Kohler KS540 [21/92] Troubleshooting

2122 690 01 Rev. -- KohlerEngines.com

Troubleshooting

Engine Cranks But Will Not Start

● Battery connected backwards.

● Blown fuse.

● Carburetor solenoid malfunction.

● Choke not closing.

● Clogged fuel line or fuel fi lter.

● Diode in wiring harness failed in open circuit mode.

● Interlock switch is engaged or faulty.

● Key switch or kill switch in OFF position.

● Low oil level.

● Quality of fuel (dirt, water, stale, mixture).

● Spark plug lead disconnected.

Engine Starts But Does Not Keep Running

● Faulty carburetor.

● Faulty cylinder head gasket.

● Faulty or misadjusted choke or throttle controls.

● Fuel pump malfunction-vacuum hose clogged or

Engine Starts Hard

● Clogged fuel line or fuel fi lter.

● Engine overheated.

● Faulty ACR mechanism.

● Faulty or misadjusted choke or throttle controls.

● Faulty spark plug.

● Flywheel key sheared.

● Fuel pump malfunction-vacuum hose clogged or

leaking.

● Interlock switch is engaged or faulty.

When troubles occur, be sure to check simple causes which, at fi rst, may seem too obvious to be considered. For

example, a starting problem could be caused by an empty fuel tank.

Some general common causes of engine troubles are listed below and vary by engine specifi cation. Use these to

locate causing factors.

Engine Will Not Crank

● Battery is discharged.

● Faulty electric starter or solenoid.

● Faulty key switch or ignition switch.

● Interlock switch is engaged or faulty.

● Loose wires or connections that intermittently ground

ignition kill circuit.

Engine Runs But Misses

● Carburetor malfunction.

● Engine overheated.

● Faulty spark plug.

● Ignition module faulty or improperly gapped.

● Interlock switch is engaged or faulty.

● Engine overheated.

● Faulty spark plug.

● Idle fuel circuit in carburetor plugged/restricted.

● Idle speed adjusting screw improperly set.

● Inadequate fuel supply.

● Low compression.

● Quality of fuel (dirt, water, stale, mixture).

● Restricted fuel tank cap vent.

Engine Overheats

● Cooling fan broken.

● Excessive engine load.

● Incorrect oil viscosity/type.

● Internal wear or damage.

● Low crankcase oil level.

● Quality of fuel (dirt, water, stale, mixture).