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post #1 of 69 Old 06-10-2017, 09:08 AM Thread Starter
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26 hp Kohler,,strange problem found

Unique thing happened to this,,IMO

Kohler courage 26 hp sv735-3022

It was run low on oil ,,,and engine seized!! Oil drain plug came loose on its own,,oops!!

But this is not the problem I am referring to,,because I have seen this happen before. And always on the Courage series!! So sad.

So i tear the engine apart to see what rods broke ,,or whatever!!

And I get the cover off,,,,huh?? No broken anything!!! And everything looks perfect. So what is holding it from moving???

Reach in and remove rod caps. And Pistons slide up into cylinders!!! lol Still cant figure what is locking this up.

Pull,flywheel,heads, valves and cam!!! Now it just a crank,,hanging in block and it is locked into the casing,,,on the flywheel end.

And it is locked in hard!!!

I cannot,,so far get it out!! Seems there is a brass bushing maybe that the crank rides on,that is smoked. I can barely see the edge of it.

For me,,I have never seen this happen before. And I am not sure if it is fixable. Parts list does not show a bearing or bushing there. So what does the crank ride on at that end of casing??

All the internal parts to this 2 year old engine are in perfect shape!! Can still see the factory honing on cylinders.

I am going to heat it up and try getting it out today. But it is a strange sight seeing this crank hanging in this bare block like this!! lol

Ill get some pics before I remove it. I will be lucky if I dont break the aluminum casing getting this apart. I have no idea whats going to happen when heating aluminum and then hitting it.

I am also second guessing if this was from low oil,,because I found at least a quart still in engine,,,,and nothing else looks like it was hot.

Has anyone seen this happen before?? Is this the end of this engines life??
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post #2 of 69 Old 06-10-2017, 10:07 AM
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Re: 26 hp Kohler,,strange problem found

Quote:
Originally Posted by flash5153 View Post
Unique thing happened to this,,IMO

Kohler courage 26 hp sv735-3022

It was run low on oil ,,,and engine seized!! Oil drain plug came loose on its own,,oops!!

But this is not the problem I am referring to,,because I have seen this happen before. And always on the Courage series!! So sad.

So i tear the engine apart to see what rods broke ,,or whatever!!

And I get the cover off,,,,huh?? No broken anything!!! And everything looks perfect. So what is holding it from moving???

Reach in and remove rod caps. And Pistons slide up into cylinders!!! lol Still cant figure what is locking this up.

Pull,flywheel,heads, valves and cam!!! Now it just a crank,,hanging in block and it is locked into the casing,,,on the flywheel end.

And it is locked in hard!!!

I cannot,,so far get it out!! Seems there is a brass bushing maybe that the crank rides on,that is smoked. I can barely see the edge of it.

For me,,I have never seen this happen before. And I am not sure if it is fixable. Parts list does not show a bearing or bushing there. So what does the crank ride on at that end of casing??

All the internal parts to this 2 year old engine are in perfect shape!! Can still see the factory honing on cylinders.

I am going to heat it up and try getting it out today. But it is a strange sight seeing this crank hanging in this bare block like this!! lol

Ill get some pics before I remove it. I will be lucky if I dont break the aluminum casing getting this apart. I have no idea whats going to happen when heating aluminum and then hitting it.

I am also second guessing if this was from low oil,,because I found at least a quart still in engine,,,,and nothing else looks like it was hot.

Has anyone seen this happen before?? Is this the end of this engines life??
OK.. is the engine still on the mower.. I guess everybody is gonna wait till we see pics..


the round fenderd JD's
4-JD 60's.. 2-JD 70's.. 6-JD 100's.. 2-JD 110's.. 2-JD 112's..

3 JD LT 155's.. JD R-72.. JD Scotts 2048.. JD 111.. JD Sabre 1742..
WH RJ-58.. WH Lawn Ranger.. WH 654.. WH 854.. 2- MF 14's..
Craftsman GT 6000.. CC 70.. CC 100.. CC 129..
total tractors is 30..
home built log spliter 4x24 ram.. 20hp.. 11 seconds per cycle..

give a monkey a wrench & he can ruin the world.. whirly 7/27/2018
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post #3 of 69 Old 06-10-2017, 11:10 AM
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Re: 26 hp Kohler,,strange problem found

That is strange indeed. Have you tried a mallet? I would try the sharp shock of a hammer before I would go applying heat to one part only. I'd be more afraid the torch would unevenly heat something and it would be totally destroyed.
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post #4 of 69 Old 06-10-2017, 11:11 AM Thread Starter
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Re: 26 hp Kohler,,strange problem found

No engine is pulled and torn completely apart.

