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1. Section 5 Fuel System and Governor Grooved Wear Governor These engines are equipped with a centrifugal flyweight mechanical governor The governor is iy designed to hold the engine speed constant under A changing load conditions The governor gear flyweight mechanism is mounted inside the crankcase and driven off the gear on the crankshaft Operation Centrifugal force acting on the rotating governor gear assembly causes the flyweights to move outward as speed increases See Figure 5 8 As the flyweights move outward they cause the regulating pin to extend Figure 5 7 Inlet Needle and Seat Wear Damage from the governor gear assembly Details 10 After the parts have been cleaned or exchanged slide the inlet needle onto the float tab reinstall the float assembly into the carburetor and verify that the correct float height has been restored 11 If there were gum or varnish deposits in the area of the inlet needle and seat there is a good possibility that the main nozzle may also need cleaning before the bowl is reinstalled The main nozzle is threaded into the tower and can be removed for cleaning but be careful not to Speed Increasing Speed Decreasing damage it as it is not available as a service part a Usea thin flat blade screwdriver to remove Figure 5 8 Action of Governor Gear the nozzle from the tower If it does not turn easily use some carburetor cleaner to clean The regulating pin contacts the ta
2. So ee alan Section 5 Fuel System and Governor Pilot Jet Plug Screw Washer Seal Main Jet Screw Main Nozzle Main Pipe Float Float Gasket Drain Plug Gasket Bowl Retaining Screw Co Q MEA e 11 8 2 Float Pin Clip Needle Assembly Spring Throttle Adjusting Screw Spring Idle Fuel Adjusting Screw Limiter Cap Screw Ball Figure 5 4 CS8 5 12 Carburetor Exploded View 5 5 Section 5 Fuel System and Governor Carburetor Service If symptoms described in the carburetor troubleshooting guide indicate a problem within the carburetor the following steps can be used to remove the carburetor from the engine and provide the necessary service 1 Remove the air cleaner cover wing nut filter element with precleaner the air cleaner base mounting screws and hex flange nuts from the mounting bracket s and main mounting studs 2 Disconnect the breather hose from the valve cover or air cleaner base and remove the base from the engine 3 Disconnect the fuel line from the carburetor inlet 4 Disconnect the choke link and spring at the carburetor end CS8 5 12 only 5 Slide the carburetor off of the mounting studs while disconnecting the throttle link and dampening spring 6 Clean all dirt and debris from exterior of carburetor 7 Remove the screw from the bottom center of carburetor bowl Carefully separate the bowl from the
3. Hard starting or loss of power accompanied by high fuel consumption may be symptoms of faulty valves Although these symptoms could also be attributed to worn rings remove and check the valves first After removal clean the valve heads faces and stems with a power wire brush Then carefully inspect each valve for defects such as warped head excessive corrosion or worn stem end Replace valves found to be in bad condition A normal valve and valves in bad condition are shown in the accompanying illustrations Normal Even after long hours of operation a valve Bad Condition The valve depicted here should be can be reconditioned and reused if the face and replaced Note the warped head margin damaged and margin are in good shape If a valve is worn to where too narrow These conditions could be attributed to the margin is less than 1 32 in do not reuse it The excessive hours or a combination of poor operating valve shown was in operation for almost 1000 hours conditions under controlled test conditions 10 7 Section 10 Internal Components Leakage A poor grind on face or seat of valve will allow leakage resulting in a burned valve on one side only Coking Coking is normal on intake valves and is not harmful If the seat is good the valve could be reused after cleaning Excessive Combustion Temperatures The white deposits seen here indicate very high combustion temperatures usually due to a lean fuel mixture
4. Oil Type Use high quality detergent oil of API American Petroleum Institute service class SG SH SJ or higher Select the viscosity based on the air temperature at the time of operation as shown in the following table RECOMMENDED SAE VISCOSITY GRADES A ANA TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE Synthetic oils should not be used NOTE Using other than service class SG SH SJ or higher oil or extending oil change intervals longer than recommended can cause engine damage A logo or symbol on oil containers identifies the API service class and SAE viscosity grade See Figure 6 1 S Figure 6 1 Oil Container Logo 6 Check Oil Level The importance of checking and maintaining the proper oil level in the crankcase cannot be overemphasized Check oil BEFORE EACH USE as follows 1 Make sure the engine is stopped level and is cool so the oil has had time to drain into the sump 2 Clean the area around the oil fill cap to keep dirt debris etc out of the engine 3 Unthread and remove the oil fill cap 4 The oil level should be at the point of overflowing out of the filler neck See Figure 6 2 6 1 Section 6 Lubrication System Bring Level Up To Point of Overflow Level Figure 6 2 Cutaway Showing Proper Oil Level 5 Ifthe level is low add oil of the proper type to bring the level up to the point of overflowing NOTE To prevent extensive engine wear or damage alw
5. Remove the air cleaner base from engine as follows 1 Remove the hex flange screw s securing the air cleaner base to the mounting bracket s based on the specific model involved See Figures 9 5 9 6 and 9 7 Figure 9 5 CS4 CS6 Air Cleaner Base Section 9 Disassembly Remove Fuel Tank 1 Make sure the fuel tank is empty If the fuel shut off valve is mounted directly to tank close the valve See Figure 9 2 2 Loosen the clamp and disconnect the fuel line from the outlet of shut off valve fuel tank mounted valves on CS4 CS6 CS8 5 spec 92xxxx CS10 and CS12 engines See Figure 9 9 On the CS8 5 spec 95xxxx loosen the clamp and disconnect the fuel line from the inlet of the shut off valve blower housing mounted valves See Figure 9 10 Figure 9 6 CS8 5 spec 92xxxx CS10 and CS12 Air Cleaner Base Figure 9 9 Disconnecting Fuel Line on CS4 CS6 CS8 5 spec 92xxxx CS10 and CS12 Figure 9 7 CS8 5 spec 95xxxx Air Cleaner Base 2 Remove the two hex flange nuts securing the base to the carburetor mounting studs 3 Disconnect one end of the breather hose from the valve cover or air cleaner base 4 Pull the air cleaner base off the studs Figure 9 10 Disconnecting Fuel Line on CS8 5 spec 95xxxx 3 Remove the four fuel tank mounting screws and lift off the fuel tank assembly Figure 9 8 Removing Air Cleaner Base 9 3 Section 9 Disassembly 4 On CS8 5 spe
6. Worn or broken piston rings Worn cylinder bore Worn valve stems valve guides 9 21 219 Oil Leaks From Oil Seals Gaskets 1 Crankcase breather is clogged or inoperative 2 Loose or improperly torqued fasteners 3 Piston blowby or leaky valves 4 Restricted exhaust External Engine Inspection Before cleaning or disassembling the engine make a thorough inspection of its external appearance and condition This inspection can give clues to what might be found inside the engine and the cause when it is disassembled e Check for buildup of dirt and debris on the crankcase cooling fins grass screen and other external surfaces Dirt or debris on these areas are causes of overheating e Check for obvious fuel and oil leaks and damaged components Excessive oil leakage can indicate a clogged or improperly assembled breather worn or damaged seals and gaskets or loose or improperly torqued fasteners e Check the air cleaner cover and base for damage or indications of improper fit or sealing e Check the air cleaner element Look for holes tears cracked or damaged sealing surfaces or other damage that could allow unfiltered air into the engine Also note if the element is dirty or clogged These could indicate that the engine has had inadequate or infrequent maintenance e Check the carburetor throat for dirt Dirt in the throat is further indication that the air cleaner was not functioning properly 3 2 e Chec
7. 1 Remove the lower jam nut metal washer insulating washer and O Ring from the positive stud Carefully push the stud inward to separate the brush plate assembly from the end cap See Figure 8 43 Figure 8 40 Match Marks for Reassembly 4 Remove the two thru bolts with sealing O Rings from the starter See Figure 8 41 Figure 8 43 Removing Brush Plate Figure 8 41 Removing Starter Thru Bolt 5 Remove the commutator end cap and brush plate assembly See Figure 8 42 8 27 Section 8 Electrical System and Components 2 Inspect both the springs and brushes for wear fatigue or damage Measure the length of each brush The minimum length for each brush must be 9 mm 0 350 in See Figure 8 44 Replace the brush plate assembly if the condition of parts is out of specification or questionable Brushes Wear limit length 9 mm 0 35 in Figure 8 44 Brush Checking Figure 8 45 Brush Plate Details Armature Commutator 1 8 28 Clean and inspect commutator outer surface Use 600 grit sandpaper to clean if necessary Measure the mica insulation depth between the commutator segments The depth should be 2 mm 0 079 in If less cut scrape the mica to the proper measurement using a hacksaw blade or similar tool ground to fit between the segments See Figure 8 46 NOTE The mica insulation of the commutator must be undercut to ensure proper operation of the commutator D
