Kohler Courage 18 - Stop the Surging

I need to stop the surging of this Kohler Courage engine. The carburetor has a NON-adjustable jet so that won't work. But there is a Low Idle Adjustment Needle that will do the trick.
#briggsandstratton #smallenginerepair #realmanskills
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4strokerebuild....

[@steveweiss2081]

I tried this just now on my old CubCadet LTX 1045 (a piece of junk if there ever was one) and it worked. But it also caused the idle to speed up too much. I was able to get a screwdriver on it, so I just twisted it out about 5 turns, then back in 5 turns. Did this half a dozen times, then turned it back in to where the idle was normal. No more surging. I must have somehow dislodged some dirt or something because now it idles and runs with no surge. So glad to solve the issue without having to wait for a new carb. Thanks for sharing your knowledge. I would never have known about how to access that idle screw without this video.

[@RealManSkills]

Happy to help! Thanks for watching!

[@bobk.1428]

This is exactly what I needed to know. Thanks, headed to the garage….

[@RealManSkills]

Thanks for watching!

[@JUANRODRIGUEZ-lz4pi]

Thanks , I was having the same problem I adjusted the screw like you said and it worked so all the way from near Corpus Christi Texas thank you again.

[@RealManSkills]

Thanks for watching!

[@TheDavekerr]

Thank you. I was going to start searching for a jet but you saved me a lot of time

[@RealManSkills]

Happy to help! Thanks for watching!

[@MrGoosePit]

Nice. Kohler should change the name from "Courage" to "Discourage"! I enjoy all your videos. Thanks!

[@RealManSkills]

Thank you for watching!

[@artramirez3506]

Thanks for the info! My engine has been surging for a while but is still going strong otherwise on my 2009 model Troy-bilt Bronco riding mower.

[@RealManSkills]

Thanks for watching!

[@baldeagle242]

Thanks for sharing. You have a new Subscriber. 👍 I have one of these motors that blew up. I’m getting ready to do a video on replacing it.

[@brianarthur6945]

Great video ,just adjusted valves ,now going to do this adjustment on aftermarket carb ,Thanks Again

[@RealManSkills]

Thanks for watching!

[@DC-sh8mr]

Idle down before shutting off. Good info.

[@tylerdibastiani8511]

Great video! I’m having this issue with the same aftermarket carb you have at the end. I’m also carbon fouling spark plugs like crazy (2 plugs in two .5 acre cuts). New to small motor repair but I’ve run the gamut on checking the entire fuel system. I had it running well enough to cut about a week ago with no surge and came back to it barely holding an idle and surging / backfiring like crazy. Going to check this out tomorrow and see if it helps the surge at all (with my 3rd spark plug).

[@RealManSkills]

Could be a head gasket or valve problem.

[@wickedwoman5471]

Thankyou! I just bought one of those after market carbs. I needed to know where that jet was.

[@RealManSkills]

Thanks for watching! Happy to help.

[@joshuathewelder24]

My Kohler 5400 series engine surged at high throttle and I bought a couple of cans of Berryman B12 Chemtool carb and intake cleaner. I sprayed it into the carburetor and it stopped the surging

[@RealManSkills]

Yes, sometimes the surging is caused by a dirty carb. Anything that restricts gas flow could be the cause of surging. Thanks for watching!

[@headpainter1]

I had replaced my Kohler carburetor with a carburetor off of eBay. And it's been surging ever since. I checked everything. But now I believe I have found the problem. When they milled out for the slow jet idle screw, they over milled and cut a pinhole into the top of the bowl inside the carburetor, causing it to suck air from inside the bowl. I put some gas resistant sealer on it and waiting for it to cure.

[@RealManSkills]

Good detective work. Hope it works. Thanks for watching!

[@nonyadamnbusiness9887]

I got one of these POS. I grew up sitting behind a K321. The difference makes me think the Chinese bought out Kohler. I fixed surge by carefully replacing the idiotically designed gaskets on the intake. I think it's leaking again, because after a year, it's now overheating like it's running lean at full power.

[@rustymoore4352]

That fixed mine as well although I had to actually go clockwise a few turns, granted it was a new aftermarket carb

[@RealManSkills]

I mistakenly called it a jet. It's a mixture screw. Thanks for watching!

