You don't notice a starter until it fails, and by then, it's too late. You've got a full day ahead, but your machine just clicks, sputters, or refuses to turn over. Now you're stuck, wasting time, losing money, and scrambling for a fix. 

Starter problems don't show up overnight. They give off warning signs. Ignore them, and you're risking more than a stalled engine; you're putting your schedule and your bottom line on hold.

If your Kohler starter is on its way out, here are six signs you'll want to act on before you're dead in the water.

1. You Hear a Click But Nothing Happens

This is one of the most common starter issues. You turn the key or hit the switch, and all you get is a click. The solenoid may be working, but the motor isn't doing its job.

In many cases, the battery and ignition are in decent shape, but the engine doesn't turn.

That usually points to worn internal components inside the starter, like brushes, a weak solenoid, or damaged field coils. Some folks try to tap the starter with a wrench, hoping for a miracle. That's a temporary trick at best.

Before replacing the starter, double-check your battery connections and test your voltage. If those check out, odds are high the starter itself is the issue. A worn-out starter can leave you stranded repeatedly.

2. Starter Spins Without Engaging the Engine

Your starter sounds like it's working; it whirs, spins, and makes noise. But your engine doesn't respond. This usually means the starter's gear isn't connecting with the flywheel. It's spinning freely without turning anything.

This kind of mechanical failure is easy to miss if you're not listening closely. The sound is higher-pitched than normal, like a fast whizzing or whining. In some respects, that noise is your warning sign. A worn drive gear or bad alignment is often the cause.

If your starter was recently installed, it could be misaligned. In that case, you'll need to remove it, inspect the gear teeth, and realign it using shims if necessary.

Here are a few symptoms that point to a drive gear issue:

• High-pitched spinning sound with no engine response
• Starter keeps spinning longer than usual
• No resistance felt when turning the key

Direct-fit Kohler parts, like those sold by DB Electrical, are made to match OEM specifications closely, so alignment problems are less likely to happen.

3. Intermittent Starting

One day, it starts fine. The next day, nothing. Then, weirdly, it works again. This kind of inconsistency is frustrating and, frankly, a bit risky.

You might be dealing with worn contacts inside the starter or a solenoid that's starting to heat-soak. In that case, internal resistance goes up when the engine's hot, and the starter stops responding until it cools down again.

That kind of wear doesn't fix itself. In fact, it usually gets worse over time.

If you're reaching for jumper cables more than once a week, it's probably time for starter repair or full replacement. It's often cheaper to replace the starter than chase temporary fixes.

4. Grinding Noise When Starting

A grinding noise when starting your engine is never a good sign. It usually means the drive gear and flywheel aren't syncing properly. And once that starts, the damage tends to spread fast.

You might hear this after installing a new starter or if your current one has come loose. Often, people overlook torque settings or skip shims during installation. That causes misalignment between the starter gear and flywheel teeth.

Misalignment can lead to chipped teeth on both parts, which only gets worse over time. If ignored, this can result in full-on engine trouble or an expensive flywheel replacement.

To reduce grinding risk:

• Torque the starter to spec every time
• Use shims to match gear alignment
• Inspect flywheel teeth before reinstallation

DB Electrical starters are engineered for an exact fit. That includes proper gear placement, so your starter meshes with the flywheel the way it's supposed to.

5. Smoke or Burning Smell Coming From the Starter

If you see or smell smoke near your starter, shut the engine off right away. That's more than just wear; it's a sign of overheating, electrical failure, or both.

There are a few things that might cause this. Sometimes it's a short inside the starter. Sometimes it's from oil or dirt buildup. And sometimes it's just poor-quality parts that can't handle the load.

Either way, this kind of failure can damage your electrical system or even cause a fire.

Heat buildup is usually caused by one of these:

• Corroded or loose battery cables
• Oil-soaked internals increasing resistance
• Poor grounding or failing armature

Starters with sealed housings tend to hold up better here. That's one reason DB Electrical's Kohler replacements last longer than most-they're sealed tight and heat-tested under load to handle rough conditions.

6. Starter Keeps Running After Engine Is On

When the engine starts but the starter doesn't stop, you've got a serious problem. This can ruin your starter quickly and sometimes damage the flywheel too.

The most common reason is a stuck solenoid. Other times, the ignition switch keeps sending power to the starter after it should have shut off. Either way, this is one of the more destructive starter issues, and it usually requires immediate replacement.

Here are common signs this is happening:

• Starter noise continues after the engine starts
• Burning smell or smoke shortly after ignition
• Repeated fuse blows or drained battery

Ready to Replace Your Kohler Starter?

If you've noticed clicking, grinding, or random failures, these aren't minor quirks; they're signs your Kohler starter needs replacing. Ignoring them can lead to costly downtime and deeper engine trouble.

DB Electrical makes it easy to get back on track. Our starters are built to OEM specs and tested for long-lasting performance. With fast, free shipping on orders over $50 and a full 1-year warranty, you're covered from the minute you buy. Plus, our sealed housings and premium materials help prevent the starter issues that shut other brands down early.

Check out our Kohler starters today and get your equipment back to work.

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