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2022/07/30 13:39:26

oldguy

Kohler 5400 series won't start after oil change

The engine is a Kohler 5400 KS540 Serial 4900200993 with 500 or so hours. It's mounted on a Cub Cadet. I changed the oil (spilling alot on the deck and frame). Following the fill it started but I immediately shut it off as there was much oil being sprayed). I have not been able to restart it, turns over but will not fire at all. Battery shows 12.3 V, spark plug is wet and plug tester shows spark, dip stick shows oil at full mark. I can't figure what's up. Could a quick start/stop have broken the flywheel key??
Thanks

10 comments Leave a comment

SRTsFZ6

Crank the engine over with the plug out to rid any excess oil in the top end..

Try a new spark plug after verifying it works (not installed, grounded to the head). .030"

And no, a quick turn off won't shear the flywheel key.

2022/07/30 16:22:53

oldguy

Thanks for the response and for reminding me that a "spark tester" is not a spark plug tester. I cranked with the plug out and it threw a fine mist, gaped, tested and installed a new plug, and swapped out the 5yo battery for a new one. It turns over but does not fire or seem to try to fire.

Further thoughts?

2022/07/31 17:43:43

SRTsFZ6

Pull the air filter and spray some starting fluid or carb cleaner down the throat.. Crank over trying to start the machine

See if it fires momentarily... If it fires, fuel, is likely the issue.

We need to determine whether we're missing spark, fuel or a timing issue.

Also, if under the carb there is a solenoid (1 or 2 wires) attached, turn the ignition on then off(not run).
See if you can feel a clicking coming from it (opening the fuel shut off solenoid)..

2022/07/31 19:30:21

oldguy

no firing with starting fluid, not even a backfire. The solenoid clicked when I turned the ignition on.
Would a shorted kill switch or safety feature allow the engine to turn over but no spark?

2022/07/31 21:05:13

SRTsFZ6

A low oil switch, (if equipped) sometimes allows a little spark but not enough to run. Simply un-plugging it will eliminate it..

Un-plugging the small black, kill wires from the coil(s) will disable ALL the safety switches. Their located under the main engine cover..

You did confirm you have a healthy spark at the plug (grounded)?

Also, that solenoid sounds fine..

2022/08/01 07:28:23

oldguy

Not equipped with an oil sentry, assuming they are always located above the oil filter. Have good spark when plug is grounded, but will recheck. Will pull the kill wires later this morning. Appreciate your help.

2022/08/01 07:50:06

oldguy

I think I found it, maybe. The no black wires to disconnect under the cover except one grounded to metal which traced back to the carb solenoid. I disconnected it and the engine started, ran for a few seconds (poorly) then shut down. Reconnected wire and nothing except the solenoid heated up == rinse wash repeat with same results. Methinks the fuel shut off solenoid is bad.

2022/08/01 12:45:53

SRTsFZ6

To eliminate the solenoid, twist it off. They'll be a little plunger, spring loaded...

Pull the plunger and spring, re-assemble. It now does nothing and won't hamper running at all. Un-plug it as well as it sounds like it may be shorting the coil (if grounding it out-no spark)..

That solenoid should not get hot at all. Just a clicking when opening and closing. With the solenoid out, you can turn the key on and off and the plunger SHOULD pull in(allowing fuel) and close when ignition is turned off.

BTW, the solenoid has 12 volts going to it (for engine running) to OPEN and allow fuel to flow. No ground or 12 volts and it stays shut(no fuel)

2022/08/01 14:30:32

oldguy

I found it and this should out a smile on anyone's face as I wipe the egg off mine. Apparently, new air filters come with the foam outer filter stuffed inside as I found out when I started taking the carb off. Runs so much better with air

2022/08/06 13:12:22

SRTsFZ6

Tks for the update, congrates in the fix!

2022/08/06 17:49:46

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Kohler 5400 series won't start after oil change

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