8. Adjusting Low Idle Fuel and Speed NOTE Certified engines have a limiter cap on the idle fuel adjusting needle Adjustment can only be performed within the limits allowed by the cap 1 Start engine and run at half throttle for 5 to 10 minutes to warm up The engine must be warm before making final settings 2 Low Idle Fuel Needle Setting Place the throttle into the idle or slow position Turn the low idle fuel adjusting needle in or out within the adjustment range to obtain the best low speed performance 5 4 3 Low Idle Speed Setting Place the throttle control into the idle or slow position Set the low idle speed to 2000 RPM 150 RPM by turning the low idle speed adjusting screw in or out Check the speed using a tachometer NOTE The actual low idle speed depends on the application refer to equipment manufacturer s recommendations The recommended low idle speed for basic engines is 2000 RPM To ensure best results when setting the low idle fuel needle the low idle speed must not exceed 2000 RPM 150 RPM Idle Speed Limiter Cap Figure 5 2 Carburetor Adjustments Pilot Jet Screw Main Jet Main Nozzle Float Float Pin Float Gasket Drain Plug Spring Washer SNA ARA pa Bowl Retaining Screw Float Bowl Clip Needle Assembly Spring Idle Fuel Adjusting Screw Limiter Cap Screw Figure 5 3 CS4 and CS6 Carburetor Exploded View
9. Figure 8 67 Installing Frame with Brush Plate Assembly Figure 8 65 Holding Insulator in Place 11 Remove the tool and install the commutator end cap aligning the cutout with the insulating 9 Stand the armature drive end cap assembly on grommet See Figure 8 68 end so the commutator end is up Place brush armature installation tool over the end of armature shaft until it rests against the commutator See Figure 8 66 8 34 Section 8 Electrical System and Components 14 Connect the braided brush lead to lower main solenoid terminal and secure with the loose hex flange nut See Figure 8 70 Figure 8 68 Installing End Cap 12 Install and tighten the two thru bolts 13 Make sure the dust cover is in place on solenoid Figure 8 70 Connecting Brush Lead Install solenoid engaging the plunger end with the yoke of the drive lever Check by pulling solenoid towards the rear Mount the solenoid to the starter using the two hex flange nuts Tighten securely See Figure 8 69 Figure 8 69 Installing Thru Bolts 8 35 Section 9 Disassembly A WARNING Accidental Starts Disabling engine Accidental starting can cause severe injury or death Before working on the engine or equipment disable the engine as follows 1 Disconnect the spark plug lead s 2 Disconnect negative battery cable from battery General Clean all parts thoroughly as the engine is disassembled Only clean parts can be acc
10. Install the governor lever onto the shaft Do not tighten at this time Adjustment will be made later Figure 11 86 CS4 CS6 Governor Lever Details Ze Connect the governor spring to the arm of the governor lever and into the slot in the throttle lever See Figures 11 89 11 90 and 11 91 according to model number for proper assembly if necessary Section 11 Reassembly Figure 11 87 CS8 5 spec 92xxxx CS10 CS12 Figure 11 89 CS4 CS6 Spring Hole Position Governor Lever Installation 3 Connect the throttle link and the shorter end of dampening spring from the top down into the hole s in long end of governor lever as shown in Figures 11 86 11 87 and 11 88 l Figure 11 90 CS8 5 spec 92xxxx CS10 CS12 Spring Hole Position Figure 11 88 CS8 5 spec 95xxxx CS10 CS12 Governor Linkage Connected to Governor Arm Figure Hole Number Position CS4_Allmodels meo 2 CS6 All models except listed 11 89 specs CS6 Specs 911510 11 89 dd IS Figure 11 91 CS8 5 spec 95xxxx Spring Hole i l 11 90 Position 11 90 CS10 All models except listed specs CS10 Specs 931512 931612 931614 931615 CS10 Spec 931618 11 23 Section 11 Reassembly CS12 CS12T CS12T CS12TG CS12TP CS12TR CS12TR CS12STG CS12ST CS12S CS12ST CS12TG CS12STG CS12GT CS12STG CS12STG CS12STG CS12STG CS12STG CS12T CS12S CS12T CS12T CS12TG CS12TP CS12TR CS12TR CS12
11. Uno Pee 5 0 0 6 aia A 120 Num 85 ft lb A A A 120 N m 85 ft lb Fuel Tank Fuel Tank Pastener Screws PORQUE anio 8 12 Num 71 106 in lb Ignition Spark Plug Type E A PP OS OO EE E E A E A BPR4ES 13 16 hex GRADO T RN14YC 13 16 hex CHAMPIONS bruto test RC14YC 5 8 hex ot do AA A A A E errr mee ee 0 76 mm 0 030 in parece TOUS aiii 20 Num 14 7 ft lb 177 in lb tion Module A GaP ia dd 0 4 0 6 mm 0 015 0 023 in Ignition Module Mounting Screws Torque aa 10 N m 88 in lb TO NOUS SCG MOT do aras 5 8 N m 44 70 in Ib Muffler Muffler Torque Flange Nuts amp Bracket Bolts COSTO HET 8 12 N m 71 106 in Ib e a E N EN E A N A 18 22 N m 159 195 in Ib Oil Sentry Cil sent Oe OV e 10 N m 88 in lb Oil Sentry Indicator Light Retaining Nut Torque sss sese sees 0 6 0 8 N m 5 7 in Ib Piston Piston Rings and Piston Pin Piston to Piston Pin Clearance Eo A 0 002 0 018 mm 0 0001 0 0007 in A oo E tenance nue 0 004 0 020 mm 0 0002 0 0008 in Piston Pin Bore I D New E T 16 002 16 013 mm 0 6300 0 6304 in RGD SCC 9 0 0 AM E E OEA 18 004 18 015 mm 0 7088 0 7093 in ESPE IO aos os 20 004 20 015 mm 0 7876 0 7880 in E A no O E E E E 20 004 20 015 mm 0 7876 0 7880 in Max Wear Limit E E E E A A 16 03 mm 0 6311 in CI PEC ci 18 03 mm 0 7098 in RG a E 20 03 mm 0 7886 in A A 20 03 mm 0 7886 in Section 1 Safety and General Information Piston Piston Rings and Piston Pin cont
12. 10 8 Gum Gum deposits usually result from using stale gasoline Gum is a prevalent cause of valve sticking The cure us to ream the valve guides and clean or replace the valves depending on their condition Stem Corrosion Moisture in the fuel or condensation are the most common causes of valve stem corrosion Condensation occurs from improper preservation during storage and when engine is repeatedly stopped before it has a chance to reach normal operating temperatures Replace corroded valves Section 10 Internal Components Valve Seat Cover Typical Overheating An exhaust valve subject to overheating will have a dark dicoloration in the area above the valve guide Worn guides and faulty valve springs may cause this condition Also check for clogged air intake blocked fins and lean fuel mixture when this condition is noted Valve Guides If a valve guide is worn beyond specifications it will not guide the valve in a straight line This may result in burnt valve faces or seats loss of compression and excessive oil consumption To check valve guide to stem clearance thoroughly clean the valve guide and using a split ball gauge measure the inside diameter Then using an outside micrometer measure the diameter of the valve stem at several points on the stem where it moves in the valve guide Use the largest stem diameter to calculate the clearance Compare measurements and clearance to the specifications
13. Adjust improper gap setting the gap to 0 76 mm 0 030 in by carefully bending the ground electrode See Figure 8 1 This engine uses the following spark plugs 4 Reinstall the spark plug into the cylinder head Type The original spark plug is an NGK Torque the spark plug to 20 N m 177 in Ib BPR4ES The Champion equivalent of that NGK spark plug is RN14YC2 The service replacement is Champion RC14YC Kohler Part No Wire Gauge 66 132 01 S Equivalent alternate brand spark plugs can also be used Spark Plug Gap 0 76 mm 0 030 in Thread Size 14mm Reach 19 1 mm 3 4 in Hex Size 12 20 6 mm 13 16 in 15 9 mm 5 8 in Spark Plug Service Every 100 hours of operation remove the spark plug check its condition and reset the gap or replace it with anew plug as necessary 1 Before removing the spark plug clean the area Ground around the base of the plug to keep dirt and Electrode 0 76 mm debris out of the engine 0 030 in Gap Figure 8 1 Servicing Spark Plug 2 Remove the plug and check its condition Replace the plug if worn or reuse is questionable 8 1 Section 8 Electrical System and Components Inspection Inspect the spark plug as soon as it is removed from the cylinder head The deposits on the tip are an indication of the general condition of the piston rings valves and carburetor Normal and fouled plugs are shown in the following photos Normal A plug taken from a
14. For checking camshaft endplay AAA Cylinder Leakdown Tester For checking combustion retention and if cylinder piston rings or valves are worn Electronic Fuel Injection EFI Diagnostic Software Kohler 25 761 23 S Use with Laptop or Desktop PC EFI Service Kit For troubleshooting and setting up an EFI engine Kohler 25 761 05 S Kohler 24 761 01 S Individual Components Available Design Technology Inc Pressure Tester DTI 019 Noid Light DTI 021 90 Adapter DTI 023 Oetiker Clamp Pliers DTI 025 Code Plug Red Wire DTI 027 Code Plug Blue Wire DTI 029 Flywheel Holding Tool CS Series SE Tools KLR 82407 A ars SE Tools KLR 82408 To remove flywheel from engine Flywheel Strap Wrench To hold flywheel during removal AIN R 2 1 Section 2 Tools amp Aids Tools con IO Hydraulic Valve Lifter Tool To remove and install hydraulic lifters Kohler 25 761 38 5 Ignition System Tester For testing output on all systems except CD Kohler 25 455 01 S For testing output on capacitive discharge CD ignition system Kohler 24 455 02 S Offset Wrench K M Series To remove and reinstall cylinder barrel retaining nuts Po Eee necia io Kohler 25 761 06 S To test and verify oil pressure Rectifier Regulator Tester 120 volt current Kohler 25 761 20 S Rectifier Regulator Tester 240 volt current Kohler 25 761 41 S Used to test rectifier regulators Individual Components Available Design Technology Inc CS PRO
