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I believe it's a 2018 if it matters. From zero throttle to half throttle the engine is at idle at about 1600 RPMs. From half throttle to Full Throttle the RPMs increase to about 2600 Rpms (sitting still, pto not engaged). What should I be expecting on this mower? I feel like the throttle lever /...

Both spark plugs look golden brown. No real difference. Both appear healthy. Edit: That is an interesting note about the lifters/valves. I'll check clearances. To be honest, I haven't pulled a Courage apart yet. It'll be a learning experience.

This motor should have hydraulic lifters so valves can't be adjusted. But I'll pull the valve covers off and look for any anomalies. Maybe a worn cam causing valves not to fully travel or something. At least I can rule some things out maybe.

Which cylinder is the problem? 180 is too high isn't it? 140 is a little low, but very acceptable for an engine with hours on it. Right??

Follow up post. I disconnected the main harness and direct connected 12v to the DSAM and the Solenoid. Motor fired right up with no issues. Revs up and down (no load) easily. Must be something in the main harness. Luckily I don't need that. To the trash can it goes. This is just a spare motor...

I don't think this is the issue. I've triple cleaned the main engine harness plug and it looks good. However the rest of the harness is complex and just laying all over the workbench. So it's possible there are deeper issues involved in the harness as a whole. I'll be removing the harness later...

Yep, thanks. I've got it on my bookmarks already. Invaluable with these motors.

Yeah good point. If feels like the source of the issue is the DSAM since when disconnected the voltage shows right. But maybe it's simply the normal load of the DSAM that is overpowering the system from a separate issue. When this was on the mower I checked spark on both cylinders and I was...

The short video attached should explain it better than I can. Essentially I'm not getting 12v to my fuel shutoff solenoid unless I unplug the 12 volt lead to my DSAM. One thing to note in addition to what I mentioned in the video about unplugging the other leads to see if anything changed...

Ah, good point. Won't bog down so easily. Makes sense.

I've got an Ariens Ikon X 52 that came with a 22hp Kohler Courage motor. And I have a 26hp Kohler Courage sitting in my garage. The motors look identical even down to the shroud. I'm guessing it's just a longer stroke or a slightly bigger bore to get that extra 4hp. So... stupid question I...

Thanks. That's even more a mystery then. I'm left to wonder if it was replaced with NOS somehow or a full used motor. Probably the latter. No idea what the true hours are now. Ugh. I'll have to research if it has compression release to know if I can even get a compression reading to gauge the...

I just bought a 2018 Arien IkonX 52 and noticed that the Kohler Courage 22 that is on it has a "build date" of 1/31/2006. Anyone know if that seems normal? A motor that was built 12 years before the mower? Or should I assume this has a different motor than what it came with? Just curious really.

I don't think only having the blades engaged while sitting still would constitute a real load. The rpms with the blades engaged were 3400+ just sitting there (that's why I ruled out the deck being an issue). It's a moot point at this juncture anyways, I just sold it. I sold it for more than I...

This spins free. But if it didn't, this would present itself even at idle. Not just under load.

Yeah, I've been down that long road. Freshly rebuilt motor. Brand new MDI ignition system with new plugs. Completely new fuel system including carbs (which even new, were opened up and gone through). The motor low and high idles great. Runs smooth through the full rpm range sitting still. Just...

The mower is a Gravely 260z with (let's just call it) a brand new engine/fuel system and for the sake of argument, a new deck/blades/pto. Engaging blades causes a momentary drop of a 4-500rpms but then quickly high idles again at 3400+. About 10-20 feet into mowing however (sticks forward) the...

Well, I think we can rule out the engine/carbs. After a full rebuild there is no change. I found some little things during the rebuild that were not perfect but fixed them as I went through it. The engine is operating as it should. But the problem still exists. An interesting note. When I run...

Yeah, she's clean. I'm on hold waiting for a ring compressor in the mail today. I'm used to just pinching in 2stroke rings but this oil ring ain't having it. 😜

The Kohler manual says: Three different types of connecting rod bolts have been used and each has a different torque value. If 8 mm straight shank type bolts are used, torque in increments to 22.7 N·m (200 in. lb.). If 8 mm stepdown bolts are used, torque in increments to 14.7 N·m (130 in...

No, I didn't. Just TDC. I guess it's a moot point at this stage since I just honed both cylinders for new rings. However I will say that both cylinders looked really good. A bit glossy but with visible cross hatching in both still. No scoring or anything. I don't have any bore measuring tools...

It has not. However the seat is already disabled. I'll double check but I'm pretty sure it's just the two seat switch wires twisted together and insulated. If there was something "off" in that I'd feel like it would cause problems in all levels of operation though.*shrug. And certainly wouldn't...

I'm replacing the one with wear on it (see post #52), and I'm disassembling the other three and cleaning them. That said, I've pulled one apart already and it looked super clean with no issues. On that note however, and I talked with someone else about this too, but I'm not 100% sure what kind...

In my OP checklist I put a string on the governor lever (which is of course attached to the throttle) and under the rpm drop under load I pulled on the string to no effect. Full throttle has the throttle plate fully open (verified). So that tells me the throttle is full open under load. Also...

This motor has no compression release. And hydraulic lifters with no valve adjustment.

Line 30 and 31 of my OP checklist sort of verified that at least the intake seal isn't leaking (and this motor has no seal on the exhaust valve by design). But I removed the #1 valves yesterday and they don't seem loose in the guides. Not tight, but not loose either. Guides are positioned...