[@shadmeyer7791]

It’s the fuel pump,it slowly pumps fuel meaning it’s about to be replaced.

[@ENDERTON2000]

Great video, I had to remove a Welch plug to get yo mine... HOWEVER... it didn't help.😢 Another guy posted about the gasket behind the carb spacer, checked mine...and.... It didn't help either 😢 This mower has been worked on by someone who probably shouldn't be using fisher price tools, things broke, missing, blades mounted upside down. You name it. Multiple barb issues, but that's for another time. Mine ended up being a poorly adjusted governor lever. But thanks for the video

[@RealManSkills]

Thanks for watching.

[@Summer41977]

I’m going to try this! Thank you

[@RealManSkills]

Thanks for watching!

[@elobrero3910]

I have this issue. Going to give it a shot.

[@RealManSkills]

Hope it works out! Thanks for watching!

[@elobrero3910]

@@RealManSkills Also, the one i got does not have the choke linkage and dont know how that works. If possible can you do a vid on the choke system?

[@RealManSkills]

@@elobrero3910 Can't at the moment. I don't have that unit around right now.

[@elobrero3910]

All good. Thank you!

[@kennethcoffia7816]

Thank you very much......Fixed my problem..

[@RealManSkills]

Happy to help!

[@tonymontana897]

That was awesome. I wonder if it's the same for the Kohler Courage 25 ?? Mine does surge too and am new to the Courage Engines.

[@tonymontana897]

@Maverick Omar What does that have to do with this video ???

[@thomashoward9806]

Check plastic junk between carb and intake. Mine was cracked sucking air causing surge.

[@RealManSkills]

Thanks for suggesting that. Something to keep in mind.

[@straightopoint]

Ever tried non-ethanol gasoline? Try it sometime. Works wonders.

[@RealManSkills]

That's all I ever use in my small engines.

[@straightopoint]

@@RealManSkills Most people don't. Thanks.

[@peterswatton7400]

Cheers. My problem solved.

[@RealManSkills]

Thanks for watching!

[@davidreid8401]

Ok so you first say your going to turn it counter cloclo kwise then after removing the air filter cover you explain how your turning the screw for needle clock wise. Which is it? Counter clock wise or clockwise. I now know where the problem is but not the direction I should be turning in order to stop the surge. I've listened three times now and you give both directions.

[@RealManSkills]

Sorry, just like a regular screw, clockwise for in and counterclockwise for out. Counterclockwise will open it up and allow more fuel through.

[@saleemkader2126]

THANKYOU

[@RealManSkills]

Thanks for watching.

[@dietcoke5628]

I bought an aftermarket carb like the one you have and as I try to adjust that screw it turns in back the wrong way by itself.

[@RealManSkills]

I wonder if a dab of lok-tite might help?

[@davidwhiteman8491]

How can u remove the plastic fuel cap on the mix reg Tks

[@tex_gil117]

I tried this on my courage 18 on my cub cadet and it didn't work. Idk what's going on with it but it's like the choke is backwards lately. I used to start it in one position and now it's complete opposite and still dies.

[@RealManSkills]

I hope you get it figured out. Maybe a new carburetor is the solution.

[@Smalltechguy]

sounds good. Did you try and set the throttle to the low setting to see if it will start surging again??

[@RealManSkills]

The owner is my neighbor and I hear it running great every time he mows the grass. Thanks for watching.

[@marcdesir4646]

Question. I keep having fire coming out of the exhaust. How do I stop it?

[@RealManSkills]

There are several possible reasons. I don't have space here to go through all the possibilities. However, a interweb search comes up with a lot of info.

[@shawnprime1143]

Just curious, my new kohler 5400 18.5 HP has a very slight skip, not bad under load, but on the mid to lower idle. Is it the same adjustment on these newer engines?

[@RealManSkills]

I don't think that I have ever worked on a Kohler 5400. Sorry

[@samkitty5894]

How did you start your engine not seated? Bypassing the safety switch?

[@RealManSkills]

Concrete blocks on the seat

[@samkitty5894]

How about a small piece of cardboard to keep the seat contact open...@@RealManSkills

[@stevealaska73]

How's it doing these days? Mine is doing the same thing. Was that full throttle you were at? I'm pretty sure it was. Mine purrs low throttle and surges awful at full throttle if you throw it into full throttle. Not so much if you gradually add throttle. It's a jerk when it wants to be.