15. engine S designates slanted cylinder configuration and 6 designates horsepower A suffix letter designates a specific version as follows A Model No CS6ST Command Engine ns oti Slanted Cylinder T Horsepower 4 4 HP 6 6 HP 8 5 8 5 HP 10 10 HP 12 12 HP Spec No 911509 Engine Model Code Model CS4 CS6 608 5 300 cc CS10 CS12 CS8 5 250 cc C Serial No Year Manufactured Code Code Year Code 1998 33 1999 2000 2001 36 2002 37 28 23701265 Year 2003 2004 2005 2006 2007 Variation of Basic Engine Section 1 Safety and General Information Identification Decal Figure 1 1 Engine Identification Decal Location Designates Retractable Start Electric Start Tapered Crankshaft Threaded Crankshaft Gear Reduction 2 1 or 6 1 KOHLER IMPORTANT ENGINE INFORMATION THIS ENGINE MEETS U S EPA PHASE ll 2002 2005 CALIFORNIA AND EC STAGE II SN 4 EMISSION CONTROL REGS FOR SI SMALL OFF ROAD ENGINES FAMILY TYPE APP MODEL NO SPEC NO DISPL CC SERIAL NO OEM PROD NO EMISSION COMPLIANCE PERIOD EPA CATEGORY A CERTIFIED ON UNLEADED GASOLINE REFER TO OWNER S MANUAL FOR SAFETY MAINTENANCE SPECS AND ADJUSTMENTS 1 800 544 2444 www kohlerengines com KOHLER CO KOHLER WISCONSIN USA REF si CS6ST A 911509 B 2823701265 C Factory Code Figure 1 2 Explanation of Engine Identification Numbers NOTE CS8 5 engines have been produced in two di
16. ground cable terminal which could cause an explosion if hydrogen gas or gasoline vapors are present 1 Regularly check the level of electrolyte Add distilled water as necessary to maintain the recommended level NOTE Do not overfill the battery Poor performance or early failure due to loss of electrolyte will result Battery Figure 8 27 Battery Voltage Test 8 21 Section 8 Electrical System and Components Electric Starting Motors Electric start engines in this series will use either an inertia drive or a solenoid shift starter Each style has its own respective starter solenoid incorporated into the mounting configuration The inertia drive starters are covered first beginning on page 8 25 and the solenoid shift style covered starting on page 8 31 Starting Motor Precautions NOTE Do not crank the engine continuously for more than 10 seconds at a time If the engine does not start allow a 60 second cool down period between starting attempts Release the switch as soon as the engine starts Failure to follow these guidelines can burn out the starter motor NOTE If the engine develops sufficient speed to disengage the starter but does not keep running a false start the engine rotation must be allowed to come to a complete stop before attempting to restart the engine If the starter is engages while the flywheel is rotating the starter pinion and flywheel ring gear may Clash resulting in damage of the St
17. 08 in Figure 11 26 Oil Seal Installation Depth Pre lube all bearing surfaces with engine oil CS4 CS6 Reinstall the washer behind crankshaft key and crankshaft key Install the chain around both the crankshaft sprocket and the output shaft sprocket assembly then slide the complete assembly into place Reinstall the wave washer onto the output shaft See Figures 11 27 11 28 and 11 29 Section 11 Reassembly Figure 11 27 CS4 CS6 Installing Thrust Washer Figure 11 30 Installing Mounting Bolt and Washer Figure 11 28 CS4 CS6 Installing Sprockets and Figure 11 31 Torquing Mounting Bolt Chain CS8 5 12 Install the key into the keyway of the crankshaft Install the crankshaft gear onto the engine crankshaft Secure with the flat washer and hex flange screw See Figure 11 32 Torque the screw to CS8 5 spec 92xxxx CS10 CS12 60 70 N m 44 51 ft 1b CS8 5 spec 95xxxx 22 N m 195 in Ib Figure 11 29 CS4 CS6 Installing Wave Washer Install hex flange screw and flat washer into crankshaft Torque the screw to 20 24 N m 177 212 in Ib See Figures 11 30 and 11 31 Figure 11 32 11 8 Section 11 Reassembly Install the counter gear into the pre oiled bearing boss in the closure plate engaging teeth with gear on crankshaft Install the output shaft gear assembly into the corresponding pre oiled bearing boss in the closure plate See Figure 11 33 Figure 11 35 CS8 5
18. 1 4167 in Max Wear Limit De o E E I E EE 27 9 mm 1 098 in Bu cds o e o E OO POUUNPO0 0 OP EP A 31 9 mm 1 2559 in Me o a 0 00 y A A 35 9 mm 1 4134 in A E o mo 35 9 mm 1 4134 in Crankshaft et eE TBE EV d NGL T 0 02 mm 0 0008 in A ro r e E 0 04 mm 0 0016 in Cylinder Bore Cylinder Bore I D New A A No ee re ree 56 005 56 015 mm 2 2049 2 2053 in Bo EIN ES OE E P E A A AE EA E EA 66 005 66 015 mm 2 5986 2 5990 in ESSE OOO ed 75 005 75 015 mm 2 9530 2 9533 in eE 0 0 00 9 A rr rrr reer O PO A 78 00 78 02 mm 3 0709 3 0717 in A U T 78 00 78 02 mm 3 0709 3 0717 in o a A o EE EOI 85 00 85 02 mm 3 3465 3 3472 in Max Wear Limit o A o 56 15 mm 2 211 in A A AE A E ET A E E 66 15 mm 2 604 in R LR aen mrt emer rere ener tet 75 15 mm 2 959 in Be etei o E eee OO o ET 78 65 mm 3 096 in e ono A 78 65 mm 3 096 in TT 85 65 mm 3 372 in Max Ouro KOUNd EPA o EEr 0 05 mm 0 002 in Cylinder Head Cylinder Head Bolt Torque E E eS 20 N m 177 in lb Bo dl A IS A 50 N m 36 ft 1b Max Out of Flatness sss sees eee 0 1 mm 0 004 in Electric Starter Thru Bolt Case Torque E 5 3 N m 47 7 in lb 1 12 Section 1 Safety and General Information Electric Starter cont Mounting Bolts To Block Torque ES igo eagle ee iced E E AEE snanleicoeiaostees 16 N m 141 in Ib EN Flywheel Flywheel Retaining Screw Torque ESTO TT 65 Num 48 ft Ib e o L tree tafe ras nai A 65 N m 48 ft Ib
19. Components Battery Charging Systems General CS engines may be equipped with a 7 amp 10 amp or 18 amp regulated battery charging system Refer to the selection tables below and the appropriate wiring diagram based upon the specific Model and Spec No Wiring Diagram Selection Tables The following selection tables and individual wiring diagrams Figures 8 4 through 8 22 provide a reference for troubleshooting and servicing Locate the appropriate diagram based on the Model and Spec No involved Model No Spec No Figure No Page No Fodel No Spec No Figure No Page No 8 8 Cser 901506 86 s8 CS85ST 921508 89 CS8 5TG Model No Spec No Figure No CS6TG 911510 CS8 5TG 951507 CS6TG 911511 CS8 5ST 951508 CS6T 911512 CS8 5T 951509 CS6ST 911513 CS8 5T 951510 R CS6ST 911509 CS8 5TG 951506 i 7 8 21 8 6 Section 8 Electrical System and Components Model No Spec No Figure No PageNo Model No Spec No Figure No Page No 3 16 anur o31611 8 6 oane 931612 86 R 931614 815 a a 327 auer 931510 89 8 10 _ _Model No Spec No Figure No Page No 8 18 8 5 8 5 8 22 sor 931617 8 5 i a a Hydro 12 75 csi0TG 931620 8 5 CS125_ 941621 8 6 8 7 Section 8 Electrical System and Components Ignition Module Ground Electronic Ignition System Grou
20. Exhaust Valve Guide I D New E o o o nn a a nO E E Max Wear Limit E A E Co Gio 0 a ROCAS ogee pap E E A eee Section 1 Safety and General Information peated tenons 10 N m 88 in Ib PT 30 N m 22 ft lb ee 22 N m 195 in lb H 22 N m 195 in lb as 65 N m 48 ft Ib eee 65 N m 48 ft Ib eaten 6 5 N m 57 in lb ondo 7 N m 62 in lb naaa 10 N m 88 in Ib rosana tangas 7 N m 62 in lb ee 7 9 N m 62 80 in Ib Denied 9 11 N m 80 97 in Ib G 10 N m 88 in Ib ET 11 N m 97 in Ib eee 0 04 0 06 mm 0 0016 0 0024 in nan 0 037 0 064 mm 0 0015 0 0025 in nn 0 06 0 08 mm 0 002 0 003 in ss 0 045 0 072 mm 0 0018 0 0028 in pilas 5 5 mm 0 22 in iaa 6 0 6 012 mm 0 2362 0 2367 in sordo rencia 5 60 mm 0 220 in ias 6 10 mm 0 240 in Laila 5 5 mm 0 22 in ias 6 0 6 012 mm 0 2362 0 2367 in S 5 6 mm 0 220 in ne 6 0 mm 0 236 in Section 1 Safety and General Information Valves and Valve Lifters Valve Guide Reamer Size STD TH 5 5 mm 0 216 in B A cece A A AT N A E E 6 0 mm 0 236 in Intake Valve Minimum Lift hace apc A V AE A E E T 2 4 mm 0 094 in G o a e rec E EET E A A A E 2 7 mm 0 106 in Exhaust Valve Minimum Lift Go TE PEAT T centeane eet 2 7 mm 0 106 in Bei s a e E N N E E A E EE 2 9 mm 0 114 in Nominal Valye ocat Anp NS ahaa sar gaia sant e iaa Eie 45 Valvesto lappet Clearance COMA seiesncsasanvensorsuneariesmmaraisar
21. In and check if the Hold In coil holds the plunger retracted See Figure 8 30 Do not allow the test leads to remain connected to the solenoid for a prolonged period of time If the plunger fails to stay retracted the solenoid should be replaced Manually Push Plunger In 12 volt Test Leads Connect Only Long Enough to Test Figure 8 30 Testing Hold In Coil Function Test Test 4 Solenoid Hold In Coil Contact Continuity Test Use an ohmmeter set to the audible or Rx2K scale and connect the two ohmmeter leads to the two large post terminals Perform the preceding test 3 and check for continuity See Figure 8 31 The meter should indicate continuity if no continuity is indicated the solenoid should be replaced Repeat test several times to confirm condition Section 8 Electrical System and Components Operation When power is applied to the starter the armature rotates As the armature rotates the drive pinion K 4 moves out on the splined drive shaft and into mesh VOM Meter y with the flywheel ring gear When the pinion reaches z the end of the drive shaft it rotates the flywheel and cranks the engine Leads Plunger Pushed In When the engine starts the flywheel rotates faster than the starter armature and drive pinion This moves the drive pinion out of mesh with the ring gear and into the retracted position When power is removed 12 volt Test Leads from the starter the armature
