How to repair Kohler Courage Oil Leaking

[@happyrecluse2849]

Thanks for this. I have a 1042, and have not had many problems since I bought new in 2012. Shortly after my dealer shut down and began doing my own services to it. One tip I would like to pass along, is if you need to line up something to assemble, I use home made studs, basically bolts with a reasonable amount of shoulder and trim off the head. Gotten quite a collection over the years in imperial and metric as a industrial service tech. Keep up the good work....

[@bocfat]

your video was first I saw that showed the updated valve cover, thank you, thumbs up!

[@JohnsonsSmallEngines]

I’m glad this video was helpful. Thank you for the thumbs up and kind comment.

[@JohnDoe-pq8yw]

Awesome man !!! I just bought a beater for 200 bucks and when I got it running, it was smoking and sure enough, this was the 2nd issue. I expect an issue or 2 more but that's what I get for being cheap. God bless brother.

[@JohnsonsSmallEngines]

Thank you for watching and sharing. I’m glad it was helpful! Please give this video a like and share my channel with your friends to help it grow. It would be greatly appreciated!

[@Johnny53kgb-nsa]

Very well explained. My Husqvarna lgt2554 while cutting grass sprayed oil out, including on my left leg. I just started looking at it, and noticed my oil filter is double gasketed . Normally I tune it up myself each year, but the last time, I had a shop do the work because I also wanted the carburetor looked at. At first I thought valve cover gasket, but, it's clean around it. Thanks, John

[@JohnsonsSmallEngines]

I'm glad you figured it out! It must have been a younger mechanic. I have had the happen and normally the oil will leak as soon as you start the engine. I always make sure the gasket is not stuck to the oil bracket when replacing the oil filter. That is a learning process normally for a younger upcoming mechanic.

[@chuckpickering6040]

Thank you for making this video. I have ordered the kit and am waiting on it to arrive. Mine had a leak so bad it actually did catch fire! Thankfully I had a fire extinguisher. I put the fire out with no major damage except a corner of the engine cover melted a bit! The leak actually got so bad after the fire I was afraid to run the mower. I'll even buy a torque wrench for this job!

[@jimh.412]

Did it fix the leak? I just ordered the kit and am going to do it next week

[@ciphercode2298]

I bought my cub cadet ltx1040 used a couple years ago and only found out about the common problems with this motor after I bought my tractor. It had 260 hours on it when I bought it and runs fine. After listening to other peoples nightmares I pulled the hood off and the flywheel shroud and checked the pan bolts and the valve cover. Someone already had put lock tire or something on the engine pan bolts and the valve cover wasn't leaking. I've had it almost 3 years now and so far so good.ive had deck and pto problems, but the engine has performed admirably.

[@JohnsonsSmallEngines]

Glad to hear :) You are one of the lucky ones!!

[@ciphercode2298]

@learn2farm509 mine just passed 280 hours without issue. One of my chinesium idler pulleys seized up after only being on there 3 months and blew to pieces while I was mowing the other day,but I had a spare. I'll keep patching it back together until the engine or tranny goes out and its cost more to fix than its worth

[@loupalladino9578]

I have this exact problem and had planned on this maintenance later this year. Thanks!

[@JohnsonsSmallEngines]

Hi Lou, I’m glad this was helpful and thank you for commenting.

[@danielself4370]

I fkund that my mower already had the new kit installed and still developed a leak. Oh well I may be replacing that many times😊

[@scottcolegate6249]

65 inch pounds equals 5 foot pounds on a torque wrench for people who don't have a inch torque wrench

[@garysnider5885]

Had this problem with Troy built 2014 Kohler 22. Failed repair by 2 different shops last repair 2 seasons ago. Happy to see Kohler finally addressed problem. Appreciate video good job. simple easy fix I did myself.

[@JohnsonsSmallEngines]

Thanks Gary, I'm glad to hear you were able to repair it. Thank you for the kind comment.

[@chuckriggsjr.6021]

I have a Toro with a 20 HP Kohler courage. Same issue. I used red RTV n made a gasket with that.

[@allenrutkowski6203]

I did the same and it didn't work. Buying the gasket now.

[@crisprtalk6963]

42$ to buy the part to fix a problem they created.

[@rainz62]

I've watched multiple videos on this issue and have come to the conclusion that one of the biggest issues seems to be the cover being too soft. For people without a torque wrench or one that is functioning properly they appear to be over tightening the cover which is causing an inward divot on the bolt holes making the gasket unable to seal properly. I've ordered a new cover so I can say if it's a more solid build. My thought was, and I don't know if it will work, but to use a metal gasket on the outside under the bold to distribute the pressure the bolt has on the cover itself. It appears this is what they've done by including the bottom pressure plate. Anyone have any thoughts on this?

[@rainz62]

As a second thought, if I had the tools to make my own metal plate like the one they provided for the bottom, I'd make a new one that goes around the entire outside rim of the cover.

[@blueplasma5589]

Is torque wench in/lb. or ft/lb. ?

[@JohnsonsSmallEngines]

in/lb.

[@morkarmorgan3161]

wow you did a great job, Thanks.

[@JohnsonsSmallEngines]

I'm glad it was helpful and thank you for the kind comment. Please give this video a like and share my channel to help it grow. It would be greatly appreciated!

[@alandust2188]

Is it normal for oil to be seeping into the valve cover area? Thanks Again for your videos!

