Kohler KT735 Cranks But Won’t Start; Fuel Solenoid Issue?

I was having an issue with my Toro MX5050 zero turn lawnmower cranking but not starting. The engine is a Kohler 7000 Series, KT735, 24 hp with smart choke. In this video I talk about the fix that I found and how I found it.

[@Oldnoitall]

My Kohler has been shutting off and on for a few weeks finally had it down to starving for fuel and found a foam ear plug in gas tank was getting ready to yank on that solenoid hooky do

[@Toga_Lock]

I had this same issue. The mower would run if I took a jumper wire straight from the battery to the solenoid. Ended up replacing the ignition switch. That worked for a few months, then it happened again. Another ignition switch. Probably a short somewhere for me.

[@bchurliman]

Thank you for the video. Having similar problem with no power to fuel solenoid.

[@reecerandall918]

I dont have time to track down that stuff. I bypass everything by putting a jumper wire to the key switch. Also if they dont work when testing, I cut the plunger off.

[@TheClintmeister]

I took the solenoid off with a thin wrench and cut the top (plunger/fuel jet shut off) then bolted it back in. Problem solved.

[@mattwebb8234]

This might be my problem too

[@oklahomaokie]

I think we have pretty much the same set up. Mine is not getting fuel to the filter unless my gas tank is 100% full. About 2 minutes after starting is uses a few ounces of fuel and my line to my filter will not flow any gas. As soon as I refill my gas it will then flow and run again for a few minutes. My gas line enters my tank from the top side. Any advice?

[@Wes_Barton]

Sounds like there possibly could be a crack or slit in it somewhere near the top. Once the fuel level drops below it, it starts pulling air and loses suction. Like a straw when it’s got a hole in it.

[@oklahomaokie]

@wesleyebarton I ended up cutting my hand and got stitched up. Haven't went back to it yet. Good idea. Thanks

[@MLDIYSH]

Well I still have power to the fuel solenoid so that plug wont apply here. Would anyone know a solution to: Cranks but wont start. Fuel solenoid working with key on, both spark plug produce spark. Carb, fuel filter, fuel pump changed. Wont Start. Starts with starter fluid, then dies. TIA

[@Wes_Barton]

I experienced the same thing on a tiller when I had installed a new aftermarket carburetor. I replaced it with a genuine Honda carburetor specific to the engine model, and it ran perfect.

[@davelundergoesunder]

Thank you for the video. Good diagnosis.

[@Ben-Hawy]

Most of the time it’s a loose fuel solenoid plug 🔌 under the carburetor, usually the plastic plug gets cracked

[@Wes_Barton]

Good tip!

[@davidreasons9730]

My Kohler 28 is acting up right now seems like when I first start it and start cutting it's good about an hour into it starts backfiring and popping like it's running out of fuel and then both tanks are got plenty in it

[@Ben-Hawy]

@@davidreasons9730 Check the governor adjustment, throttle adjustment, make sure all the bolts are tight and not loose and make sure the carburetor doesn’t have dirt in it, it’s acting like a clogged fuel filter

[@manofculture4945]

@@davidreasons9730 I had the same issue with my john deere and changed the ignition coils and now it runs like new. Really cheap and easy fix took me about 20 min

[@flashatrno]

Thanks for the video. You helped me get my Bad Boy to start. The choke was sticking on mine. I never would have thought to check that. Awesome!

[@nelsonsantos770]

I took the fuel shutoff soleoid and it runs, but I have to be very careful to completely use fuel in carburator.

[@qingzheng5155]

Noooooooooooooo 😭🤨😭

[@lukelyons7224]

Fixed my problem! Thank you sir

[@Donnie_Prestwood]

At 4:19, the rubber hose you see I know connects to the bottom of the air filter housing but where is it coming from and is it the crank case vent hose? Mine is putting oil in the carb.

[@davidreasons9730]

Thank You Mine 61" Z Master commercial and when it runs fine on the right tank but the left tank it after cutting for about 15 or 20 minutes. Gas it will start acting up and eventually die so I've got some kind of a fuel issue and I'm going to check this right here to see if this could possibly be at Monza Kohler 28

[@manofculture4945]

It could be the gas cap on the left tank is not venting properly. Maybe it isn’t but try switching the caps

[@TheClintmeister]

The 7000 series likes to burn up coils. Run a ground from the battery to the motor. I just did a video of how the charge controller/voltage reg. burns up easily, and I permanently fixed it. Lots of problems with the Kohler motor. They like the E3 sparkplugs too.

