatsu so they're good, but everything else is a load of BS.
How do you lock the engine when doing leak down test ?
Just put it in gear ?
That's actually a very good point, there's a spot at TDC (Top Dead Center) where your cam will rotate on the lobe, but the piston won't move.
It's like, maybe a 1/4" left to right that the flywheel will move, basically, if you get directly in the center of that spot, the flywheel shouldn't turn.
But, if it does, you can always get someone to hold a Johny bar with a socket on the main flywheel nut!
Are these made in north America or China ,Its hard to get good quality today. I have only worked on the older ones .Good video.
I don't know to be honest, but unfortunately my customer had nothing but problems with this engine. It's finally running great now!
@@EliminatorPerformance Sorry to bring this back up. But how much did your customer end up paying for all these repairs? I would think at some point, it is worth just buying a new tractor!
@@alklesczewski1207 I honestly forget, but it was a few hundred with all the work combined. New intake valve, new carb, EGR removal, bunch of stuff. What a bad engine lol nothing but problems, although since the final repair and after all the changes, it still runs great
How much did they charge you for the head work??
$40 tax included, brand new valve, cut the valve and seat. The new valve was out 0.002" which was crazy
hey man I have a Cab Cadet ltx1040 Whit Kohler engine 19hp exhaust are glowing red what can I do???
Your carburetor is probably running too lean, I'd recommend a carburetor rebuild or replacement. Also, make sure you have proper spark plug in the engine, too hot a plug will cause that too!
Eliminator Performance thanks man
Eliminator Performance I need replaced the spark plug to ? or what you mean?
@@mglvasquezvasquez8843 spark plugs have different heat ranges (example: bpr6es bpr7es bpr8es) so make sure your spark plug is correct #
Eliminator Performance what is the correct spark plug for KOHLER COURAGE 19HP ?
Tell me more about that screen in front of the garage door lol
I built it, just 2x2 wood with some screen stapled to it, then in the winter we staple some thick plastic to it
Not a big deal but 4 for intake and 6 thousandths exhaust is what most people set lash to. Even says that in manual. I've got a kohler 735s that runs like it's got a miss even tho the coils are new carb cane off another 735s that runs great. I think it needs a valve job. Can't use the good engine because it's from a cub cadet w a 1 inch pto crank and the craftsman needs a 1 1/8" pto.
Pain. Kohler single cylinder models def have issues.
Kohler is a good strong engine, just not the Kohler Courage series (especially the single cylinder). Briggs and Stratton used to be good engines, but now only the larger 37 hp Vanguard series is good. Read up on it and the history.
Yea the courage engines are definitely not Kohler's best moment. Thanks for watching!
Great vid, I don’t like Kohler engines
Either
Thanks for watching!
kit is now $20 bucks
I think the owner should have just replaced with a used engine. Maybe could have found an old Brigs.About 20 year old brigs.
It runs good now lol just unfortunate that he had all these issues
Those pistons rings are junk
No they're still good, sure they let some pressure by but it's less than 10%, which means they're within tolerance.