22. Module Oil Sentry N Gauge ap Ground i Stator W W Starter A one Ground Solenoid Ground Plug Ground Battery Electronic Ignition System 10 Amp A Charging System with Rectifier Ae REJNA Regulator and Oil Sentry System 1 Electric Start Inertia Drive Starter Ground Figure 8 8 Main Switch Oil Warning Unit BW R v y BW lg Ground 4 Oil B D Sentry Fuse 20 A Wire Lead L Light Engine Charge Lamp R W Ground Starter Solenoid B Ignition Module Oil Sentry E Ground G C auge Ww Stator de Battery Rectifier Regulator Starter Electronic Ignition System 18 Amp Motor Charging System with Rectifier wil Ground Regulator and Oil Sentry System Y Electric Start Inertia Drive Starter Charge Lamp Figure 8 9 8 10 Section 8 Electrical System and Components Main Switch Oil Warning Unit E YR YR L BW YR Ground 1 Y Ground a E Oil Sentry Rectifier Y amp Light Wire Lead Ignition N Y Module B Mk Fuse Oil N SI Sentry Lead Starter Gauge Solenoid Spark E par Ground Ground L L Ground roun A Plug A d A L L Ground Grou nd Battery Electronic Ignition System 0 4 or 2 Amp Charging System Rectified Only Oil Sentry System Electric Start Inertia Drive Starter Figure 8 10 M Starter Motor Ground F Ground Oil Warning Unit L L 4 BW Ground 7 Y Oil B Sentry TM Rectifier E
23. Nut Adjust Set Governor 1 Adjust and set the governor as follows See Figures 108 and 109 a Rotate the governor lever clockwise until it stops b Turn the governor shaft clockwise until it stops c Torque the clamp bolt to CS4 CS6 8 N m 71 in Ib CS8 5 12 10 N m 88 5 in Ib Section 11 Reassembly Figure 11 108 CS4 CS6 Adjusting Governor Figure 11 110 CS4 CS6 CS8 5 spec 92xxxx CS10 CS12 Shut Off Valve Orientation 2 Install the fuel tank assembly onto the mounting brackets Secure with the four M6 hex flange screws and a flat washer CS8 5 spec 92xxxx CS10 CS12 only under each screw head Torque the screws to 8 12 N m 71 106 in Ib 3 Connect the fuel line to the shut off valve and secure with the clamp Figure 11 109 CS8 5 12 Adjusting Governor Install Fuel Tank a CS6 CS8 5 spec 92xxxx CS10 CS12 If the fuel shut off valve was removed or serviced separately install and secure with the flange nut so the outlet faces directly to the left The O Ring on the fitting must be in good condition Replace if deteriorated in any way Figure 11 111 Tightening Fuel Tank Mounting Screws CS8 5 spec 95xxxx 1 Install the fuel tank support to top of crankcase Align the four mounting holes with the crankcase locations Install and finger tighten the four M8 hex flange screws with flat washers under each head Install the single M6 hex flange screw in the hole
24. PERO ai 74 954 74 998 mm 2 9509 2 9527 in Sash II E 77 954 77 998 mm 3 0691 3 0708 in Bo A A E II EE A eeedeotnannendastnune 77 954 77 998 mm 3 0691 3 0708 in T Ae A seals sheen dnoneehenn E E 84 954 84 998 mm 3 3446 3 3464 in Max Wear Limit B TT 55 900 mm 2 20 in S A o q A 65 900 mm 2 60 in RC PA A E OE 74 898 mm 2 9487 in Beea e 9 T A A NS 77 898 mm 3 0669 in I O O O OO EE EE E E 77 898 mm 3 0669 in ES ua AE EEE E E E E E EE ET 84 898 mm 3 3424 in Piston Thrust Face to Cylinder Bore Running Clearance L 0 015 0 040 mm 0 0006 0 0016 in e TTT 0 002 0 066 mm 0 0001 0 0026 in Reduction System Case Mounting Bolt s Torque e AA EE E A Crankshaft Gear Bolt Torque Go T Eo e E E A E E E E RE 0 0 0 6 e AA Be o 0 eS 6 6 E o AT L e bi Retractable Starter Mounting Screws to Blower Housing Torque e n A R RA Rocker Arm Stud Into Cylinder Head Torque E E EE batyns dachsaacnaandbicens Adjusting Jam Nut LOTUS rosa Throttle Control Throttle Control Lever Fastener Torque Qe Eo o IPPO A Valve Cover Valve Cover Fastener Torque e A A tenses te Valves and Valve Lifters Intake Valve Stem to Valve Guide Rumning Clearance A a o o E E ET A A o eae eee cae Exhaust Valve Stem to Valve Guide Running Clearance E A o ee E eee eer ert eee ee E A e E Ro O E A Intake Valve Guide LD New oo enn R NE E E Max Wear Limit E A ee ee ere er eee ee eer ee lt 10 RPP FO O E E E E aces
25. Regulator Test Harness DTI 031 Special Regulator Test Harness with Diode DTI 033 Spark Advance Module SAM Tester To test the SAM ASAM and DSAM on engines with SMART SPARK PODEA Starter Brush Holding Tool Solenoid Shift SE Tools KLR 82416 To hold brushes during servicing Starter Retaining Ring Tool Inertia Drive i To remove and reinstall drive retaining rings excluding FASCO starters nail ae Starter Servicing Kit All Starters To remove and reinstall drive retaining rings and brushes SE Tools KLR 82411 Individual Component Available Starter Brush Holding Tool Solenoid Shift SE Tools KLR 82416 Tachometer Digital Inductive Design Technology Inc For checking operating speed RPM of an engine DTI 110 Vacuum Pressure Tester Kohler 25 761 22 S Alternative to a water manometer A A a SE Tools KLR 82413 For sizing valve guides after installation Valve Guide Service Kit Courage Aegis Command OHC SE Tools KLR 82415 For servicing worn value guides 2 2 Section 2 Tools amp Aids wooo Electric Starter Drive Lubricant Inertia Drive Kohler 52 357 01 S Electric Starter Drive Lubricant Solenoid Shift Kohler 52 357 02 S RTV Silicone Sealant Kohler 25 597 07 S Loctite 5900 Heavy Body in 4 oz aerosol dispenser Only oxime based oil resistant RTV sealants such as those listed are approved for use Loctite Nos 5900 or 5910 are recommended for best sealing characteristics Loctite
26. This creates two flame fronts which meet and explode to create extreme hammering pressures on a specific area of the piston Detonation generally occurs from using low octane fuels Abrasive Worn Rings Preignition or ignition of the fuel charge before the timed spark can cause damage similar to detonation Preignition damage is often more severe than detonation damage Preignition is caused by a hot spot in the combustion chamber from sources such as glowing carbon deposits blocked fins improperly seated valve or wrong spark plug Scored Piston and Rings Figure 10 13 Common Types of Piston and Ring Damage See Figure 10 13 for common types of piston and ring damage 10 10 Replacement pistons are available in STD bore size and in 0 25 mm 0 010 in and 0 50 mm 0 20 in oversizes Replacement pistons include new piston ring sets and new piston pins Service replacement piston ring sets are also available separately for STD pistons and for 0 25 mm 0 010 in and 0 50 mm 0 020 in oversized pistons Always use new piston rings when installing pistons Never reuse old rings The cylinder bore must be deglazed before service ring sets are used Some important points to remember when servicing piston rings 1 If the cylinder bore does not need reboring and the old piston is within wear limits and free of score or scuff marks the old piston may be reused 2 Remove old rings and clean up grooves Never r
27. as shown in Figure 2 2 Figure 2 2 Rocker Arm Crankshatt Tool Section 3 Troubleshooting Troubleshooting Guide When troubles occur be sure to check the simple causes which at first may seem too obvious to be considered For example a starting problem could be caused by an empty fuel tank Some common causes of engine trouble are listed below Use these to locate the causing factors Engine Cranks But Will Not Start 1 Empty fuel tank Fuel shut off valve closed Key switch or kill switch in off position Low oil level Dirt or water in the fuel system Clogged fuel line Spark plug lead disconnected Faulty spark plug Faulty ignition module et ee ra Engine Starts But Does Not Keep Running 1 Restricted fuel cap vent 2 Dirt or water in the fuel system 3 Faulty choke or throttle controls 4 Loose wires or connections that short the kill terminal of ignition module to ground 5 Faulty cylinder head gasket 6 Faulty carburetor Engine Starts Hard 1 PTO drive is engaged Dirt or water in the fuel system Clogged fuel line Loose or faulty wires or connections Faulty choke or throttle controls Faulty spark plug Low compression Faulty ACR mechanism Weak spark ignition oe E ee E Engine Will Not Crank 1 ED Se e S PTO drive is engaged Battery if equipped is discharged Safety interlock switch is engaged Loose or faulty wires or connections Faulty key switch o
28. as shown and thread it into the throttle control bracket Torque the four M8 screws to 27 31 N m 238 274 in lb and the single M6 screw to 8 12 N m 71 106 in 1b See Figure 11 112 11 29 Section 11 Reassembly Figure 11 112 CS8 5 spec 95xxxx Installing Fuel Tank Support 2 Install the fuel tank assembly with the fuel line connected to the outlet fitting into the fuel tank support Route the fuel hose beneath the linkages and align the mounting holes Secure with the four M6 hex flange screws Torque the screws to 8 12 N m 71 106 in 1b 3 Ifthe fuel shut off valve was removed or serviced separately reassemble it and secure it to the mounting bracket Torque the top mounting screw to 8 12 N m 71 106 in lb See Figure 11 113 Figure 11 113 CS8 5 spec 95xxxx Shut Off Valve Details 4 Connect the fuel line from the fuel tank to the inlet fitting of the shut off valve and secure with the clamp Mount the bracket shut off valve assembly to the blower housing aligning the indexing mark and screw hole Install the hex flange head screw and torque to 8 12 N m 71 106 in 1b See Figure 11 114 11 30 KOHLER Figure 11 114 CS8 5 spec 95xxxx Mounting Shut Off Valve 5 Connect the fuel line to the outlet of the shut off valve and the carburetor inlet Secure with the clamps Install Outer Air Cleaner Cover 1 Install the outer air cleaner cover onto the stud over the element Secure
