Kohler Courage Starter Problems/ Slippage trick that works

In this video I show a really nice method of how you can fix a slipping starter pinion on a Kohler Courage engine. It works very well but keep in mind if there is deep cuts in the friction material you may still have slippage. But since the starters cost on average 80 dollars this could be a great way to fix your mower to get you by intel you have the chance or money to get a new starter as there are no service parts for these starters.

[@strawboss59]

Good stuff Kevin, I just bought a used tractor with this starter and it was giving me grief so I removed it.Turns out the helical grooves were jammed up with old lubricant and dirt so the drive disk wouldn't release. Once I use your remove and reassembly info for the friction disk assembly I should be golden, thanks.

[@denmanshaffer2773]

I tried this and it worked great (for now). Also helps to have both the drive plate and the rubber friction disc absolutely clean and free from any oil or grease. I used some undercoating from Harbor Freight.

[@grahamguy623]

This worked on my 1988 Kohler K582 Starter! You tip is greatly appreciated. I mixed sand into some old appliance epoxy paint that I had and brushed it onto the surface. It dried rock hard with a nice coarse surface like 180 grit sand paper.

[@kevinbolin7665]

Great …..I am truly glad this method has became so popular among my youtube followers as well as viewers . What really is just icing on the cake so to speak is quite often it can save big bucks towards the avoidance of purchasing a new obligated starter when the rubber becomes brittle prolonging the use .

[@mr.kleanentertainment8898]

Man I can’t thank you enough for this information. I see it was put up a while back but nonetheless it’s information is just as powerful today. Thank you brother

[@bryancollingwood5338]

Kevin, a great big thank you for this vid, I have been able to get my two old mowers back to life. I have two Kohler Courage 20 hp singles both about 10 yrs old and cutting 5 acres. Apart from those stupid fuel shut off solenoids the starter problem is the only prob, I have had, I guess regular attention to maintenance and oil changes pays off, Thanks again.

[@kevinbolin7665]

Glad to have helped..Thanks for being a respectful viewer.

[@CRyan-iz3wr]

Great video. My gear was stuck up and was trying to start from that position. Acted like a weak battery or bad starter. Something told me to pull the shroud and have a look. Sure enough it was stuck in the engaged position. I had to get the grass cut so i sprayed wd40 all over it and tapped it down with a hammer and punch. Worked fine and got the grass cut 2 weeks in a row. Brought the mower home from the lake to address a high rev issue and the starter just spun. Took off shroud to watch it and sure enough, it spun, lifted into flywheel gears and kept spinning. Thought i was going to have to buy a starter but knew i better check the internet first. I will be doing your trick tomorrow. Thank you very much.

[@jl329g]

Thank you very much. It works very well. For my case, there was no damage. The slipping was caused by wd-40 that I sprayed to the gear and spring. I just cleaned it and roughed up the 'clutching' surfaces, both the metal and the rubber sides, with 80 grit sand paper, and it backed to as new. Without your video, it would have taken me at least half a day. I was just 15 minutes with guidance of your video. Appreciate it!

[@saleemkader2126]

Excellent video , i was stuck putting it back together as magnets had moved glued them back with permatex silicone adhesive .

[@josmith5459]

Has to be the most helpful video I've watched thanks for the help

[@indianabob7166]

Great idea. I did this at the end of last summer 2016, it's still working as of April 2017. thanks-----

[@kevinbolin7665]

Thanks / Its a great way to save some cash and has proven its self a very handy method .

[@jjr694]

Thx for posting. This video helped. Had same starter slip problem.

[@lincolnsaint5082]

Just found out why it is a bad idea to lubricate this kind of bendix.Never had any experience with it.Thanks now i know what to do.

[@1954Mikael]

Thanks. You made my day Witherspoon this video 🤙

[@frankvanderwerf2162]

Thanks man! You made my day. In my case it was only a matter of cleaning. But your assembly instruction was very helpfull. So many thanks from The Netherlands!

[@kevinbolin7665]

Very welcome....glad to have helped...

[@stevejenne2685]

appreciate the video. I took out my starter, disassembled and the rubber contact piece was all but shot, so i couldn't just spray the other piece with the bedliner material for a fix. But the good news is there is a starter repair kit for $20 that includes the rubber piece, contact plate, new spring and end washer and ring clamp (sorry, probably using all wrong words :). The 10 MM socket trick didn't work to put on ring clamp, but i just used to pliers to pull the ring wide until it fits, and again to bend it on tight. Tried starting after the fix and same whir sound without starting :(. Took off engine cover to reveal the main flywheel that the starter engages had some broken off teeth, which was the problem. Temporary fix is to rotate the broken teeth part of the flywheel to the other side and it starts fine, but i reckon i'll have to eventually replace the flywheel. At least i have new starter parts now though :)

[@MrsBuddevil]

Kit part number?

