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So, I bought this mower in May... and it has only accumulated 5 hours since. Ever since day one, it blows smoke on startup. Only for a few seconds, one cloud, then nothing. I’m considering calling Caldwell, where I purchased it, just to get this on file... but is this common? The mower doesn’t smoke outside startup, has good power, starts easy... but it seems odd to see smoke on a new motor.

So, after reading a few comments on other forums, and other posts... I decided to check the oil fill level. Cold, it is about 1/4” above the full line. This, on a dip stick that has an operational range of 1/2”. Today I’m going to suction some of the oil from the crank case, and see if it makes a difference at start up.

I don't know about the new Kohler engines but that used to be a pretty common complaint on the older V twins. It didn't affect durability back then and it probably doesn't now ... but I can imagine how much fun it is to be in the corner of the garage getting it fired up and being in the middle of it.

So, I decided to suction the excess oil from the crank case... only to find the oil is a milky tan color. I certainly hope this is some fancy break-in oil... but I’m guessing not. I’ve been working on machinery for 30 years, and never seen such a thing. The mower has a whopping 4.9 hours.

Milky oil is an emulsion , usually with water.
do you wash the mower with a pressure washer ?
Do you have young children who might be "helping daddy "

It has 4.9 hours on it. Never washed. Never in the rain. Literally never been in contact with water. I did however read other reports that Kohler uses a breakin oil that is murky and green, which is exactly what I have. It seems it’s normal.

Kohler doesn't put oil in their engine prior to shipping to the mower manufacturer, nor do they have any break in oil in their stock, and don't recommend the use of special break in oils. Actual Kohler oil is so clear than you will have a hard time seeing the oil level line on the dipstick. So Hustler would of put the oil in the engine not Kohler.

Either way... I’ve now seen several Kohler EFIs with this green oil...

Caldwell response...

Ok, so I spoke with our Tech Brian. He explained the process to me a little better and says he has definitely seen some brands of break in oil turn this color when it interacts with gas. He wasn’t concerned, but said to keep an eye on it for a little bit after the oil change. It may take a couple of oil changes to get all of the gas out of the oil. You can actually smell it, barely, on the dipstick most likely, even after the first oil change.

The exact process of what causes oil in the gas is as follows:

Gas can bypass the rings more easily on a unit until it is “broken in” and the rings are seated well.
Anytime the unit is ran for less than 10-15 minutes, there will be more unburnt fuel in the cylinder than if the unit was allowed to run longer. The fuel will drain down and bypass the ring via the ring gap even when the unit is fully broken in.
There will always be some fuel that could technically bypass the rings once it is ran past the 10-15 minute barrier, but as the engine heats up the likelihood is less and once the oil heats up it will vaporize the gas and push it out the evap line into the carb to recycle it. In your case I suspect it was simply letting more pass then could be burnt up.

At any rate, we don’t believe you have an issue. I am not an expert on this this, and am trying to relay what the Tech described to me, so if something doesn’t make sense, please don’t hesitate to ask.

Run it until it blows and warrant it. What I did with the Kawalski on my Cub. Ran it until it came apart and got a new one (engine), no charge. My flywheel let go at speed and ate everything up with 10 hours on the machine. Got a new motor and that was around 500 hours ago. Stuff happens and like ILENGINE said, I've never seen break in oil in a Kohler motor.

Seems a lot of guys have seen this on thier ECV860s on the first change... weird.

Changed the oil/filter. No change. Mowed for an hour... shut down for 10 minutes to blow it off before parking it, and it then blew a big cloud of smoke on startup again. I think I need to head to my closest dealer and have them fire up an ECV860 on the lot to show me how “normal” this is.

Fizzerpilot said:

Changed the oil/filter. No change. Mowed for an hour... shut down for 10 minutes to blow it off before parking it, and it then blew a big cloud of smoke on startup again. I think I need to head to my closest dealer and have them fire up an ECV860 on the lot to show me how I realized that this post is about 3 years old

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I realize this post is about 3 years old but it annoyed me enough to revive it. Wondering what the conclusion was?
I have an old Snapper 150z zero turn that looks like new and everything works perfectly. This week the old Briggs 18.5 horse started smoking and I'm looking at a Kohler 25 horse EFI to replace it. I found a used one, fairly local with about 150 hours on it for $400.
Anyway, I happened on this post looking to see what the general consensus is on Chinese Kohler motors.
Not for nothing but I'm with "SidecarFlip" . If I had this exact scenario I would drive my brand new mower onto my trailer, drain 90% of the oil, run it wide open until something went BOOM, replace used oil and drop it off at the dealer.
I don't condone doing scumbag things but I won't be taken advantage of either. I honestly don't understand why the dealer would care. If this was my business I would have taken your mower back and given you another brand new one with my sincerest apology.