29. cam This holds the exhaust valve off of its seat during the first part of the compression stroke After the engine speed increases above approximately 600 RPM centrifugal force causes the spring loaded arm to move outward causing the pin to retract When in this position the pin has no effect on the exhaust valve and the engine operates at full compression and power When the engine is stopped the spring returns the lever and control pin assembly to the compression release position ready for the next start z Operation AA O ZER Decomp Weight Figure 10 1 ACR Operation Details 10 1 Section 10 Internal Components Benefits As a result of the reduced compression at cranking speeds several important benefits are obtained 1 Manual retractable starting is much easier Without ACR manual starting would be virtually impossible 2 Electric start models can use a smaller starter and battery that are more practical for the application 3 ACR eliminates the need for a spark retard advance mechanism A spark retard advance mechanism would be required on engines without ACR to prevent the kickback that would occur during starting ACR eliminates this kickback making manual starting safer 4 The choke control setting is less critical with ACR In the event of flooding excess fuel is blown out the opened exhaust valve and does not hamper starting 5 Engines with ACR start much faster in cold weather than
30. charge rate does not increase when load is applied test stator Tests 2 and 3 If voltage is 20 0 volts or more stator is OK Rectifier regulator is faulty Replace the rectifier regulator If voltage is less than 20 0 volts stator is probably faulty and should be replaced Test stator further using an ohmmeter Test 3 If resistance value obtained is within the range specified the stator is OK Charging System Normal Resistance ohms 1 2 and 1 6 amp 0 90 1 6 ohms 0 85 and 3 0 amp 0 28 0 50 ohms 7 10 and 18 amp 0 10 0 30 ohms If the resistance is infinity ohms no continuity the stator is OK not shorted to ground If resistance or continuity is measured the stator leads are shorted to ground Replace stator If the voltage is 15 0 volts or less the charging system is OK The battery is unable to hold a charge Service or replace battery as necessary If voltage is more than 15 0 volts the rectifier regulator is faulty Replace the rectifier regulator Section 8 Electrical System and Components Battery 2 Keep the cables terminals and external surfaces of the battery clean A build up of corrosive acid General or grime on the external surfaces can cause the A 12 volt battery not furnished with a minimum battery to self discharge Self discharge occurs current rating of 160 CS4 CS6 or 200 CS8 5 12 cold rapidly when moisture is present cranking amps should be sufficient for cranking
31. engines without ACR 6 Engines with ACR can be started with spark plugs that are worn or fouled Engines without ACR are more difficult to start with those same spark plugs Camshaft amp Tappets Inspection and Service Inspect the gear teeth of the camshaft If the teeth are badly worn chipped or some are missing replacement of the camshaft will be necessary If unusual wear or damage is evident on either lobe or the mating tappet the camshaft and both tappets must be replaced Check the condition and operation of the ACR mechanism See Figure 10 2 10 2 Inspect Inspect Figure 10 2 Camshaft and Tappet Inspection Points Measure the cam lobe profile A and B as shown using an outside micrometer and compare with specifications listed Figure 10 3 Cam Lobe Checking A Cam Lobe Dimension A CS4 CS6 26 9 0 05mm 26 68 0 05 mm 1 06 0 002 in 1 05 0 002 in CS8 5 CS10 32 55 0 05 mm 32 55 0 05 mm CS12 1 28 0 002 in 1 28 0 002 in Section 10 Internal Components Crankshaft Inspection and Service Inspect the gear teeth of the crankshaft If the teeth are badly worn chipped or some are missing replacement of the crankshaft will be necessary Inspect the crankshaft bearing surfaces for scoring erooving etc Do not replace the main bearings unless they shown signs of damage or are out of running clearance specifications If the crankshaft turns easily an
32. exactly in neutral to prevent resistance which could keep the engine from starting 2 Check for seized engine components such as the bearings connecting rod and piston Transmission or Engine 8 22 Section 8 Electrical System and Components Troubleshooting Guide Electric Starting System 1 Test battery on unit 1 a Battery voltage should be at least 12 volts If low charge battery a Connect a DC voltmeter across the battery terminals and read battery voltage key Battery voltage should not fall below 9 volts switch off during cranking If it does battery may be faulty or there may be a short in the starting b Turn key switch to start position and circuit Have battery load tested If battery read battery voltage again Turn switch off passes load test check circuitry Remove the electric starter cover panel and check 2 If fuse is blown check for a wiring problem the fuse inside the plastic holder The fuse outside bare wire short circuit Correct problem and the holder is a spare replace fuse Try to start engine If it still won t start go to step 3 Disconnect the red white solenoid lead from red If solenoid engages and starter begins to crank white switch lead at the bullet connection Be sure the key switch is faulty or there is a wiring transmission is in neutral and PTO is off problem to from the key switch Check wiring Connect one end of a jumper lead to the positive and test key switch cir
33. for the bearings The closure plate and components are new or have been reconditioned and crankcase must be clean all component subassembly work has been completed The sequence may vary to accommodate options or 2 Use an arbor press to make sure the bearings are special equipment Detailed procedures can be found installed straight into their respective bores until in subsequent subsections fully seated 1 Install oil seals and bearings NOTE Install the bearings and oil seals step 3 2 Install governor cross shaft with their manufacturer s marks or 3 Install crankshaft numbers visible facing you 4 Install connecting rod with piston and rings 5 Install camshaft and valve tappets Oil the bearings liberally with engine oil when 6 Install balance shaft assembly CS8 5 12 only installing 7 Install oil sentry gauge and governor gear to closure plate 8 Install closure plate assembly 9 Install reduction assembly some models 10 Install stator and wire shield 11 Install flywheel 12 Install ignition module 13 Assemble and install cylinder head 14 Install push rods rocker arms studs and rocker shaft 15 Install valve cover 16 Install fuel tank supports throttle lever wiring and electrical components 17 Install governor lever throttle and governor springs 18 Connect electrical leads and install electric starter Figure 11 1 Installing Bearings Using a Press electric starter only 19 Install blower
34. fuel line may not be used Order replacement hose by part number through a Kohler Engine Service Dealer Fuel System Tests When the engine starts hard or turns over but will not start it is possible that the problem is in the fuel system To find out if the fuel system is causing the problem perform the following tests KOHLER IMPORTANT ENGINE INFORMATION THIS ENGINE MEETS U S EPA PHASE Il 2002 2005 CALIFORNIA AND EC STAGE II SN 4 EMISSION CONTROL REGS FOR SI SMALL OFF ROAD ENGINES FAMILY 6 YYMXS 1171 EA TYPE APP MODEL NO SPEC NO DISPL CC SERIAL NO OEM PROD NO EMISSION COMPLIANCE PERIOD EPA CATEGORY A CERTIFIED ON UNLEADED GASOLINE REFER TO OWNER S MANUAL FOR SAFETY MAINTENANCE SPECS AND ADJUSTMENTS 1 800 544 2444 www kohlerengines com KOHLER CO KOHLER WISCONSIN USA REF sis Figure 5 1 Family Number Location Troubleshooting Fuel System Related Causes Test Conclusion Check the following a Make sure the fuel tank contains clean fresh proper fuel b Make sure the vent in the fuel cap is open c Make sure the fuel valve is open Check for fuel in the combustion chamber a Disconnect and ground the spark plug lead b Close the choke on the carburetor c Crank the engine several times d Remove the spark plug and check for fuel at the tip Check for fuel flow from the tank to the carburetor a Remove the fuel line from the inlet fitting o
