Kohler ECV860 Troubleshooting
| Engine Model: Kohler Command Pro ECV860 EFI |
| Engine Type: 4-cycle V-Twin cylinder vertical shaft air-cooled gasoline |
| Total Displacement: 50.3 cu.in (824 cc) |
| Rated Engine Power: 29 Hp (21.6 kW) at 3600 rpm |
| Fuel System Type: Electronic fuel injection (EFI) |
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| Engine will not start or starts up hard |
No gasoline in tank - Fill it up.
Low-quality gasoline - Use quality fuel.
There is air in the fuel system - Bleed the system.
Spark plug wire connection are damaged - Inspect spark plug wiring connection, change or repair.
Defective spark plug - Change spark plug as required.
Plugged fuel filter - Replace fuel filter.
Faulty safety switch - Change damaged switch.
Loose or damaged crankshaft position sensor - Change as required.
Faulty or incorrectly adjusted throttle position sensor - Adjust or replace throttle position sensor.
Low system voltage - Check voltage regulator and replace if required.
Fuel injectors are clogged or faulty - Service or change fuel injectors.
Restricted fuel lines - Clean fuel system lines.
Low cylinder compression - Check cylinder block and replace worn parts.
Throttle cable is adjusted incorrectly or damaged - Change cable or adjust correctly.
| Engine runs intermittently |
Air intake screen is blocked - Wash or clean as required.
Ignition system is defective - Inspect ignition system and change failed components.
Throttle cable is stuck or faulty - Change or service the cable.
Clogged air filter - Replace or clean air filter.
Dirty or faulty fuel pump - Clean or install new fuel pump.
Dirty or faulty fuel injectors - Test fuel injectors and change if necessary.
Fuel lines are dirty - Service fuel lines.
Throttle position sensor damaged or incorrectly adjusted - Adjust or replace throttle position sensor.
| Engine starts but stops suddenly |
Defective spark plug - Change spark plug.
Ignition coil is not working - Ignition coil must be replaced.
Weak or damaged valve springs - New valve springs need to be installed.
Valves sticking - Clean the valves.
Fuel filter is dirty - Replace fuel filter.
Air filter is blocked - Clean or replace air filter.
Dirt in the fuel lines - Fuel lines need to be cleaned.
Fuel injectors are faulty or clogged - Inspect fuel injectors and change as required.
Wrong governor setting - Set governor properly.
Engine oil level low - Fill up the oil to required level.
Excessive engine load - Load reducing is recommended.
Air intake screen is blocked - Clean and wash as required.
Incorrect ignition timing - Set the ignition timing correctly.
Improper valve setting - Valves needs to be set correctly.
Low octane gasoline - Change gasoline.
Engine overload - Load reducing is recommended.
Lack of engine oil - Need to add engine oil.
Improperly adjusted low idle speed - Adjust idling as required.
Dirty or damaged fuel pump - Inspect fuel pump and change as required.
Worn crankshaft or main bearings - Replace crankshaft or bearings.
Valve clearance is improper - Check and adjust.
Damaged cylinder bore or piston rings - Change defective components.
Plugged air filter - Clean or replace air filter.
Fuel pump is defective or dirty - Clean or replace fuel pump.
Fuel lines are dirty - Fuel lines need to be cleaned.
Incorrect governor adjustment - Set governor properly.
One fuel injector malfunction - Inspect fuel injector and change as required.
Ignition system malfunction - Check ignition and replace faulty components.
Worn cylinder head gasket - Replace the gasket as required.
Stuck or burned valves - Replace or clean valves.
Damaged or worn push rod - Change push rod.
Cylinder block components are worn - Replace defective components.
Oil filter is dirty - Clean or replace oil filter.
| Engine using too much gasoline |
Throttle opening is not full - Adjust or change throttle cable.
Fuel injectors are clogged or faulty - Test fuel injectors and change if necessary.
Faulty or loose spark plug - Tighten or change the spark plug.
Valves are worn, stuck, or burned - Clean or replace valves.
Worn rings, piston, or sleeve - Replace faulty components.
Excessive valve clearance - Adjust to proper valve clearance.
| Engine oil consumption is too high |
Damaged gaskets or seals - Install new components.
Valve stems or guides are damaged - Valves need to be changed.
Seized or wear piston rings - Piston rings replacement required.
Scored piston or cylinder liner - Check piston and liner, replace as required.
Plugged breather pipe or hose - Change or service.
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