[@tobynohio]

This does work some but I have also had better results with rubberized undercoating. Same brand. They are very similar products. This is just a bad design. Problem is usually you will have no rubber friction material left. It will be powdered and gone. I have used a large about one inch diameter grommet from the hardware store pull out trays. Slide it right over the top of the collar on the bottom of the gear and then spray with some undercoating and let dry over night. Works like a charm. Often longer than new one.

[@rexc.7230]

I'm trying this tomorrow with one I'm working on. 👊

[@bamamike1013]

My Courage 20 starter just started slipping on my Troy-Bilt Bronco. This might be the ticket. Thanks Kevin!!!

[@stevejenne2685]

if not there is a $20 fix....3209801 ATP Starter Drive Bendix Kit W112115 from advancetruckpartsusa.com

[@bamamike1013]

@@stevejenne2685 Thanks Steve!!!

[@kevinbolin7665]

@@stevejenne2685 Glad to hear the rumors where true and someone decided to make service parts for these starters .......always hoped a option like this would become available .

[@drawfark]

What a cool thing to share! Thank You!

[@kevinbolin7665]

Your very welcome....This trick can work great if the rubber on the pinion isn't to bad .

[@jpcirb]

I used this. Thank you very much

[@alexquiton7279]

Thank you so much, I just clean mine with brake cleaner both helix and the rubberized suction cup and now it doesn’t spin freely 🙏

[@kevinbolin7665]

I can see its been 11 months that has passed …..I am truly sorry I must have just missed this comment …...but just by chance you still own the equipment rest assured this method works .

[@rosemcbirney5123]

Can I push the thrust washer in to the rubber part before assembly or does it have to find it own way in as I just bought anew bendix kit

[@ronaldlong2760]

Thank you so frickin much! Totally helped!

[@kevinbolin7665]

Your welcome ....I know how much it sucks having to contend with these junkie starters . I wish this method was a permanent fix sadly it just buys you time as the rubber material truly just breaks down after about 3 to 4 years from new. And as a result the truck bed liner material then has nothing to create friction with and once again a slipping starter drive will be the issue ......Still it can buy you time to purchase a new starter......

[@robeftyearian8760]

That was very helpful man thank you keep up the good work

[@LawnZip]

Good video! Thanks!

[@philliphall5198]

I will try it next Thank You ☺️

[@cmandas1598]

Great information but I'm stuck trying to figure out how it comes apart... that last clip you put in

[@byronwestbrook6036]

Thanks, man! I got mine apart and it was missing those two little washers just like you mentioned. I ordered a Bendix rebuild kit, but none of the kids include those washers. Do you have dimensions on them? Can I buy them somewhere? Or maybe just go without? Kohler doesn’t sell Bendix parts anymore.

[@mikestackhouse9001]

Kevin, I have a Lawnboy with a Kohler xtx650 engine, electric start. Battery and switch are good. When i turn the key, the pinion gear just spins below the flywheel, will not engage. Would this condition be caused by what you have talked about in the video or could it be a bad solenoid inside the starter? I cant even find a part number for the starter. Help!

[@jeffwiggins3351]

Thank you for the advice:>)

[@robeftyearian8760]

Very good video tganks

[@bernieanderson8118]

Thanks 'Cooder Nice Vid.! Keep 'er 'tween the ditches!!

[@kevinbolin7665]

LOL.....I will try .....no gar ront tea

[@brucehutcheson5371]

I had this issue and the part shown at 00:23 where he says you have this friction stuff breaking apart, I used a Dremel Tool and ground down that rubber surface until it was smooth and that allowed the starter bendix to grab and engage the starter to the engine.

[@spike121964]

Excellent. Cheers

[@ronhat-nx6yq]

This friction material is just rubber glued to the starter engagement gear. Instead of using a solenoid to shove the gear into the flywheel, they are using a spiral gear, what he calls the helix, to both engage and disengage the gear and that rubber to act as a clutch. Cheaper to manufacture than a solenoid but will not withstand the pressure. When that rubber breaks of, it starts breaking teeth off the flywheel.

[@martysmallenginerepair5634]

I just used this method of spraying the helix with Bedliner and it works perfect!