35. hex flange screws to 30 N m 265 in 1b Leave the three cover panel screws out at this time Figure 11 92 CS8 5 spec 92xxxx CS10 CS12 Installing Electric Starter 2 Connect the electrical leads for the Oil Sentry ignition module keyswitch solenoid and starter Attach the red white wire harness lead to the solenoid terminal opposite the terminal containing the starter lead Figure 11 93 CS8 5 spec 92xxxx CS10 CS12 Reconnect Electrical Leads Figure 11 94 CS8 5 spec 92xxxx CS10 CS12 Reconnect Solenoid Wiring Harness Lead CS8 5 spec 95xxxx CS10 CS12 with Solenoid Shift Starters 1 Align and mount the electric starter motor to the crankcase Install and torque the two hex flange screws to 30 N m 265 in Ib See Figure 11 95 Mounting Screws Figure 11 95 Solenoid Shift Starter Mounting 2 Connect the electrical leads for the Oil Sentry ignition module keyswitch solenoid and starter Attach the red white wire harness lead to the spade terminal of solenoid Attach the red harness lead with the ring terminal to the main upper terminal on the solenoid that is attached to the battery cable Secure the wires together and out of the way using the beaded tie 11 25 Section 11 Reassembly Install Blower Housing and Electric Starter Cover Panel If So Equipped 1 Install the blower housing behind the throttle link and dampening spring Start all the hex f
36. housing and electric starter cover panel 20 Install carburetor Section 11 Reassembly Figure 11 2 Installing Bearing in Closure Plate Figure 11 4 Installing Governor Shaft 3 Use a seal driver and install the crankshaft oil seals manufacturer s numbers visible into crankcase and closure plate Seals should be installed to a depth of 2 mm 0 080 in below outer surface See Figure 11 3 Apply a light coating of lithium grease to seal lips when installing Figure 11 5 Installing Outer Washer 3 Install the second flat washer onto the shaft Position the shaft so the lower flat section faces to the right 3 o clock position and insert the hitch pin so the end of the clip comes in contact with the raised section of the housing boss limiting the inward movement of the arm See Figures Figure 11 3 Installing Oil Seal 11 6 and 11 7 Install Governor Cross Shaft NOTE Verify that correct installation has been 1 Install the governor shaft seal with the made at this time manufacturer s marks out into the governor shaft bore in crankcase until flush with the top A 1 2 in O D seal driver or round stock may be used to install 2 Install one thrust washer onto the governor cross shaft and slide the shaft up through the inside of the crankcase Figure 11 7 CS8 5 12 Installing Hitch Pin Install Crankshaft 1 Carefully slide the flywheel end of the crankshaft through the main ball bearing and s
37. in place with lock clip Install the lock clip with its rounded edges down Figure 11 64 Installing Valves Using Valve Spring Compressor 4 If intake or exhaust port studs were removed previously reinstall them at this time Torque the studs to CS4 CS6 CS8 5 spec 95xxxx 4 5 N m 35 44 in Ib CS8 5 spec 92xxxx CS10 CS12 12 19 N m 106 168 in Ib Install Cylinder Head 1 Check to make sure there are no nicks or burrs on the sealing surfaces of the cylinder head or crankcase Rotate the crankshaft to position the piston at TDC on compression stroke Install the dowel pins into the recesses around the lower cylinder head bolt holes Install a new cylinder head gasket Section 11 Reassembly Figure 11 65 Installing Dowel Pins and New Head Gasket 5 Install the cylinder head and start the four hex flange screws Torque the screws in several increments using the sequence shown See Figures 11 66 and 11 67 to CS4 CS6 20 N m 177 in Ib CS8 5 12 50 N m 36 ft Ib Figure 11 67 Cylinder Head Screws Torquing Sequence 11 17 Section 11 Reassembly Install Push Rods Rocker Arms Studs and Rocker Shaft NOTE Push rods should always be installed in the original location 1 Identify the proper position of each push rod Dip the ends of the push rods in engine oil and install them in their respective locations seating each into the tappet socket Figure 11 70 CS
38. inside plastic through the end Cap support can occur Figure 8 49 Installing Armature Figure 8 51 Assembled Brush Plate 3 Install the starter frame magnet end first over the armature aligning the scribed marks made earlier See Figure 8 50 Figure 8 52 Brush Plate and Terminal Components 8 29 Section 8 Electrical System and Components 5 Assemble the end cap assembly to the starter inserting the commutator below the brushes and gently guiding the end of the armature shaft into the bushing within the end cap against the brush spring tension See Figure 8 53 Figure 8 55 Assembling Starter Lead Figure 8 53 Installing End Cap Assembly 6 Align all scribe marks and install the thru bolts with O Rings Torque the bolts to 5 3 N m 48 in Ib See Figure 8 54 Figure 8 56 Installing Solenoid Connections 8 Apply a light film of molybdenum disulfide to the splines of armature shaft and install the drive pinion spring and spring holder 9 Push the spring holder down and install a new retaining ring into the groove of the armature shaft Squeeze it with a pliers to compress it into the groove It must fit into the recess in the end of Figure 8 54 Torquing Thru Bolts the spring holder 7 Attach the starter lead from the solenoid to the 10 Install the starter back onto the engine Refer to stud and add the lock washer and outer hex jam Section 11 Reassembly nut to secure Hold the l
39. level plug and fill plug into their respective locations The fill plug contains a vent hole and must be installed on top See Figure 11 46 Torque the plugs to 15 19 N m 133 168 in 1b 11 12 Figure 11 46 Fill Vent Plug Installation CS8 5 12 1 If any bearings were removed press the new bearing s into the housing so the manufacturer s marks are visible Pre lube the bearings with engine oil on installation 2 Install a new oil seal in cover to a depth of 2 mm 0 08 in See figure 11 47 Apply a light coating of lightweight lithium grease to the lip of the seal 2mm 0 08 in Figure 11 47 Oil Seal Installation Depth Section 11 Reassembly 3 Slide the crankshaft gear onto the splines of the crankshaft Secure with the flat washer and hex flange screw Torque the screw to 20 24 N m 177 212 in lb Figure 11 50 Installing Output Shaft Assembly 6 Reinstall the two dowel pins into their respective locations in the closure plate Install a new housing cover gasket dry onto the dowel pins Figure 11 48 Installing Crankshaft Gear Mounting Screw and Washer 4 Lubricate the bearing surfaces with oil and install the counter gear into the closure plate bore engaging teeth with gear on crankshaft Figure 11 51 Installing Dowel Pins and Gasket 7 Install the reduction housing cover and secure with the six mounting screws Torque the screws to 28 32 N m 247 283 in Ib Fi
40. most electric start engine models The actual cold cranking 3 Wash the cables terminals and external surfaces requirement depends on engine size application and with a mild baking soda and water solution starting temperatures Cranking requirements increase Rinse thoroughly with clear water as temperatures decrease and battery capacity shrinks Refer to the operating instructions of the equipment NOTE Do not allow the baking soda solution to this engine powers for specific battery requirements enter the cells as this will destroy the electrolyte If the battery charge is not sufficient to turn over the engine recharge the battery Battery Test To test the battery you will need a DC voltmeter Battery Maintenance Perform the following steps See Figure 8 27 Regular maintenance is necessary to prolong battery life 1 Connect the voltmeter across the battery terminals A WARNING Explosive Gas Batteries produce explosive hydrogen gas while being 2 Crank the engine If the battery drops below 9 charged To prevent a fire or explosion charge batteries only volts while cranking the battery is discharged or in well ventilated areas Keep sparks open flames and other faulty sources of ignition away from the battery at all times Keep batteries out of the reach of children Remove all jewelry when servicing batteries Before disconnecting the negative ground cable make sure all switches are OFF If ON a spark will occur at the
41. on the PTO 6 Crank engine over using recoil or electric starter face find a bolt of appropriate length and and check results thread size Insert the bolt through the slot and thread it into the selected hole to prevent e Standard Compression Pressure the tool from moving Tighten the screws to 400 600 kPa 57 85 psi with ACR mechanism lock the holding tool onto the crankshaft If a in operation PTO face hole is not accessible tighten the screws to lock the holding tool onto the Cylinder Leakdown Test crankshaft Insert the end of a 3 8 breaker A cylinder leakdown test can be a valuable alternative bar into the slot so the handle of the breaker to a compression test especially on engines with ACR bar is perpendicular to the crankshaft By pressurizing the combustion chamber from an external air source you can determine if the valves or rings are leaking and how badly 3 3 Section 3 Troubleshooting b Ifthe flywheel end of the engine is more accessible you can use a breaker bar and socket on the flywheel nut screw or a flywheel holding tool to hold it in position When using these methods you will need an assistant to hold it during the test c If the engine is mounted in a piece of equipment you may be able to hold it by clamping or wedging a driven component Just be certain the engine cannot rotate off of TDC in either direction 4 Install the adapter into the spark plug hole but do not attach it to the tester at
