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    Kohler Courage 20 / SV600 Walbro 3 carburetor leaking from float valve

    Hey thanks! I chem dipped the carb and it started running much more smoothly. The fuel tank was clean and the fuel lines are holding up just fine. I *could* stand to clean the outside of the engine a bit more, but it is running all right. I only had the shroud off to test the carb/governor, and...
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    Kohler Courage 20 / SV600 Walbro 3 carburetor leaking from float valve

    So my last dilemma... I bought this mower from a fellow on Facebook... He buys, "fixes" and resells used mowers. He told me that "this is still his mower and he'll work on it for free, I just have to give him a call and get the parts for him..." I wasn't sure that I wanted to give him a call...
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    Kohler Courage 20 / SV600 Walbro 3 carburetor leaking from float valve

    Haha that might be up for debate!!! :D We'll see how it holds up. Now I'm just waiting for the plastic cam gears in my Kohler Courage engine to break. It's just a matter of time ;)
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    Kohler Courage 20 / SV600 Walbro 3 carburetor leaking from float valve

    I bought a '99 Maxima back in 2014 to learn to drive stick. I think I spent like $2k on tools while I owned it but a lot of them came in handy here. Shame is that I own everything needed to fix a Japanese import but nothing is standard lol. I had to go buy a 7/8" impact socket just for this...
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    Kohler Courage 20 / SV600 Walbro 3 carburetor leaking from float valve

    Just a follow up to finish discussing my fixes. I've fixed just about everything so far... there were a few more problems... Accelerator bracket replacement I replaced the old accelerator bracket with a new one, but this was while replacing all the internal belts In order to replace this I...
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    Troubleshooting Slow Troy Bilt Bronco (2011) - FIXED!

    Hey! I'm sorry to necro this thread but I think I am having the *exact* same problem with the exact same tractor. I have the new bracket but I've been monkeying around with it for the last hour and it doesn't want to cooperate. I was wondering if anyone knew of a good resource on how to execute...
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    Kohler Courage 20 / SV600 Walbro 3 carburetor leaking from float valve

    It runs! It's still a little lean on the bottom of the throttle but it cuts the lawn so it's going to stay that way. There are still a couple things wrong with it; it moves at about 2 mph... slower than a walk. I believe the accelerator bracket that connects the pedal to the transmission has...
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    Kohler Courage 20 / SV600 Walbro 3 carburetor leaking from float valve

    So I tweaked the governor a whole bunch and had someone sitting on the mower who could turn it off quickly. The factory adjustment in the manual actually turns the governor *up* all the way, hence the crazy overspend. After turning it down the mower was actually idling a little lean - maybe...
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    Kohler Courage 20 / SV600 Walbro 3 carburetor leaking from float valve

    Yeah sadly I have done all of that, including backing out the idle adjustment screw almost all the way. I think the governor is shot. I need to monkey around with it a little more, but I really hate to run the engine in an overspeed condition for any period of time. Man this thing is proving...
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    Kohler Courage 20 / SV600 Walbro 3 carburetor leaking from float valve

    Ok so now it's running too fast :P I tweaked the governor back to the recommended factory setting but that doesn't seem like it matters... Thing is running like gangbusters. I have a new governor spring hiding somewhere... could that be the problem? I turned the idle fuel jet as low as it can...
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    Kohler Courage 20 / SV600 Walbro 3 carburetor leaking from float valve

    So, I reattached the carb, did "the right stuff" trick with the valve cover gasket and reassembled almost everything. I finger tightened the valve cover bolts with the socket and then did about one extra turn with the ratchet. It seemed snug but I didn't kill it. I also put a quart and a half of...
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    Kohler Courage 20 / SV600 Walbro 3 carburetor leaking from float valve

    Thanks! Super close on the torx; they were T-45! I had some large allen wrenches that happened to have a T-45 in them... I hated having to loosen the muffler, but it will mow the lawn with a loud exhaust just as well as with a quiet one. A new gasket has been ordered but I'm hopeful that I'll...
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    Kohler Courage 20 / SV600 Walbro 3 carburetor leaking from float valve