The test results of this are in post #32 and a follow up in post #46 in the Kohler thread I linked to above. There is also a video of it starting at idling (low and high), and of it running and dropping rpms in post #31

Thanks for the response. A few weeks ago I moved this to the Kohler forum and streamlined the long list of things I've ruled out. Since they were all kind of all over the place here. https://www.lawnmowerforum.com/threads/cv740-27hp-bogs-severely-under-average-load.75051/ It's becoming a long...

I was in the shop this morning and took a better look at my lifters (and got a better pic). They are all perfectly smooth except #1 intake (top left in pic1 with matching cam lobe the one nearest to it). You can feel that wear on the lifter with your finger. A. would you be concerned about...

We talked about it in a different thread. I had the DSAM system apparently. The box was 24 584 27 and the coils were 24 584 15. I assume now they were all working fine?

Yeah, and although I'm sure they're not perfect, as mentioned before... I don't think this is my problem. So with that being so, I'm not willing to drop $500 on a new crank/cam/and lifters for sure. I'll bleed the lifters like you mentioned, hone and ring job the cylinders (need to make sure I...

See the pic. It's hard to get a good one as the mating surface of the lifters are almost chrome and it reflects my led shop lights. 😜 On this subject, in your experience are these Kohler lifters the exact same as GM/Chevy small block lifters? I've heard they're the same (and they look the same)...

Yes. I should have taken a video. When I unplugged either side, it was difficult to start. With both cylinders it's usually it's a pretty easy crank or two even at low idle throttle position, but with one side unplugged it struggled to start. A little 50-75% throttle feathering and she would...

It's belt driven hydros. I've definitely considered malfunctioning hydros externally putting too much load on the motor, but that doesn't explain my carbon fouled cyl #1 (only). And this thing should normally run at 3300rpms under normal loads. I only weigh 175lbs 😜. Back to the blades.. When...

I'm in the office today, I'll look when I get home. Are you implying that a crack could allow the gear to slip? I thought we ruled that out when we verified exhaust tdc to be correct?

I currently have the belt off so I could take a video of the spindles spinning by hand. They don't sound gritty to me like bad bearings would. I'll check again though with some side tension applied. And I'll take a pic of the blades but I did sharpen them. No idea what they are though. It's...

Ok, so I really don't know what I should do at this point. To be honest, I don't see anything glaringly wrong anywhere inside this motor. No cracks or case defects. Cam lobes all measure the same, governor gear assembly looks good. Crank seals are tired but they weren't leaking (I'm going to...

Nope. I haven't done a full inspection but I got a pretty good look at the heads when they were off and a decent look at the cylinder sections. That said, it wouldn't surprise me if this thing got a bit hot in it's 1200hr life. I'm in Florida so we're in a pretty warm climate and the fins were...

Essentially yes. I would say that I feel like when I first got it I could still mow my lawn with a bit of a struggle. But now I feel like I'm a bit worse. Seat of my pants meter only. I could just be frustrated. None of the data has changed though. Still bogging about the same. Still getting...

I did this and just grounded the unplugged boot with a alligator clip test lead. (note, I think these new MDI coils have built in protection though. As they have a lead running back from the boot and grounding out under a bolt of your choosing). Neither side runs great by itself and neither...

Ok here you are with the videos. First video, cold starting and running. Second video could use some narration as it's loud and bumpy (my yard isn't as smooth as I'd like) and I'm trying to drive a 2 stick zero turn with one hand in most of it. 1. First part is me running with blades...

Yeah I'm almost certain it's correct. I base this on the following: the flywheel that comes with the 24-755-308-S MDI conversion kit has 8 gear teeth between the keyway and the start of the magnet. So does my flywheel. It's a little different in overall design but the timing degree is the same...

Well, it's not the exhaust. Interesting note, it runs like absolute dog sh@t without the muffler attached. Still dropping rpms though. With the added poor running, it was almost un-driveable now. Also interesting, is the residue left from each cylinder. I took pics. The exhaust from the heads...

If it's the exhaust, I'll throw a party I swear. Fingers crossed. If not, I'll take a video. Or two. One of it starting cold and throttling up and down with no load. And one mowing showing the precise issue on the tach.

I just took a look in the Kohler manual. It appears as if 7mm is a bit out of spec? Unless this needs to be done on a hot engine (hydro lifters freshly pumped up)? The motor has been cold and sitting for a few days. Again though, #1 and #2 are the same amount out of spec. So it wouldn't explain...

No, I bought it about a month ago with a slew of problems. Mostly electrical issues which I sorted out. It was completely missing a starter relay for example. And wires were cut and/or not hooked up to the ignition switch (ad said it needed a new switch, but it did not) But no, it always had...

I've taken the exhaust off a few times now. It's not hard. It'll be loud but I'll try running it without to see what happens. Previously I blew through each exhaust port with (sealed) compressed air. #1 wasn't "holding pressure" different than #2 or anything but the testing method did seem...

No, valve covers are still off. I'm kind of tired of disassembling this thing and then putting it back together so I took a break today and cleaned up my gas leaf blower instead. I will though. And you're talking about just at high idle with the intake hoses off? What does that indicate if there...

Correct. So the big question is how to test that hydro system? Or instead, what would cause a hydro system to have excessive load? If that's even possible? Fluid level is good and looks clean but it has a massive filter that I haven't changed. A clogged filter can't be an issue though, as it...

Following up on the valve timing check. At TDC exhaust stroke (on both cylinders), the valves teeter right at exactly TDC. I'm going on a limb and saying it's not my issue. 😭 The more I dig in, the more this motor is proving to me that it's healthy. Ugh. Is there any chance this is an external...