[@JohnsonsSmallEngines]

Not sure what you mean? If there is oil dripping down from above the valve cover onto the valve cover you may have as oil leak somewhere else? It is not normal for any oil to be leaking around the outside of the engine.

[@alandust2188]

Sorry, when I remove the valve cover, should there be a small amount of oil inside AND is this normal or is it a problem. Thanks Again!@@JohnsonsSmallEngines

[@JohnsonsSmallEngines]

Yes, when you takeoff the valve cover, you will have oil in it because oil gets pumped up into that valve trying to lubricate it. The reason why this video is up is because those gaskets leak and you have to take care of that if you have a leaking problem to answer your question yes, the oil is supposed to be up in the valve area after taking off to cover.

[@alandust2188]

@JohnsonsSmallEngines Thanks Again and I don't want to sound like a broken record but I really enjoy your videos 😊.

[@JohnsonsSmallEngines]

Thank you for watching them! Spread the word about my channel to help it grow! Thank you for supporting the channel!

[@donfinkey692]

Great job!

[@JohnsonsSmallEngines]

Thanks Don!

[@dlowe404]

Great tutorial and info. Thanks. Just subbed

[@JohnsonsSmallEngines]

I’m glad it was helpful and thank you for supporting my channel!

[@vanover69]

Great video...I have a issue I hope you can help me with. I have a Honda GX390 on a generator. I replaced the output shaft oil seal as it was leaking. I installed the new seal flush with the engine case. After running for awhile it started leaking again. I thought the seal needed to be counter sunk a bit so I replaced it again. And after running for a short time it has started leaking again. Im not sure where to go from here. Both times replacing the seal I used steelwool to clean the shaft and it seems smooth with no defects. Any advice would be great! Thanks in advance

[@JohnsonsSmallEngines]

You need to call a Honda dealer to see what they recommend. Honda may have a crank shaft sleeve kit.

[@keithstocker2942]

I have this problem with my 18hp Kohler. I plan on ordering the replacement. Would gasket sealer give any extra protection?

[@JohnsonsSmallEngines]

I try not to use silicone if its not needed. The kit will give you everything to repair. No sealer needed.

[@yvesrobichaud4164]

Where did you get the part and do you have the part number

[@JohnsonsSmallEngines]

The link is in the description below the video.

[@ExoTraveler]

I have the 17hp version of this. Bought a used mower and looks like this may be my issue. It's full of crud at the moment. Can you powerwash it clean to so you can actually watch for a leak? Worth trying to snug the bolts a bit?

[@JohnsonsSmallEngines]

Yes, definitely pressure washing is fine just be careful around the air cleaner and carburetor. This engine has a history of the oil pan bolts on which are on top of engine around and under the flywheel loosen up and oil will leak. Take the top cover off, it’s only 4 bolts, and check top oil pan bolts with ten mm wrench. Check for cracks around the top of the block under and around the oil pan. If all is good there, yes perform the valve cover kit.

[@ExoTraveler]

@@JohnsonsSmallEngines appreciate it!

[@ExoTraveler]

@@JohnsonsSmallEngines So ripped into this today. Previous owner must have siliconed it up or something. It was a hot mess. I got it cleaned up and went to put the kit in, but if I use the bracket, the exhaust bolts get in the way of snugging them down. Maybe the 17hp doesn't use the bracket? Seems very odd to me so I aborted for now.

[@tuliocrespi5580]

Es una latita pero de ahi a cambiarla es un lujo acá en argentina

[@jimh.412]

Thanks for the video my man. Just bought a cheap MTD Gold with the Kohler courage 20 and it smokes. Hoping this will fix it 👍

[@JohnsonsSmallEngines]

I’m glad it was helpful. Let me know how you make out. Thank you for watching and the kind comment. Please give this video an like, subscribe if you haven’t yet and share my channel with your friends to help it grow. It would be greatly appreciated!

[@jimh.412]

​@@JohnsonsSmallEnginesDo you need to drain all the oil before removing the gasket cover? Thanks!

[@JohnsonsSmallEngines]

No but I would make sure to lift the front of tractor so you will not loose any out the front and make sure you clean area up where the gasket sits in install.

[@jimh.412]

@@JohnsonsSmallEngines OK thanks. 👍

[@jimh.412]

​@@JohnsonsSmallEnginesYep this stopped the smoking/leaking oil. Thanks for all your help. 👍

[@TurdFerg117]

I have this problem as well

[@davidlee186]

I have this same problem. you think they would offer you a break on parts, after all its there design flaw.... Best price seen $45.00

[@mattchandler8129]

I have the same engine in my Craftsman and it’s problem after problem after problem.

[@JohnsonsSmallEngines]

Hi Matt, the Kohler Courage engine was a big disappointment and that is putting it nicely.

[@kerry1111111]

Looks like they should have put in two bolts on the bottom instead of the one. Someone wasn't thinking.

[@4144758]

Thanks

[@JohnsonsSmallEngines]

I'm lad it was helpful.

[@samjam2376]

Yep, mine caught on fire.

[@dlowe404]

👍🏿💯

[@machz800]

This manufacturer of that engine and lawn tractor should close shop because Cub Cadet and Kohler engine's are pure junk !!! I have more of these machines in my shop then any other make , transmission problems and cracked blocks JUNK !!!!

[@easton_F350]

I have a cast-iron Kohler in my case 224 most reliable engine I’ve ever owned