[@RealManSkills]

Engines surge when they aren't getting enough fuel. So when it's low, it doesn't need much and runs smoothly.

[@patrickrafferty9156]

@@RealManSkills Interesting, I have the 19 hp courage and it surges only when I drop the throttle. When full throttle, no choke it runs almost perfect, I also notice excess vibrations on my feet though. Waiting for parts to fix this junk. Next mower will not have a Kohler engines for sure !

[@RealManSkills]

@@patrickrafferty9156 It makes me think that there is a slow idle jet in the carb that is clogged. I'll keep my eye out for that. Thanks for watching.

[@suzieq8379]

@@patrickrafferty9156 how did you fix it i cant figure out why my courage 19 is surging at 1st seemed not to when pto was engaged ive checked everything

[@patrickrafferty9156]

@@suzieq8379 Its not fixed, I ordered a bunch of parts. Waiting for these to do the repair.

[@thomashoward9806]

On the internet Koehler show up teen different carburators.

[@icemannky33]

I tried this but not better yet. But also my emergency shut off solenoid is leaking fuel and the wire broke off. What do you think?

[@RealManSkills]

Try a new carb.

[@user-qq1ps8ty8c]

Did you get a new wire? Check the pressure in the LEFT steering tire. Never start it with the AC on! Makes your starter run hot and overheat your radiator. Be sure your using the right coolant and thermostat for your region. You know. Simple things....

[@chuckd7423]

@@user-qq1ps8ty8c ?????????? Those are your suggestions for fixing a riding lawn mower with a surging engine?

[@rogerd943]

as far as that needle you removed at the end - you have no idea where it was set. what you should have done is screw it in, counting the turns, until it is LIGHTLY seated, then remove it. that way you can set it back where it was set out of the box. not that that is the correct setting but it is certainly closer than just removing and guessing.

[@ChewFawtyEssex]

I have a Kohler Courage 19 and just put a new carb on it and it is hesitant to start. Cranks fine and will sometimes start but usually I need to give it a spritz of starting fluid. Would I need to adjust the screw that is on the top of the carb to richen up the mixture?

[@bigal7255]

bought used courage 20 in a husqvarna 46 inc cut...the linkage I guess gov linkage is not hooked to anything can you show proper linkage for this carb set up thank you

[@RealManSkills]

If I had that tractor, then I would. However, I don't own that one at this moment.

[@mikespain8655]

That is the air/fuel mixture screw adjustment, not a jet. Good job, engine was running too lean.

[@RealManSkills]

Thanks for the correction.

[@Sean-Aviation]

this done at the very low rpm of the throttle, right?

[@RealManSkills]

No, it was done at high throttle.

[@Sean-Aviation]

@@RealManSkills Yea i hate the annoying surging. same with my generator. having said that, i even took out the mower carb and didnt see it has any adjustment screw as yours. it has a mechanic bolt that acts as a stopper to the butterfly...

[@dreadnought2024]

weak governor spring....

[@danobrien155]

Th as nks

[@davidmann4533]

A little ratcheting screwdriver would’ve been the correct way to make that adjustment

[@RealManSkills]

Where's the link to your video?

[@tomgramke8474]

Uhhh, your telling everyone clockwise turns... you are turning it counter-clockwise.

[@RealManSkills]

Uhhh, at 3:32, I visually corrected myself.

[@LameGuyStuff]

Hey Tom, you seem to be able to spell really well for someone who can't read.

[@spikeleestree8015]

Very mild surge. That is the air fuel mixture screw. That usually doesn't work on many more severe issues. They do have a low/ idle circuit. The Jet for that is in the ventury and in the fuel pickup tube in the bowl. Sometimes this ckt can become clogged and not allow enough fuel at idle to run wo hunt surge condition. U didn't let it run at idle so we dont know if u actually repaired it lol

[@RealManSkills]

The owner is my neighbor. I hear it run every time he mows the grass. Sounds great so far. Thanks for watching.

[@baldeagle242]

Thanks for sharing. You have a new Subscriber. 👍 I have one of these motors that blew up. I’m getting ready to do a video on replacing it

[@RealManSkills]

Thanks for watching!