Kohler Lawn Mower Stator Replacement, Small Engine #237878-S

Total Parts Cost

$NaN

06:06

Description

This video provides step-by-step instructions for replacing the stator for single cylinder Kohler Command small engines, commonly found in riding lawn mowers, riding tractors, zero-turn radius mowers, and commercial walk-behind mowers produced by Kohler, Toro, Exmark, and John Deere. The most common reason for replacing the stator is when the battery keeps draining.

All of the information in this stator replacement video is applicable to the following brands: Kohler, Toro, Exmark, John Deere.

Tools needed: socket wrench, multi screwdriver, nutdriver bit, Phillips bit, flat-head bit, strap wrench, hammer, puller

Step By Step Instructions

Print Instructions

Before you begin this repair, make sure the engine has cooled remove the wire and boot from each spark plug

Then loosen the bolts securing the battery cables and disconnect them; black first, then red.

Your next step is to loosen the cover knob to release the air filter cover and pull the cover off.

Now remove the wingnut securing the inner air filter cover and pull the cover off along with the air filter and pre-cleaner.

Next, remove the bolts to release the fuel pump.

Disconnect the regulator/rectifier wire harness.

Remove the bolt to release the dipstick tube from the bracket and pull it out of the engine sump. be prepared for a small amount of oil to spill out.

Remove the screws to release the brackets holding the oil breather in place and pull the breather out of the valve cover.

Now remove the screws securing the throttle control bracket and move the bracket out of the way.

Use an Allen-head wrench to remove the bolts securing the grass shield and pull the shield off along with the support ring.

Now remove the mounting screws securing the blower housing.

Pull the housing off. Be aware this may require some effort.

Now pull off the flywheel fan and spacers.

Next, you will need to stabilize the flywheel. You can use a strap wrench to do this.

Have an assistant hold the flywheel in place then position a socket on the retaining bolt and strike it with a hammer to loosen. This will probably require some effort.

Remove the bolt and washer.

Now use a puller to detach the flywheel from the shaft.

Remove the puller and the strap belt. You will now need to remove both of the ignition coils.

Remove the bolts securing the coils and move the coils out of the way.

Use a large flathead screwdriver to help lift the flywheel off.

Next, remove the bolts securing the backing plate and pull the plate off.

Next, use a small flathead screwdriver to depress the connector tabs to remove the stator wires from the wire harness.

Use a socket to remove the mounting bolts securing the stator and pull the old stator out.

Install the new stator by aligning it on the engine block and routing the wires through the channel.

Secure the mounting bolts.

Depending on your model, you may have to shorten the stator wires and splice on the provided connectors or simply bundle the wires and secure with a zip tie.

Reconnect the wire connectors to the harness.

Replace the backing plate and secure the bolts.

Reposition the flywheel by aligning the slot in the flywheel with the flywheel key and sliding it onto the crankshaft.

Now reposition both ignition coils and insert the mounting bolts.

Pull the coils back and tighten the bolts.

Now, rotate the flywheel so the magnets align with the coil.

Insert a business card and loosen the bolts to align the coil the correct distance from the flywheel.

Re-tighten the bolts and remove the business card.

Repeat the process for the second coil.

Reinsert the retaining bolt and washer then torque the bolt to manufacturer specifications.

Replace the flywheel fan and spacers.

Now reposition the blower housing.

Secure it with the mounting screws.

Align the support ring, then reposition the grass shield and secure the bolts.

Realign the throttle control bracket And secure it with the screws.

Align the oil breather’s rear retaining bracket and reinsert the breather into the valve cover then position and secure the front retaining bracket with the screws.

Reinsert the dipstick tube into the engine sump align it with the bracket and secure the bolt.

Reconnect the regulator/rectifier wire harness.

Reposition the fuel pump and secure the bolts.

Replace the air filter and pre-cleaner onto the elbow assembly along with the inner cover and secure with the wingnut.

Replace the cover and tighten the cover knob.

With the new stator in place, you can now reconnect the battery cables red first, then black.

Finally, reattach the wire and boot to each spark plug.