Best Stripes said:

I realize this post is about 3 years old but it annoyed me enough to revive it. Wondering what the conclusion was?
I have an old Snapper 150z zero turn that looks like new and everything works perfectly. This week the old Briggs 18.5 horse started smoking and I'm looking at a Kohler 25 horse EFI to replace it. I found a used one, fairly local with about 150 hours on it for $400.
Anyway, I happened on this post looking to see what the general consensus is on Chinese Kohler motors.
Not for nothing but I'm with "SidecarFlip" . If I had this exact scenario I would drive my brand new mower onto my trailer, drain 90% of the oil, run it wide open until something went BOOM, replace used oil and drop it off at the dealer.
I don't condone doing scumbag things but I won't be taken advantage of either. I honestly don't understand why the dealer would care. If this was my business I would have taken your mower back and given you another brand new one with my sincerest apology.

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If you seize up the engine and can't mix the fresh oil with the old oil it will be readily apparent when they crack it open that you did this on purpose. That could be an uncomfortable situation.

No not break in oil. It is water from condensation from starting the mowers running them in and out and not getting them hot enough to evaporate the moisture. If you run an engine and for short periods of of time and shut it off it will create moisture and turn the oil milky and over fill the engine when you check the oil. Enough of it can damage the engine. Change the oil and filter immediately. This is not a warranty failure. Warranty covers defects in material and workmanship. Moisture is not a material in the engine and workmanship had nothing to do with it.

Take the dipstick out and take a cigarette lighter to if spits, sputters and pops it is water. If it burns it has gas in the oil if it does nothing it is oil.

Fizzerpilot said:

our Tech Brian. He explained the process to me a little better and says he has definitely seen some brands of break in oil turn this color when it interacts with gas.

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Is this a 2 stroke engine? Oil interacting with gas now? No wonder there is so many Kroller engine failures out there.

Fizzerpilot said:

Ever since day one, it blows smoke on startup

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Take it back to the dealer.

Again I'm not condoning screwing anyone over. Don't let yourself get screwed either. I'm confused as to why lawn equipment manufacturer's are held to a lower standard than all other manufacturers? Walmart and Amazon have better customer support on their Chinese junk. If you bought any brand new car this would be completely unacceptable. We spend 3, 4, 6 K on a zero turn. Force your dealer to do the right thing, if they are dicky about it go right to the manufacturer. If they are dicky about it get an attorney. Unacceptable.

Just for reference, I'm in my mid 40s and have only ever sued one person. A young lady that hit my Cadillac , had no insurance and refused to pay. After winning in court 10 plus years ago I still get a check in the mail every other month for $5 lol.
When I drive by her house and see that rusted 14 year old junk Chevy Cavalier sitting in the driveway it puts a smile on my face. She cant sell it, trade it in or even scrap it. My name is on the title in the lein holder spot lmao.

Best Stripes said:

Just for reference, I'm in my mid 40s and have only ever sued one person. A young lady that hit my Cadillac , had no insurance and refused to pay. After winning in court 10 plus years ago I still get a check in the mail every other month for $5 lol.
When I drive by her house and see that rusted 14 year old junk Chevy Cavalier sitting in the driveway it puts a smile on my face. She cant sell it, trade it in or even scrap it. My name is on the title in the lein holder spot lmao.

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Still a crappy way to get your money back. I'd be pretty annoyed by that.
Either way they should have to fix the smoke issue on a new engine. Mine is 15 years old and doesn't smoke at all. My dad's 18 year old Kohler command smokes on startup, but it has 1100+ hours on it.

I really am considering taking a chance on the 25 hp efi Kohler. Just the thought of efi on my zero makes my junk move.
I'll probably rebuild my old 18.5 Briggs though. I don't need extra headaches.

Best Stripes said:

I really am considering taking a chance on the 25 hp efi Kohler. Just the thought of efi on my zero makes my junk move.
I'll probably rebuild my old 18.5 Briggs though. I don't need extra headaches.

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EFI sounds cool, but I don't have any issues with the carb on mine. I don't know the maintenance history but it starts flawlessly when I use the choke.
Rebuilding the old one sounds fun and rewarding though.

Update... wow this is an old thread. After 3 full years and 120 hours, there is no smoke at all... she just runs. Starts easy, mows great, and no smoke on startup. I change the oil annually, and have never seen any discoloration. About to change the oil this coming week for the new season, but she has been reliable.