    Ok still working on this... Got some Berryman chem-dip and the carb just went in for a bath. Current problem: Valve cover. This dumb mower has an extra bracket installed that is pinning the valve cover in place... Here it is from the front: And here it is from the back: I am tempted to...
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    Kohler Courage 20 / SV600 Walbro 3 carburetor leaking from float valve

    And some more pics / video because I want you all to hear and see what this is doing. I got it fired up and running again, but this time I changed the setting on the tach. Sure enough, at half the measured RPMs from before this thing makes a little more sense: It seems like it doesn't want...
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    Kohler Courage 20 / SV600 Walbro 3 carburetor leaking from float valve

    Mine also appears to be overtightened. The rim of the valve cover actually looks bent to me... I have some sealant and a new cork gasket on the way. Also tried adjusting the low speed idle screw but the thing doesn't seem to want to idle under 3k rpms... Not sure...
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    Kohler Courage 20 / SV600 Walbro 3 carburetor leaking from float valve

    Ok another update. I was able to turn the "low idle fuel adjusting needle and spring" a bit past where the limiter wanted to stop. Not all that hard to do. The mixture definitely got a little more rich. I also adjusted the governor to try and speed up the engine a little because it was keeping...
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    Kohler Courage 20 / SV600 Walbro 3 carburetor leaking from float valve

    Hey thanks! I have solved that particular issue and now seem to have a fuel mixture problem. I really appreciate you pointing out that part number though! Thank you!
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    Kohler Courage 20 / SV600 Walbro 3 carburetor leaking from float valve

    I saw a video with a fix for this particular carb that involved removing the limiter from the fuel adjustment knob and turning it up even further than normally allowed. Is there a reason that it would be running outside of spec when it fired up and ran just a couple months ago? It definitely...
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    Kohler Courage 20 / SV600 Walbro 3 carburetor leaking from float valve

    Ok! Back with more because it's Friday... As mentioned previously, I've gotten the thing to start but it runs pretty rough and needs the choke closed to keep running. If it only runs at half choke then does that mean my fuel mixture is lean? Not enough gas too much air? I dialed the governor...
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    Kohler Courage 20 / SV600 Walbro 3 carburetor leaking from float valve

    Awesome I will give that a try :) I have only tried to fire it up a few times so far
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    Kohler Courage 20 / SV600 Walbro 3 carburetor leaking from float valve

    Ok! So it started and it runs but I have to keep it on full throttle plus about 50% choke. The choke plate looks like it's about 80% closed when it's running successfully (I've been monkeying with everything so this is probably my fault lol). I put fresh ethanol free gas in it and opened the...
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    Kohler Courage 20 / SV600 Walbro 3 carburetor leaking from float valve

    Good news so far! No leaks from the carb last night despite gas being in the mower. I cycled the fuel solenoid a couple times this morning and heard it click every time the ignition was put into "accessory" mode (or whatever the term for that is on a mower). No fuel leaking yet! I am going to...
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    Kohler Courage 20 / SV600 Walbro 3 carburetor leaking from float valve

    You guys are all amazing! I don't think I can respond to everyone all at once :) Thank you for all the pointers. I bought some Permatex valve grinding compound and cleaned the seat; that q-tip baaaarely fit in there. I'm using the replacement needle as well. So here are the results (so far...
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    Kohler Courage 20 / SV600 Walbro 3 carburetor leaking from float valve

    Hey thanks! I replaced the bowl gasket prior to getting on these forums - that seems like it is holding ok :) The fuel is leaking out of the side of the carb at the air inlet, so... does that seem like a bad seal at the float valve needle allowing fuel to seep into the bowl and slowly leak out...
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    Kohler Courage 20 / SV600 Walbro 3 carburetor leaking from float valve