42. rod so the dipper is down and the match marks are aligned See Figure 11 14 Torque in increments to CS4 CS6 12 N m 106 in Ib CS8 5 12 20 N m 177 in Ib Figure 11 14 Rod Cap Dipper Position Install Valve Tappets and Camshaft 1 Identify the valve tappets as to their proper locations Lubricate the face and stem of each tappet with engine oil Install each into their respective bores 2 Lubricate the camshaft bearing surfaces and cam lobes as well as the camshaft bore in the crankcase with engine oil Section 11 Reassembly 3 Rotate the crankshaft to TDC so the timing mark 2 Install the balance shaft aligning the timing mark dimple on crankgear smaller gear is in the 4 hole with the timing mark dimple on the o clock position Install the camshaft into the larger crankgear See Figure 11 17 crankcase aligning the timing marks on the two gears See Figures 11 15 and 11 16 NOTE Timing mark is the hole on CS4 CS6 and the small dimple on CS8 5 12 Figure 11 17 CS8 5 12 Aligning Balance Shaft and Crankgear Timing Marks Install Governor Assembly The governor gear assembly is located inside the Figure 11 15 CS4 CS6 Aligning Crankshaft and closure plate If servicing was performed or the Camshaft Timing Marks governor was removed reassemble as per procedures under Governor Reassembly in Section 10 Install Oil Sentry Gauge 1 Mount the Oil Sentry gauge into the closure plate us
43. shaft assembly 21 Remove camshaft and valve tappets 22 Remove connecting rod with piston and rings 23 Remove crankshaft 24 Remove governor cross shaft 25 Remove oil seals and bearings Loosening removing the electric starter cover panel will provide access to upper housing mounting screw Disconnect Spark Plug Lead 1 Disconnect the lead from the spark plug See Figure 9 1 NOTE Pull on boot only to prevent damage to spark plug lead Figure 9 1 Disconnecting Spark Plug Lead 9 1 Section 9 Disassembly Turn Fuel Shut Off Valve to Off Position HT TT L Pst Figure 9 2 Fuel Shut Off Valve Drain Oil From Crankcase 1 Remove one of the oil drain plugs and one of the oil fill caps Drain Plug Figure 9 3 Oil Drain Plug 2 Allow ample time for the oil to drain from the crankcase 3 On engines with a 2 1 reduction system tip the engine toward the flywheel to drain most of the oil out of the reduction housing then drain out of the crankcase Remove Muffler and Heat Shield Assembly 1 Remove the hex nuts from the exhaust studs and the hex flange screw from the muffler bracket 2 Remove the muffler assembly from the exhaust outlet 9 2 Erns renrersn ns vd MILARI FI MeL Che Figure 9 4 Removing Muffler 3 Remove the exhaust gasket from the outlet Remove Air Cleaner Assembly Remove the air cleaner components from the air cleaner base as outlined in Section 4
44. to minimize gum deposits in your fuel system and to insure easy starting e Do not add oil to the gasoline e Do not overfill the fuel tank Leave room for the fuel to expand Fuel Type For best results use only clean fresh unleaded gasoline with a pump sticker octane rating of 87 or higher In countries using the Research fuel rating method it should be 90 octane minimum Unleaded gasoline is recommended as it leaves less combustion chamber deposits Leaded gasoline may be used in areas where unleaded is not available and exhaust emissions are not regulated Gasoline Alcohol blends Gasohol up to 10 ethyl alcohol 90 unleaded gasoline by volume is approved as a fuel for Kohler engines Other gasoline alcohol blends are not approved Gasoline Ether blends Methyl Tertiary Butyl Ether MTBE and unleaded gasoline blends up to a maximum of 15 MTBE by volume are approved as a fuel for Kohler engines Other gasoline ether blends are not approved Fuel Filters Serviceable screen filters are located within the inlet of the fuel tank and the shut off valve Periodically inspect and clean or replace as required 9 1 Section 5 Fuel System and Governor Fuel Line In compliance with CARB Tier III Emission Regulations engines with a Family identification number beginning with 6 or greater see Figure 5 1 must use Low Permeation SAE 30 R7 rated fuel line certified to meet CARB requirements Standard
45. 12 Installing Dowel Pins and Gasket 6 Assemble the cover onto the closure plate aligning the dowel pin and hole locations 7 Install the cover mounting screws and torque to l CS4 CS6 10 N m 88 5 in Ib Figure 11 33 CS8 5 12 Installing Counter Gear and CS8 5 12 30 N m 265 in 1b Output Shaft Gear Assembly 5 Install the dowel pins into their respective locations in the closure plate and install a new gasket dry onto the dowel pins See Figures 11 34 and 11 35 Figure 11 36 CS4 CS6 Torquing Cover Mounting Screws Figure 11 34 CS4 CS6 Installing Dowel Pins and Gasket Figure 11 37 CS8 5 12 Torquing Cover Mounting Screws Section 11 Reassembly EE J B O It PT Chain Case Cover Gasket Dowel Pin Oil Seal Bearing Washer Bolt Washer Shaft 2 Idle Sprocket Chain Washer Straight Key R B 10 N m 88 in Ib Figure 11 38 CS4 CS6 2 1 Reduction Assembly Components No Description Chain Case Cover Gasket Dowel Pins Oil Seal Bearing Bolt Washer Idle Gear Straight Key Shaft Oil seal installation depth 2mm 0 08 in O O Y OO EQ N 65 N m 48 ft Ib 30 N m 265 in Ib Figure 11 39 CS8 5 12 2 1 Reduction Assembly Components 11 10 Section 11 Reassembly 6 1 Reduction Assemblies 5 Install the reduction housing to the closure plate CS4 and CS6 as shown and secure with the four hex flange 1 If any bearings were removed press the ne
46. 1b 1 9 Section 1 Safety and General Information General Specifications cont Oil Capacity Approx TTT 0 6 L 0 64 U S qt MO GP A A E ct N nab oesues 1 0L 1 1 U S qt R E eka Ps 6 6 0 0 TT Met Ente A 5 iecies sunset o 1 1 L 1 2 U S qt Fuel Tank Capacity e E E E T deedeeseneieeae 3 9 L 4 1 U S qt C Ge T O E a aid 6 0 L 6 3 U S qt Beis on e sn A T O T To Uo A no A 69 LOG US qt Angle of Operation Maximum At Full Oil Level All Directions 20 Air Cleaner Dase TIE a HH 5 8 N m 44 71 in Ib Base Nut Torque Ce IT 5 8 N m 44 71 in Ib Oee oa e 0 a 6 o MEP FOO nt ener E Terre mere cnr errr tre 5 8 N m 44 71 in Ib Ue e A A Po p d 10 12 N m 88 106 in lb ES A nn A NEE T 10 12 N m 88 106 in lb Camshaft An E 0 05 mm 0 0020 in Bore I D Max Wear Limit ie Ores MOORE O o e o eT ee ee 14 95 mm 0 583 in Me o A In o A E AET 15 95 mm 0 627 in Camshaft Bearing Surface O D Max Wear Limit do e PA ESE e ee ee 15 05 mm 0 592 in D oto E o In o 505 A EE E 16 05 mm 0 649 in Carburetor Fuel Bowl Retaining Screw Torque e a oo o 7 N m 62 in lb A A o o A E ES 9 N m 79 in lb Throttle Choke Plate Screws Torque siena a darte rnr ranes 1 5 2 5 N m 13 22 in lb Connecting Rod Connecting Rod Fastener Torque Mo Bao E oO T 12 N m 106 in Ib ES gt 21 eh a 6 0 0 0 errores 12 N m 106 in Ib e o I 20 N m 177 in lb h rT 20 N m 177 in lb Connecting
47. 4 CS6 CS8 5 spec 95xxxx Assembled Rocker Arms in Position CS8 5 spec 92xxxx CS10 CS12 Install the rocker arms and adjuster assemblies into their original locations Seat the push rods into the cupped end of the rocker arms Oil the rocker arm shaft and install it through the cylinder head supports and rocker arms Center the rocker arm shaft so it does not protrude out either side See Figure 11 68 Installing Push Rods Figures 11 71 and 11 72 2 CS4 CS6 CS8 5 spec 95xxxx Install the push rod guide plate aligning the holes for the rocker arm studs Screw in the rocker arm studs and torque to 10 N m 88 5 in 1b See Figure 11 69 Figure 11 71 CS8 5 spec 92xxxx CS10 CS12 Assembling Rocker Arms and Pivot Shaft Figure 11 69 CS4 CS6 CS8 5 spec 95xxxx 3 CS4 CS6 CS8 5 spec 95xxxx Assemble the rocker arms adjusters and locknuts onto the studs and push rods 11 18 Section 11 Reassembly Figure 11 74 CS8 5 spec 92xxxx CS10 CS12 Adjusting Valve to Rocker Arm Clearance Figure 11 72 CS8 5 spec 92xxxx CS10 CS12 4 Adjust the valve tappet clearance as follows d Hold the adjuster from turning and tighten a Make sure the piston is still at the top of the the locknut Torque locknut to compression stroke CS4 CS6 CS8 5 spec 95xxxx 10 N m 88 5 in Ib b Insert a flat feeler gauge between the rocker CS8 5 spec 92xxxx CS10 CS12 arm and the valve
48. 4 ohms or an open circuit is indicated infinity ohms the solenoid is a Set an ohmmeter on the Rx1 scale and zero faulty and must be replaced the meter Connect one ohmmeter lead to the terminal of the red white lead from the The meter should indicate an open circuit solenoid Connect the other ohmmeter lead to infinity ohms no continuity the solenoid mounting bracket When the circuit is completed applying 12 With the ohmmeter still on the Rx1 scale volts to the energizing coil an audible click connect the leads to the two large post should be heard as the solenoid engages terminals and the ohmmeter should then indicate continuity between the large terminals If Leave the ohmmeter leads connected to the the results are other than indicated replace large terminals Connect a jumper lead from the solenoid the positive terminal of the battery to the terminal of the red white solenoid lead Connect another jumper lead from the negative terminal of the battery to the solenoid mounting bracket Solenoid Shift Starters Perform the solenoid tests on page 8 24 8 23 Section 8 Electrical System and Components Solenoid Test Procedure Solenoid Shift Style Starters Disconnect all leads from the solenoid including the positive brush lead attached to the lower stud terminal Remove the mounting hardware and separate the solenoid from the starter for testing Test 1 Solenoid Pull In Coil Plunger Actuation Test Use a 12
