Small Engines (Lawn Mowers, etc.): Kohler starting problems, starter solenoid, poor earth

Question
Paul,
I have a late model Snapper Zero turn (MZM2300kh) with a Kohler 23 hp air cooled gas engine.  In the last year i have started having a problem at start-up.  You hit the key, and the machine either acts as though the battery is weak, you hear a single click, or nothing.  If you turn the key 2 or 3 times, the machine will start.  I have checked, charged and rechecked the battery, which tested good at my local parts store.  I have cleaned all contacts from the battery to the starter.  I have tested the power lead to the starter, which tests equal to the volts the battery reads, usually between 12.4-12.5 volts at the batter and to the starter when the key is engaged.  All the safety switches seem to be working fine also.  At first I considered a relay to the starter, but when the volts came up strong, abandoned this idea, I thought a new HD battery next, but mine seems fine 235CCA, though I do see the OEM was a 340CCA.  My next thought is a new starter (part # 25 098 08), but hate to shell out upwards of $130.00 to find that, that was not the answer.  I had one dealer tell me "old mowers just do that"  I do not accept that as an answer.  The mower has always been stored, and well maintained so this is a real frustration.  Any idea's and thoughts would be greatly appreciated.  Thanks  Kent

Answer
hi kent

have you tried test  by  bypassing solenoid  by using heavy starter wire ( like battery jump cable) to connect battery positive directly to starter motor  terminal

if motor cranks well and starts right up  may be a  starter volt drop problem in either  positive or earth return leg side  

you could possibly have a poor earth for battery as well , main ignition switch could be playing up too , does the starter solenoid have a good ground , could still be  a starter solenoid  though from burnt contacts ?


make sure decompressor on engine is working  - it should open a valve slightly just before tdc and let some  compression out for easier starting during cranking  ?

if these check out   go 340 cca  battery as oem spec  that's good grunt for starting


give it whirl        easy things 1st         easy likley  / then  easy un likley  
                                         then difficult / likley   then  diificult / un likley

let me know  


cheers paul    hope it helps