[@pl747]

I went ahead and ordered a new starter drive for my 20 hp Magnum. Even brand new, the metal gear piece that spins up and into the rubber piece with the teeth is just plain smooth steel too. Piss poor design. I am going to grind little grooves into it with a cut off disk before I put it on. The one I coated with the rubberized undercoating is still working for now.

[@kevinbolin7665]

I agree they truly do build them piss poor .

[@waltwood4113]

Hopefully your still on here, I have the same exact starter with an issue. My question is what your problem was the starter wouldn't engage with flywheel?? My gear ⚙ will spin but not go up and engage into flywheel teeth?..just wondering if I should try this while I ordered a new one that way I can mow my yard. Thanks.

[@kevinbolin7665]

absolutely .....my issue was the friction material used to allow the helix to engage was cracking .....and the starters pinion would not engage because of the friction material as it had become so distorted or dry rotted .

[@keithh3767]

where do you get the bendix kit for rebuild?

[@philliphall5198]

I used a electric ingraver on mine and it work for now

[@eprofessio]

I just glued mine with RTV Ultra Black Silicone. I cleaned both parts with carb spray and put the sealant on the rubber side with plenty of it and cleaned off the excess with a screw driver and paper tower. I will post in a reply to this how it works out.

[@kevinbolin7665]

Thanks ...hope it works out for you .

[@eprofessio]

I let the RTV cure a full 24 hours and this WORKS so freaking well. You can even stay in the starter for extended period for hard starts. I just played with it some more it works great.

[@eprofessio]

@@kevinbolin7665 It took everything in my bones to keep from playing with it while it cured. It works great!

[@pointerman42]

How do you get the cap, seems like plastic, off of the original starter? Also, the teeth have really wallered into the friction material. I'm thinking I'll have to replace the friction material but I need to get the old one apart and don't know how to get that plastic piece off to get to it.

[@kevinbolin7665]

Using force can often allow you to take the plastic cap off ......But a small heat gun works best as it will allow the cap to expand after about 2 min of circling the plastic cap. Note also that the friction material is fused with about 1/4 inch of the pinion gear .......Crazy way to build a starter I know but they come from factory that way.....The method I provided works great but if the friction material has large cracks then a new starter will have to be purchased in time.

[@pl747]

I had better luck using rubberized undercoating. The Rustoleum bedliner was more like paint, even after I shook it and shook it. Next time I am going to try to glue some rubber to it. But very good idea.

[@_Lassic_]

Hope it will help me, they are expensive.

[@tonymontana897]

I recently purchased a ride on mower with a Kohler Courage 25, SV-730 and the starter is acting up. When you go to crank it, it turn over like the battery is weak, then when it tries to start it makes a screeching like sound with a clang. Does it have the same issue as the one you've fixed here ? I'd like to fix it if possible rather that needlessly replace the whole thing. Thanks for the video.

[@kevinbolin7665]

Sadly your starter may have internal magnets that are broken , defective top cap bushings ,or even worst a over labored commutator / armature winding that has suffered damage . All of witch will require the purchasing of a new starter inless you have a parts starter to use for the nessuary repair.

[@tonymontana897]

@@kevinbolin7665 I suspect it may have some kind of damage so I went ahead and ordered a new OEM starter. When I fit the new one I will disassemble the old one to see what's going on inside. Thanks for responding mate.

[@TrevDoggTV]

I have to hit my starter on my Deere because I've done it so long that I broke the casing, it's all dented up and rarely works. I'm to cheap to buy a new one do to the fact the rearend is bad in it. Good motor tho 🤣 On a side note, my Kholer Courage 23 twin I just got has a bad starter, got some teeth off the flywheel. Runs great other wise

[@jma8352]

thank you!!

[@kevinbolin7665]

Very welcome /Glad to have helped..

[@topflight2358]

starter you have here is just like mine...so why when ordering , ( two diff sellers ) am i getting starters with a flat 3/4? tab to one side that keeps it from fitting into the space it goes ??

[@kevinbolin7665]

I really could not say . I think if its a OEM part then it should fit . Make sure you supply the dealer with your model and spec numbers to avoid any additional confusion . These numbers are essential in insuring the proper part can be ordered as well as fit the equipment intended . Often aftermarket starters tend to come with aftermarket issues ….When in doubt always order OEM ..

[@kevinbolin7665]

If you have been ordering what you suspect was a OEM starter . Please provide me the Model and Spec of your Kohler Courage Engine .I will be glad to help .

[@Z-Ack]

It doesnt eat at the rubber on the doohickey over time?

[@kevinbolin7665]

What ? The rubber over time gradually starts breaking down and chips away or becomes buffed where it can no longer make friction upon contact with the helix drive washer ..