    So... can I use brass polish and a Q Tip to try and clean this up? The seat is so stinkin small and it's very difficult to get anything down in there... I might try putting it together as is; used some carb cleaner and scotchbrite but it doesn't seem like it made much of a difference. I will use...
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    Kohler Courage 20 / SV600 Walbro 3 carburetor leaking from float valve

    Man the Ace around the corner doesn't seem to have what I need in stock :p 30 minutes to the next closest hardware store. Looks like the 4mm ring terminal takes a number 8 stud (this is the side on the carb, not the frame) - Ace has it but not in stock :p Supposed to snow tomorrow or something...
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    Kohler Courage 20 / SV600 Walbro 3 carburetor leaking from float valve

    Awesome thank you both :) I might stop over at Ace tonight. Life's killin me with these gas prices though lol This (from here): Looks an awful lot like this (the broken end of my grounding wire): The JST site says that it is "JST, R Uninsulated Ring Terminal, 4mm Stud Size, 0.25mm² to...
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    Kohler Courage 20 / SV600 Walbro 3 carburetor leaking from float valve

    I was extremely surprised to discover it was done this way. Rotating the carb does make sense, but it probably isn't worth the risk. Oh, also my grounding wire totally broke at the screw in the carb so I need to get a new end for it :P Any good suggestions for that? It's a silly little part but...
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    Kohler Courage 20 / SV600 Walbro 3 carburetor leaking from float valve

    Hey thanks a million for linking that :) Can't tell you how helpful that is - I spent hours trying to find part numbers and figure this out before coming here. This carb has a fuel shutoff solenoid that holds the bowl to the carb body - is that typically done with the screw? The design is...
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    Kohler Courage 20 / SV600 Walbro 3 carburetor leaking from float valve

    I especially like figure 4 - it's like, "Yank it really hard with pliers"
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    Kohler Courage 20 / SV600 Walbro 3 carburetor leaking from float valve

    Also, that is awesome that there is a member here from the other side of the planet :D I'll be learning my Aussie slang in no time. Communities like these are amazing; I've kept beaters on the road and fixed things I had no right fixing thanks to boards like this. Excited to pepper you guys with...
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    Kohler Courage 20 / SV600 Walbro 3 carburetor leaking from float valve

    This makes sense! The carb is gravity fed from a tank that sits just a little higher than the engine behind the steering wheel. I have seen some videos of people using bolts to extract the seat - I haven't seen an example for this particular carb but I think the process makes sense.... Do you...
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    Kohler Courage 20 / SV600 Walbro 3 carburetor leaking from float valve

    :ROFLMAO: Now I just feel like an idiot for not realizing that :D But that makes sense looking at the needle a little more closely
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    Kohler Courage 20 / SV600 Walbro 3 carburetor leaking from float valve

    Awesome ty for the pointers! I believe that the float assembly is behaving the way you mentioned; with the carb upside down it rests horizontal to the ground. Also, I think I have some steel wool lying around, I'll have to try to clean up the seat a little tomorrow. I may have to jaunt out to...
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    Kohler Courage 20 / SV600 Walbro 3 carburetor leaking from float valve

    Ok some more pictures. Here is the bottom of the carb: Here is a tighter version of just the float valve needle seat: Here is the float valve needle - the current one: Is carb cleaner enough to clean this up? The needle doesn't seem like it wants to get stuck when I take it in or out of...
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    Kohler Courage 20 / SV600 Walbro 3 carburetor leaking from float valve

    Ok! You are 100% correct and thank you for the info so far :) The engine appears to be spec number SV600-0224. The needle valve seat *appears* to be clean... hard to get a good picture. I have a replacement needle that I can try but the one that was in there didn't look too bad... Here are...
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    Kohler Courage 20 / SV600 Walbro 3 carburetor leaking from float valve

    Hey! I bought a used 2014 Troy-Bilt mower a few months ago and it has been leaking gas from the carb. The carburetor says "Walbro 3" on the side. As I mentioned in the title it is running a Kohler Courage 20 engine and I believe the model is an SV600. The SV470-SV620 service manual matches what...
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