[@TheClintmeister]

Also I had a set screw come loose above the oil filter and cought it in time before kaboom! Lots of oil came out but I cought it in time.

[@jennifermatoy8633]

What exactly do you mean by "they like E3 plugs....."? I have a 2016 Cub Cadet 60" zero turn and now tackling the maintenance on my own and was looking at the E3 spark plugs for mine but didn't buy any that day. I wasn't sure about them. E3, Good or bad? I'm here trying to figure out why it won't turn over.

[@TheClintmeister]

@@jennifermatoy8633 the coils that supply spark to the spark plugs. Documented many problems and Kohler has updated coils. My thoughts Kohler should have done it right the first time.

[@TheClintmeister]

@@jennifermatoy8633 the kohler v-twin up till 2019? would burn up ignition coils easily. Kohler came up with a better coil and have them for sale.

[@jennifermatoy8633]

@@TheClintmeister I'm pretty sure that's what mine is just a 2016. Sounds like a job I probably shouldn't do. I'll have my son do the coils but while at Tractor Supply getting oil, filters , etc was looking at plugs. I have 2 different types of plugs I can use. One was the E3 and all they had in stock but also had another Plug made by Kohler but I didn't see that one. Is the Kohler an E3 too? If not which one should I use? Thank you for the quick reply.

[@tksshred6649]

Thank you you save me so much time

[@freedomofspeech9423]

Thank you

[@robertbeacher3682]

Thanks......good deal

[@MrGaborseres]

Thanks for the information

[@smestel]

Thank you!!!!!!!!!!!

[@winstonsmith1917]

Thank you

[@robertjeffery6100]

Good find 👍

[@David-oq4uj]

Was your flywheel freely turning beforehand?

[@Wes_Barton]

Yes

[@mtjposhea]

I hat the same problem. I had a technical look said the was a big in the fuel tank. That will cause a problem.

[@cassiehuckaby3107]

When you turn the key could you get the fuel solenoid to actuate at all? Like did you hear the click? I just wondered if it would still click at that low voltage but not fully retract like it's supposed to.....

[@Wes_Barton]

No. I couldn’t hear it click either.

[@cassiehuckaby3107]

Thank you!

[@cindynorth1176]

I think your missing a fuse .

[@ScottieBrand]

Was it cranking and would not stay running

[@Wes_Barton]

Yes

[@ScottieBrand]

@@Wes_Barton it was the fuel pump

[@Wes_Barton]

@@ScottieBrand wrong. I replaced that too.

[@rustyscabra3764]

Hi Wes, I have the same carburetor as you a Walbro LMC. I am having surging problems, but luck on finding any adjustments. Have you run across any adjustments? Walbro has none.

[@Wes_Barton]

No I haven’t, sorry.

[@dennismock7414]

My mower will take a charge but won't stay running when I take off jumper cables

[@Wes_Barton]

Sounds like the battery is no good. The fuel solenoid needs current to remain open allowing fuel in.

[@jeffreyevans6892]

Thank you , well done!

[@joshardy25]

Would the motor crank? Also were you getting fuel when turning over?

[@Wes_Barton]

Yes the motor would crank. The fuel solenoid needle would not open (retract) to allow fuel into the bowl.

[@milonjano]

Just pull the connector off the brake module, spray contact cleaner on pins and reconnect. Problem fixed...

[@Wes_Barton]

I tried your recommendation today. Didn’t work 😞. It will not work unless there is pressure pulling up on the plug. I fooled with it for hours and the only way I could get it to stay working was to pull up on the plug using a zip tie through holes in the frame just above it.

[@milonjano]

@@Wes_Barton Yours is probably a broken pin and I had a corroded pin.

[@thomas25082]

My starts for a sec when i turn the key off wth

[@Wes_Barton]

Interesting.

[@thomas25082]

Wont start with starting fluid either

[@jacobjohnford]

Wow you saved me so so much time. I already had ten hours into various "fixes" that didn't work before finding this.

[@pahick54]

Nice work. Thanks for posting!

[@seankennedy4284]

That's not a fuel solenoid issue.

[@Wes_Barton]

It’s a wiring issue controlling the fuel solenoid.

[@frankdavidson9675]

@@Wes_Barton there is awire from switch with12v to solenoid if that lead has no volts bad switch--------m lead leaving switch this same wire gos other places also