[@papalilburn]

Good video, suggest you invest in better lighting to show the details of what you're describing.

[@terrybolin7695]

Thanks for the idea..... Just realized same last name

[@kevinbolin7665]

Welcome....LOL that is kind of a coincidence.

[@bradgoodin]

how do you get that top ring off?

[@bradgoodin]

sorry the top cap was stuck and wouldnt push down to expose the ring, and i didnt want to break it. I got it loose and apart. thanks for the video!

[@kevinbolin7665]

Briggs and Stratton makes a tool that can take these small rings off of this Kohler starter . However I often just use a small standard screw driver and carefully pry at the corner of the rings opening progressively working my way around intel it comes up .

[@thedude4632]

Wish I watched before I got another starter

[@61066clocks]

Good Info..incredibly bad design by Koyler..I think they have since upgrade this particular Gen 1 starter?

[@ronhat-nx6yq]

Just take some pliers and pull the cap off. It snaps off and snaps back on and is really not necessary for starter to function. These Kohler Engines are a very poor design and most people are having trouble with them. The starter is an example. It has a rubber material glued to the starter flywheel engagement gear. This acts as a sort of clutch but the rubber will too soon deteriorate and brake off. It just cannot take the pressure and torque. Unfortunately, when you hear the starter make a different sound when starting, the engine will still start and run just fine but you should no longer try to start the engine as the starter will then start breaking cogs off your flywheel. Flywheels are expensive. Another issue with Kohler engines is the new type ignition coils. Kohler is selling a kit to replace both coils on twin cylinder engines. It replaces these bad design coils with simpler coils that have a spark plug cable and kill switch grounding terminal and that is all. There are many other issues with Kohler engines. Check online and you will find them.

[@kevinbolin7665]

Very well written / And you are correct with only one exception that I hardly feel is worth addressing . The material applied to the gear is not glued ...its molded

[@michealkelly8689]

Exactly what happened to my engine

[@davidvines6498]

Be nice if you would show how to get the clip off

[@kevinbolin7665]

That takes time and patience ...I often use a standard screwdriver lifting up on the c ring retainer clip . I normally start where the clip has the cut and lift up gradually circling the exposed cut away portion that the clip resides into . Note Briggs makes a tool to remove the retaining clips on there starters that works very well with Kohler starters as well . But they are expensive …..So for the do it your selfer its best to just endure the headache of slowly advancing the clip out and around its retaining cut away space . Small pliers can easily manipulate the clip if slight bending happens .

[@davidvines6498]

I got it. I could not push the spring down. So I downloaded the manual and went to Starter repair. It said push it down with your hand. I had to take a small socket and free it up. The rest was easy. I’ll put the starter on in the morning and let you know if it works. Thanks a million

[@davidvines6498]

It works

[@kevinbolin7665]

@@davidvines6498 Just reading some of my old comments and replies and seen you had success/ glad it worked out for you .

[@doodah2475]

Cant you just glue it on with something

[@kevinbolin7665]

? I am not sure I understand what exactually your asking to just glue ....the pinion to the helix drive washer? ....If so No because once the starter engages the flywheel it will lock in mesh and the engine will run the pinion/ starter due to the starter being locked in mesh.....as a result the flywheel and or starter will be damaged .

[@clarkgarrison7091]

My mower has been off for awhile and starter is still to hot to handle, also when trying to start strter makes a barking sound

[@kevinbolin7665]

You need to adjust your valves or check your oil level as your may have gotten gas to mix with your oil due to a faulty carb inlet needle and seat .

[@clarkgarrison7091]

Kevin Bolin when i turn the key it makes that bark or grind sound

[@clarkgarrison7091]

Kevin Bolin its a puolon pro with a Kohlor Cammander 18 engine

[@clarkgarrison7091]

But it seems like a starter and flywheel problem

[@kevinbolin7665]

There actually could be one if the equipment was stored outside . However if the equipment was stored in a small shed or building etc its more likely your experiencing the affect of a flooded crankcase that has diluted the oil . This effect will only allow the starter to turn intel against compression stroke . Then the starter will grunt or wine ....Eventually you will burn up a starter or solenoid if you persist in trying to crank the engine over without draining the crankcase or adjusting your valves . It may be worth your time to check your carb to insure you don't have a faulty inlet needle and seat .

[@clarkgarrison7091]

Kevin Bolin so ill have to have it serviced then, brand new starter and hot as hell after 15 mins of use

[@georgeparra7953]

Very poor lighting