25 HP Kohler Command Pro Engine Problems [with 4 easy fix]

The Kohler Command Pro engine is highly reliable for powering multiple machines and equipment. This engine offers versatile performance with tower blowers, stump grinders, or even riding mowers. However, it can be different because this engine is prone to issues.

The 25 HP Kohler Command Pro experiences a variety of problems. Some of the common ones are:

1. Overheating
2. Engine Surges
3. Bad Engine Smoke
4. Faulty Spark Plugs

However, you can avoid most of these problems by ensuring proper maintenance. Anyway, let’s review the fixes for 25 HP Kohler Command Pro engine problems.

Read: Kohler Courage 26 Hp Engine Problems [+ Fixes]

25 HP Kohler Command Pro Engine Specs

The 25 HP Kohler Command Pro is a standard option for various uses. Its range of compatibility covers heavy and light elements that require power. Let us have a look at the specs of this engine to get a better view:

• Fuel Type: Gasoline
• Displacement: 725 cc
• Bore: 83 mm
• Stroke: 73 mm
• Oil Capacity: 1.9 L
• Certified RPM: 3600
• Dry Weight: 43 Kg
• Engine Type: Commercial
• Compression Ratio: 9.0:1

Troubleshooting 25 HP Kohler Command Pro Engine Problems

As stated, the 25 HP Kohler Command Pro engine can go wrong for several reasons, and many factors contribute. We’ll be discussing these issues and their potential fixes in the section below:

1. Engine Surges

In equipment like the lawn mower or the tower blower, engine surges are prevalent. Multiple factors contribute to this problem, and some of the most common ones are:

• Gasoline getting contaminated
• Dirt accumulation on the fuel tank cap
• Defected air intake gasket
• Malfunctioning plugs or cables
• Clogged Carburetor

That said, multiple symptoms will be evident in your 25 HP Kohler Command Pro for the above-mentioned problems. The prominent signs are listed below:

• Increased Vibration
• Unstable RPM
• The cyclical pattern of ups and downs needed to get the proper RPM

How to fix?

To troubleshoot the issue, you can follow the steps mentioned below to fix your surging Kohler Command Pro engine:

• Step 1: Spark Plug Wire Removal. The first step would be to prevent the equipment from starting by removing the spark plug.
• Step 2: Remove the air filter. Here, you must ensure the removal of the air filter and housing. Then, clean the filter with soapy water.
• Step 3: Take out the Tank Bolts. The next step is removing the bolts that hold the fuel tank.
• Step 4: Drag the fuel tank. You have to detach the governor link, and that’s why dragging the fuel tank is necessary.
• Step 5: Clean Carburetor. Take out the screws from the carburetor and take it out. After that, clean the surface ports of the fuel tank. Use a Carburetor cleaner to wash all the filters and ports.
• Step 6: Dump All Gaskets. Remove the old gaskets and carefully clean the intake manifold.
• Step 7: Refit everything with new gaskets. The process ends here, and you should ensure that surges don’t exist anymore. If it exists, you must replace the manifold.

2. Engine Overheating

When the engine gets hotter than the optimum level, the engine’s dying possibilities are high. The prime reasons behind this problem are as follows:

• Oil-degraded motor oil
• Defected Solenoid Plug
• Carburetor vapor lock
• Defective Spark Plugs

You can get a prior idea about this problem before it gets serious through the following symptoms:

• Burning smell
• Coolant leaks
• Misfiring engine
• White smoke

READ: 27 HP Kohler Engine Problems Troubleshooting

How to fix?

You can try out multiple fixes for this problem. Let me take you through each of them in the sections below:

a) Change The Oil

Since one of the causes is improper oil quality, you should focus on changing that. Let’s have a look at the steps:

• Step 1: Check the oil color. Using the fuel tank dipstick, inspect the current oil color.
• Step 2: Replace Oil. If the oil color is brown, change the oil and, if necessary, replace the oil filters.

b) Replace Cooler 

It is a solution when vapor lock is the reason behind the engine getting overheated. Follow the steps below to learn more:

• Step 1: Arrange Tools. Manage tools like screwdrivers, wrenches, and vice grips to start the process.
• Step 2: Pinch the fuel line. Use the vice grips to pinch the fuel line. It will aid you in turning off the gas in the carburetor. 
• Step 3: Remove the Cooler. With the help of the screwdrivers, unhook the cooler and remove it.
• Step 4: Install New Cooler

3. Faulty Spark Plugs

The issue with the defective spark plugs is one of the critical problems with the Kohler engine. These spark plugs may become faulty due to damaged wiring, dirty spark plugs and worn out plugs.

Whenever these spark plugs become defective, the following symptoms will be noticeable: 

• The engine stalls shortly after starting
• Increase in fuel consumption
• Engine runs rough

READ: Kohler EFI Engine Problems [Troubleshooting Guide]

How to fix?

The easiest way to fix this issue is to replace the spark plugs. Let me take you through the steps:

• Step 1: Cool down your engine. Before navigating to the spark plugs, cool down your 25 HP Kohler Command Pro.

• Step 2: Remove the Wire. After the engine has cooled down, you must remove the wire from each plug. 

• Step 3: Use a socket. Remove the old spark plug with the help of a spark plug socket.

• Step 4: Install a new spark plug. Thread the new spark plug carefully into the cylinder head. Use the socket to tighten it firmly. 

4. Bad Smoke Emission

Engines producing harmful smoke are a common issue, which also occurs in the case of Kohler engines. It might happen due to the following reasons:

• Dirty Air Filter
• Unadjusted Carburettor
• Defective Head Gasket

In this regard, the symptoms evident are listed as follows;

• Black smoke during acceleration
• Gray smoke during starting of the engine

How to fix?

Most of the time, the problem originates from a dirty air filter. You must replace it to fix this issue.

• Step 1: Remove the air filter cover – Start the process by rotating and taking out the air filter cover.
• Step 2: Remove the old air filter – After taking out the cover, remove the old air filter.
• Step 3: Position the new air filter on the cover – Install the new one by precisely positioning it.
• Step 4: Insert the cover into the housing – The process will end with the installation of the air filter cover from where you detached it. Rotate the knob firmly to make it secure. 

For more detailed view please watch this video below about kohler lawn mower engine air filter replacement.

Are Kohler Command Engines Reliable?

Traditionally, Kohler has offered excellent engines that are highly reliable. These engines are popular choices for equipment like lawn mowers and tractors.

That said, Kohler command engines provide economical and efficient solutions for this equipment. The functionalities of these engines make them easy to operate, and most models can cater to your specific needs.

in verdict: Maintenance Tips To Avoid Command Pro Engine Problems

You can avoid the entire hassle of fixing your 25 HP Command Pro engine by ensuring regular maintenance. Take a look at some of the important tips below that might help you.

• Change the engine oil regularly, at least once after every 50 hours of use
• Inspect the air filter and clean any debris accumulated 
• Replace fuel filters on every 100 hours
• Change the spark plugs after every 500 hours of operation
• Change engine coolant within 2 years of operation

25 HP Kohler Command Pro Engine Problems – [FAQs]

The issues with the 25 HP Kohler Command Pro engine may invoke a few confusions in your mind. To help you out, I have answered some of the prominent ones below: