Small Engines (Lawn Mowers, etc.): Exmark 52in mower with Kohler CV22S motor not charging battery..., continuity test, exmark mower


Question
I have a Kohler CV22S motor on an Exmark mower and it was charging the battery fine and then stopped.  Mower works just fine but battery dies down to where it won't want to crank the motor over at next job and have to jump start it for the rest of the jobs and then put mower on charger when I get home for the next day until I figure out charging issue.  The following are tests performed:

1)  Tested coils of resistance and are within spec according to the Kohler service manual.  
2)  When cover was off of the mower I did continuity test (from coils etc) on all wires that I could test to main harness and everything appears to be good as far as I can see.
3)  Replaced voltage regulator and problem still is there.
4)  Tested stator (motor off) and I get resistance (very low like specs want) between both terminals which appears to be ok.  
5)  Tested (motor off) for continuity between end of terminal(s) from stator to ground and it appears that the stator isn't shorting out to ground which is good.
6)  Tested voltage (motor full throttle) from stator (voltage regulator unplugged) and I get about 10 to 15 volts where as my other mower (with same motor) gets around 30-40 volts; weird.
7)  Tested voltage output when key is turned on (motor not running) from voltage regulator (middle pin) and reading around 12.7 volts.
8)  Tested voltage (motor full throttle) from output of voltage regulator (middle pin) and reading was around 12.0 to 12.5 volts.

I am stumped at this so any help would be great.  

Answer
Hello Matt:

>>From your Description it Sounds like a Bad Stator.
>>For Testing the Electrical (Charging) System on Mowers you can Use this Site Addy; http://faqs.custhelp.com/cgi-bin/faqs.cfg/php/enduser/std_adp.php?p_faqid=3438&p... and Use the Link for AC Volts/DC Amps Meter Setting Chart. This is for Briggs Engines and Works Well for Kohler and Other Engine OEMs.
>>If you Hit a Snag or this Does Not Correct the Problem,  I am Here if You Require More Assistance. Hope this Helps. Let me Know What Happens, Please. May the All Mighty Bless You and Yours. Be Safe and Happy. Thanks.

Good Luck

Respectfully

John

PS: I am Allowed to Answer 10 Questions a Day. If you See I am Maxxed Out, then Try Submitting your Question at or Just After 8pm EST (US). My New Day Starts then. Comments and Ratings are Greatly Appreciated. Thanks.

Respectfully

John