Kohler Fuel Pump Problems and How To Deal With It?

Unlike the Briggs and Stratton, Kawasaki, and Honda fuel pumps which are nothing less than an abomination, Kohler fuel pumps are reliable and durable. Kohler fuel pumps can experience problems like any other brand of the fuel pump. But they are not necessarily infamous.

A faulty Kohler fuel pump can lead to a variety of problems, including engine stalling, hard starting, and poor fuel economy. In the case of Kohler fuel pumps, you need more knowledge on diagnosis and troubleshooting.

In this article, all the kohler fuel pump problems are discussed in details. So enjoy!

Kohler Fuel Pump Problems
Kohler Fuel Pump Problems

How to Understand Kohler Fuel Pump Problems?

This one’s a bit tricky because the symptoms of a poor fuel pump can be matched with so many other issues. But the most common things to look at are as follows:

  • Engine Stalling
  • Hard Starting
  • Poor Performance
  • Surging Engine
  • Loud Whining Noise
  • Fuel Leaks

What Causes Kohler Fuel Pump Problems? (Fixes Added)

Like any other fuel pump, Kohler pumps also have common causes for it’s failure. There isn’t anything specific that you can do to damage the pump. The reasons are discussed below:

  • Dirty Fuel: Dirty fuel can clog the fuel pump and make it unable to function. In the fuel tank, fuel lines, and eventually the fuel pump, dirt, debris, and silt can build up over time.
  • Low fuel pressure: A low fuel pressure might force the fuel pump to work harder than necessary, causing early wear and eventual failure. There may be a leak due to poor vent fitting of the fuel module.
  • Electrical problems: The gasoline pump may malfunction or stop working altogether due to electrical problems, such as bad wiring or a weak battery.
  • Lack of maintenance: Failure to perform routine maintenance, such as replacing the fuel filter or checking for issues with the fuel system, may result in fuel pump issues.
  • Water in the fuel: Water can ramp up in the fuel tank, which can harm the fuel pump and cause corrosion.
  • Overtightening fasteners: Overtightening the mounting screws for the fuel pump can put a strain on the plastic casing and eventually create cracks.
  • Impact on the pump: Extreme temperatures, age, and unintentional physical impact can cause cracks in the fuel filter.

These are the reasons for a Kohler fuel pump going bad.

4 Steps to Fix Kohler Fuel Pump Problems

Here’s how to diagnose a faulty Kohler fuel pump:

Step 1: Check for Fuel Flow Issues

Fuel flow is one of the first things you should examine. Lack of gasoline can result in several issues, including poor performance and stalling your Kohler engine.

To check for problems with fuel flow, you should:

  • Before testing the fuel pump, check the fuse to make sure it is not blown.
  • Check the fuel filter for clogging, cracks, etc. You can visually inspect the fuel filter by taking it off.
  • Check the fuel lines for any signs of damage or wear. If the fuel lines are cracked or damaged, replace those.
  • Disconnect the fuel line from the fuel pump and place it in a container to check the output of the fuel pump. Check the fuel flow by starting the engine. There may be a malfunctioning fuel pump if there is little to no fuel flow.
  • A fuel pressure gauge can be used to test the fuel pressure coming from the fuel pump.


Replace any problematic part as necessary.

Step 2: Check for Vacuum Leaks

Next, look for vacuum leaks if you’ve determined that there is little to no fuel flow. The gasoline pump may work harder than necessary due to vacuum leaks, which could result in early wear and eventual failure.


Fix the vacuum leaks. Tighten or replace loose or damaged fittings. Replace damaged or cracked fuel lines.

3. Check for Electrical Issues

The next step is to look for electrical faults after ruling out vacuum leaks and fuel filter issues. The fuel pump may malfunction or stop working entirely due to bad wiring or a weak battery.


Try changing the battery. Inspect visually for bad wiring and replace poor wiring.

4. Check for Water in the Fuel

To check for water in the fuel, remove the fuel tank and inspect it for signs of corrosion or rust. The engine would start but would not run for more than a few minutes.


Drain and clean the water and it will fix the problem. If you find any rust, clean the tank and replace the fuel.

Related Post: Kohler 7000 Series Problems: Ways to Fix Them and More!

Kohler Fuel Pump Repair: When to Fix and When to Replace?

The fuel pump can often be saved. Other times the damage is just too much so you have to replace it.

Here’s When to Fix

Tighten or replace any fittings or connections that are damaged or loose as needed. To securely tighten the fittings, use a wrench or pliers. But take care not to overtighten them as this could result in more damage.

Here’s When to Replace

Replace any fuel lines that are cracked or damaged with new ones. Do the same with damaged or too old and dirty fuel filters. If the fuse is blown, replace it and test the fuel pump again.

Check the gasket for wear or damage if the carburetor is the source of the vacuum leak. Replace the damaged gasket with a new one.

It might be time to replace the fuel pump if you have examined all of the above parts and are still unable to identify the cause of the vacuum leak.

Related Post: Kohler Ignition Coil Problems: How to Fix it?

Replacing a Faulty Kohler Fuel Pump: Step-by-Step Guide

Here is a step-by-step guide to replacing a faulty Kohler fuel pump:

  • Turn off the engine and disconnect the battery.
  • Remove the fuel lines.
  • Remove the fuel pump using a screwdriver or wrench. Be sure to take note of the mounting location and orientation of the old fuel pump for the installation of the new fuel pump.
  • Install the new fuel pump. Tighten the mounting screws or bolts securely.
  • Reconnect the fuel lines to the new fuel pump using pliers or a wrench. Make sure the connections are tight and secure.
  • Reconnect the battery and turn on the engine to test the new fuel pump. Check for any fuel leaks or other problems.

Once the fuel pump has been replaced, test the engine to ensure that it is running properly.

Kohler Fuel Pump Problems – FAQs

Where to buy Kohler fuel pumps?

Kohler authorized dealers, online retailers, AutoZone and O’Reilly Auto Parts, and your local small engine repair shops.

How to find a reliable Kohler mechanic for fuel pump repair?

Kohler authorized dealers may have certified mechanics who specialize in Kohler engine repair. Contact them to find a good mechanic nearby.

What is the warranty on Kohler Fuel pumps?

Kohler offers a two-year warranty on their fuel pumps.

What is the average lifespan of a Kohler fuel pump?

A Kohler fuel pump can last for several years. Kohler recommends replacing the fuel filter every 100 hours of operation.

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