I have changed my mind about heating the aluminum casing. I think it is better to press it out.And I dont have a press.
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post #5 of 69 Old 06-10-2017, 11:14 AM Thread Starter
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Re: 26 hp Kohler,,strange problem found

This crank is really stuck in there hard. Probally welded itself to the aluminum case. I put crank thru hole in bench and hit other end so hard with dead blow hammer I thought I might break the casing if hit anymore!!
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post #6 of 69 Old 06-10-2017, 12:31 PM
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Re: 26 hp Kohler,,strange problem found

saw the pics.. that is the upper bearing on the crank.. it was ran so long with out oil gettin to it.. it would now b all 'galled' up.. the bearing surface is no good now..

even if u did get the crank out there is no way to recondition the upper bearing..

that engine is considered scrap..

look on Craigs list or Evil Bay for a replacement engine.. anything at or over 20HP will power ur mower.. the mower makers r actin like '''Tim, the tool man, Taylor.. he's the one who put a small jet engine on a zero turn mower..

OOOHHH... thanks for postin the pics.. it saved us a lotta typin..


the round fenderd JD's
4-JD 60's.. 2-JD 70's.. 6-JD 100's.. 2-JD 110's.. 2-JD 112's..

3 JD LT 155's.. JD R-72.. JD Scotts 2048.. JD 111.. JD Sabre 1742..
WH RJ-58.. WH Lawn Ranger.. WH 654.. WH 854.. 2- MF 14's..
Craftsman GT 6000.. CC 70.. CC 100.. CC 129..
total tractors is 30..
home built log spliter 4x24 ram.. 20hp.. 11 seconds per cycle..

give a monkey a wrench & he can ruin the world.. whirly 7/27/2018
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post #7 of 69 Old 06-10-2017, 03:16 PM Thread Starter
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Re: 26 hp Kohler,,strange problem found

Quote:
Originally Posted by Whirly View Post
saw the pics.. that is the upper bearing on the crank.. it was ran so long with out oil gettin to it.. it would now b all 'galled' up.. the bearing surface is no good now..

even if u did get the crank out there is no way to recondition the upper bearing..

that engine is considered scrap..

look on Craigs list or Evil Bay for a replacement engine.. anything at or over 20HP will power ur mower.. the mower makers r actin like '''Tim, the tool man, Taylor.. he's the one who put a small jet engine on a zero turn mower..

OOOHHH... thanks for postin the pics.. it saved us a lotta typin..

There is no bearing there ,,,,But i think there is a copper/brass bushing. You have a great guess there,,,but until I get it apart,,there is no way to know what it did to the casing. Might break it getting it apart,,who knows.
If it dont break,,might be able to machine a area for a new bushing,,or possibly a bearing.

The other end of crank just rides in machined casing,,,no bearing or bushing! It's possible the problem end does the same!! Parts list shows no bearings or bushings for crank anywhere.
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post #8 of 69 Old 06-10-2017, 05:27 PM
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Re: 26 hp Kohler,,strange problem found

Quote:
Originally Posted by flash5153 View Post
There is no bearing there ,,,,But i think there is a copper/brass bushing. You have a great guess there,,,but until I get it apart,,there is no way to know what it did to the casing. Might break it getting it apart,,who knows.
If it dont break,,might be able to machine a area for a new bushing,,or possibly a bearing.

The other end of crank just rides in machined casing,,,no bearing or bushing! It's possible the problem end does the same!! Parts list shows no bearings or bushings for crank anywhere.
ur right on the crank havin no bushins.. they use pollished aluminum for the crank.. all engines r built that way today.. the galling on the crank goes around the crank.. it has dug into the aluminum.. tiny bits & pieces have stuck to the crank.. even if u do get it out.. there is no way ur gonna get a new bearing surface that aligns the crank on dead center..


the round fenderd JD's
4-JD 60's.. 2-JD 70's.. 6-JD 100's.. 2-JD 110's.. 2-JD 112's..

3 JD LT 155's.. JD R-72.. JD Scotts 2048.. JD 111.. JD Sabre 1742..
WH RJ-58.. WH Lawn Ranger.. WH 654.. WH 854.. 2- MF 14's..
Craftsman GT 6000.. CC 70.. CC 100.. CC 129..
total tractors is 30..
home built log spliter 4x24 ram.. 20hp.. 11 seconds per cycle..

give a monkey a wrench & he can ruin the world.. whirly 7/27/2018
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post #9 of 69 Old 06-10-2017, 08:00 PM
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Re: 26 hp Kohler,,strange problem found

i had a 79 briggs 11hp seize like that years ago. i got crank out and emery clothed the bearing and ran it for years after. just lucky maybe.
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post #10 of 69 Old 06-10-2017, 08:42 PM Thread Starter
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Re: 26 hp Kohler,,strange problem found

I just got it out with a press,,,it came much easier than I thought. It is not bad as I thought it would be. Crank looks real good. I think it will clean right up. The casing has a few minor scars,,,picture makes it look much worse.
Im going to see if a machine shop can machine the casing and put a bushing in. And turn crank if they think it is needed.

I know I could just clean this up and this engine would run. At least for awhile. lol But I am going to see what machine shop says.

This engine was either run low on oil,,,or the crank seal was pushed in too far and blocked the oil port to this area.
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post #11 of 69 Old 06-10-2017, 10:09 PM
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Re: 26 hp Kohler,,strange problem found

Hopefully the machine shop can help you out
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post #12 of 69 Old 06-10-2017, 10:41 PM
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Re: 26 hp Kohler,,strange problem found

you can clean the aluminum off the crank with muriatic acid but be careful
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post #13 of 69 Old 06-10-2017, 10:46 PM
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Re: 26 hp Kohler,,strange problem found

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I just got it out with a press,,,

This engine was either run low on oil,,,or the crank seal was pushed in too far and blocked the oil port to this area.
this came from ur first postin..

'''''''''Unique thing happened to this,,IMO

Kohler courage 26 hp sv735-3022

It was run low on oil ,,,and engine seized!! Oil drain plug came loose on its own,,oops!!'''''''''''''

I don't think the crank seal was in too far accordin to ur pics..

so the crank is out.. now tell me how the machinist is gonna find the dead center of the bearing surface.. just remember that he's gotta machine it out to b not more 0.0002.. yup.. if he's more than that it's wasted time & $$$.. also he can't use a lathe to do the reborin for a bushin..

u might get the crank to come out OK.. steel is a lot harder than aluminum is.. usin Meratic Acid will eat all the aluminum off the crank.. but that process is dangerous to do..


the round fenderd JD's
4-JD 60's.. 2-JD 70's.. 6-JD 100's.. 2-JD 110's.. 2-JD 112's..

3 JD LT 155's.. JD R-72.. JD Scotts 2048.. JD 111.. JD Sabre 1742..
WH RJ-58.. WH Lawn Ranger.. WH 654.. WH 854.. 2- MF 14's..
Craftsman GT 6000.. CC 70.. CC 100.. CC 129..
total tractors is 30..
home built log spliter 4x24 ram.. 20hp.. 11 seconds per cycle..

give a monkey a wrench & he can ruin the world.. whirly 7/27/2018

Last edited by Whirly; 06-10-2017 at 10:54 PM.
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post #14 of 69 Old 06-10-2017, 10:54 PM
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Re: 26 hp Kohler,,strange problem found

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you can clean the aluminum off the crank with muriatic acid but be careful
Keep it away from anything aluminum when you do it.. And preferably outside in a well ventilated area.. Just sayin..

The Machine shop could machine the thing out and install a bushing (slotted for the oil supply).. If you go this route MAKE SURE the oil passages are clear and the oil pump is functioning /clean..

Oh and tighten the darn plug!


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post #15 of 69 Old 06-10-2017, 10:54 PM
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I just got it out with a press,,,it came much easier than I thought. It is not bad as I thought it would be. Crank looks real good. I think it will clean right up. The casing has a few minor scars,,,picture makes it look much worse.
Im going to see if a machine shop can machine the casing and put a bushing in. And turn crank if they think it is needed.

I know I could just clean this up and this engine would run. At least for awhile. lol But I am going to see what machine shop says.

This engine was either run low on oil,,,or the crank seal was pushed in too far and blocked the oil port to this area.
A real machine shop can bore your cases for bushings or bearings, they need both halves and will align bore them together. Also they can grind the crank surfaces for the new bearings. It's not going to be cheap but it's possible. Depends on how much you want to keep the old engine cases and crank.

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