49. 5910 Loctite Ultra Black 598 Loctite Ultra Blue 587 Loctite Ultra Copper Spline Drive Lubricant Kohler 25 357 12 S 2 3 Section 2 Tools amp Aids Special Tools You Can Make Flywheel Holding Tool Electric Start Models Only A flywheel holding tool can be made out of an old junk flywheel ring gear as shown in Figure 2 1 and used in place of a strap wrench 1 A ol Using an abrasive cut off wheel cut out a six tooth segment of the ring gear as shown Grind off any burrs or sharp edges Invert the segment and place it between the ignition bosses on the crankcase so that the tool teeth engage the flywheel ring gear teeth The bosses will lock the tool and flywheel in position for loosening tightening or removing with a puller Figure 2 1 Flywheel Holding Tool Rocker Arm Crankshaft Tool A spanner wrench to lift the rocker arms or turn the crankshaft may be made out of an old junk connecting rod 1 2 4 Find a used connecting rod from a 10 HP or larger engine Remove and discard the rod cap Remove the studs of a Posi Lock rod or grind off the aligning steps of a Command rod so the joint surface is flat Find a 1 in long capscrew with the correct thread size to match the threads in the connecting rod Use a flat washer with the correct I D to slip on the capscrew and approximately 1 O D Kohler Part No 12 468 05 S Assemble the capscrew and washer to the joint surface of the rod
50. 7 Support Bracket Screws on CS8 5 spec 95xxxx 2 Remove the valve cover and gasket from the cylinder head See Figure 9 38 The breather assembly is inside the valve cover Figure 9 38 Valve Cover Gasket and Air Shroud Removed 9 9 Section 9 Disassembly 3 Lift off the air shroud from the cylinder head CS4 and CS6 air shrouds have one mounting screw which must be removed See Figure 9 39 Figure 9 41 Cylinder Head and Gasket Removed Disassemble Cylinder Head Mounting Screw 1 Remove the spark plug Figure 9 39 CS4 CS6 Mounting Screw Location 2 Slide the rocker shaft out and remove the rocker 4 Remove the four hex flange screws securing arm assemblies on CS8 5 12 engines Mark or cylinder head Remove the cylinder head dowel note position of each part if it is to be reused pins 2 push rods and cylinder head gasket NOTE Mark the push rods so they will be reinstalled in the same location Figure 9 42 CS8 5 spec 92xxxx CS10 and CS12 Removing Rocker Arms and Spark Plug 3 Using a valve spring compressor remove the valves by compressing the valve springs and removing the keepers See Figure 9 43 Figure 9 40 Remove Cylinder Head Mounting Screws 9 10 Figure 9 43 Disassembling Valve Assemblies 4 Remove and replace the intake valve stem seal whenever the cylinder head is serviced or diassembled See Figure 9 44 Figure 9 44 Removing Intake Valve St
51. 8 071 5 984 11 732 99 00 Spark Plug Oil Fill Oil Drain Plug Mounting Face z 11 00 433 dia qty 2 16 00 630 11 00x27 433x1 063 slot aty 2 37 00 dis 65 00 1 457 E 2 559 62 00 102 00 Dimensions in millimeters 2 441 4 016 Inch equivalents shown in Figure 1 6 Typical Engine Dimensions CS8 5 spec 92xxxx CS10 and CS12 12 75 1 7 Section 1 Safety and General Information 431 00 16 968 15600 6 142 165 1 6 50 110 4 33 eel 410 00 E E 16 142 A S 428 00 So 16 850 SR 133 50 5 256 90 50 103 00 3 563 al 4 055 3 8 16 18 mm 709 deep 2 aty 4 7 697 i 2 i p L f 4 B lt lt l R 8 d A fn D asi BI AS le 7 i e y E 11 00x27 00 433x1 063 E slotted hole qty 2 SIC 16 00 630 37 00 1 457 E 57 50 2 264 5 16 24 18 mm 709 deep aty 2 5 16 24 18 mm 709 deep aty 4 Dimensions in millimeters Inch equivalents shown in Figure 1 7 Typical Engine Dimensions CS8 5 spec 95xxxx 1 8 Section 1 Safety and General Information General Specifications Power 3600 RPM exceeds SAE J1940 HP Standards nn II III 2 9 kW 4 HP A A II T EE 4 47 kW 6 HP Re E tiro 5 40 kW 8 5 HP Se IP o O OO E 6 33 kW 8 5 HP L PAPA o E A N c gs a A E O E E R 7 45 kW 10 HP OD PE o E S E E A 8 95 kW 12 HP IS P hac E E E A E A 9 5 kW 12 75 HP Peak Torq
52. CS6 b Clean the chain CS4 and CS6 in solvent to remove as much dirt as possible Dry and then check the condition of the chain If any links are tight and do not pivot freely see Figure 10 25 or the chain has stretched beyond the specified limit measured across 10 pitches see Figure 10 24 it must be replaced Figure 10 23 Clean Chain Using Solvent 12345678910 TIOTI DOT UT T TTT a oJ 0 oJ IGRT IGRT foo 6 89 5 mm 3 5 in Figure 10 24 Chain Stretch Limit Section 10 Internal Components Figure 10 25 Inspect for Binding Figure 10 27 CS8 5 12 Oil Passage 5 Check to see that the closure plate oil passages to the reduction assembly are open and not restricted See Figures 10 26 and 10 27 Figure 10 26 CS4 CS6 Oil Passage 10 15 Section 11 Reassembly General 21 Install air cleaner base and element NOTE Make sure the engine is assembled using all 22 Adjust Set governor specified torque values tightening sequences 23 Install fuel tank and fuel tank support and clearances Failure to observe 24 Install outer air cleaner cover specifications could cause severe engine wear 25 Install retractable starter or damage Always use new gaskets 26 Install muffler Typical Reassembly Sequence Install Oil Seals and Bearings The following sequence is suggested for complete 1 Make sure there are no nicks burrs or damage in engine reassembly This procedure assumes that all the bores
53. Cup S Center Screw Starter i O S Drive Plate Rope E aN gS Friction Spring e E NX Dive Pawl Ye Q J Rali d ON Pulley Recoil Spring Starter Housing Figure 7 1 Retractable Starter Exploded View To Remove Starter 1 Remove the hex flange screws three on CS4 and CS6 four on CS8 5 12 securing the starter assembly to the blower housing 2 Remove the starter assembly To Install Starter 1 Align the retractable starter with the mounting locations on the blower housing and install the hex flange screws Leave the screws slightly loose Figure 7 2 Installing Retractable Starter 7 1 Section 7 Retractable Starter Pull the starter handle out until the pawls engage the drive cup Hold the handle in this position and torque the screws to 5 5 N m 48 in Ib See Figure 7 3 Figure 7 3 Engage Pawls and Tighten Mounting Screws Rope Replacement The rope can be replaced without complete starter disassembly 1 Remove the starter from the engine blower housing Pull the rope out approximately 12 and tie a temporary slip knot in it to keep it from retracting into the starter See Figure 7 4 Figure 7 4 Removing Starter Handle 3 7 2 Pull the knot end out of the handle untie the knot and slide the handle off Hold the pulley firmly and untie the slip knot Allow the pulley to rotate slowly as the spring tension is released When all spring tension on the starte
54. LU a Throttle Stop Screw Throttle Lever Figure 5 14 CS8 5 spec 92xxxx CS10 and CS12 Throttle Lever Throttle Stop Screw Details Throttle Stop Screw Throttle Lever Figure 5 15 CS8 5 spec 95xxxx Throttle Lever Throttle Stop Screw Details 5 9 Section 5 Fuel System and Governor Low Idle Speed Adjustment The recommended low idle speed is 2000 RPM 100 RPM The low idle speed is set by turning the low idle speed screw in or out see Figures 5 16 and 5 17 1 With the engine warm move the throttle lever clockwise until it stops 2 Check the idle speed with a tachometer 3 Turn the adjustment screw in clockwise to increase the idle speed or out counterclockwise to decrease the idle speed until the correct speed is attained nN ES AS Hoax 7 Adjusting Screw Figure 5 16 CS4 CS6 Low Idle Speed Adjusting Screw 5 10 SOS LAIR IS publi RE 7 E UA Adjusting Screw Figure 5 17 CS8 5 12 Low Idle Speed Adjusting Screw Section 6 Lubrication System General These engine use a splash lubrication system supplying necessary lubrication to the crankshaft camshaft connecting rod and valve train components Oil Recommendations Using the proper type and weight of oil in the crankcase is extremely important So is checking oil daily and changing oil regularly Failure to use the correct oil or using dirty oil can cause premature engine wear and failure
55. Piston Pin O D New Bo TT 15 995 16 000 mm 0 6297 0 6299 in Be FNS E E E E A 17 995 18 000 mm 0 7084 0 7086 in ESPE 22 6 0 0 6 latas 19 995 20 000 mm 0 7872 0 7874 in SLT E EE E T E A E E 19 995 20 000 mm 0 7872 0 7874 in Max Wear Limit O EN A AAA E E A A E 15 98 mm 0 6291 in EL T A E E A E A 17 98 mm 0 7079 in BE 1 a e a E Str en nee 19 98 mm 0 7866 in ro 18 0 APPO E sat Sete tae E EE TO E 19 98 mm 0 7866 in Top Compression Ring to Groove Side Clearance sss sees 0 04 0 08 mm 0 0016 0 003 in Middle Compression Ring to Groove Side Clearance A E E A AE E EE AE 0 02 0 06 mm 0 0008 0 0024 in 5 ikea cere e OP EE A 0 03 0 07 mm 0 0012 0 0028 in Top Compression Ring End Gap D D P E A A A A E 0 2 0 4 mm 0 008 0 016 in do 1 E A o A E E 0 25 0 4 mm 0 010 0 016 in eo PEE o A e o o TO A 0 2 0 4 mm 0 008 0 016 in L 0 2 0 4 mm 0 008 0 016 in L 0 25 0 4 mm 0 010 0 016 in Middle Compression Ring End Gap a ETT 0 2 0 4 mm 0 008 0 016 in Ghote tou c 2 o A o yA 0 25 0 4 mm 0 010 0 016 in Gis 2 oe o Re rT o err eer erent Mer eee 0 2 0 4 mm 0 008 0 016 in L DT 0 2 0 4 mm 0 008 0 016 in 1 apes A A E E E TE 0 25 0 4 mm 0 010 0 016 in Oil Control Ring End Gap E o E EA E AAE 0 2 0 4 mm 0 0079 0 0157 in A A A 0 2 0 7 mm 0 0079 0 028 in Piston Thrust Face O D New co La EENET O E T E E tee EN E T 55 975 55 990 mm 2 2037 2 2043 in Be o a E E N E E E 65 975 65 990 mm 2 597 2 598 in N
56. Rod to Crankpin Running Clearance ITE 0 016 0 046 mm 0 0006 0 0018 in Mox Near PP o a en Nne 0 1 mm 0 004 in Connecting Rod to Crankpin Side Clearance A A A A E E AA A E T A E 0 2 0 6 mm 0 008 0 024 in E ar o A eE O 0 2 0 6 mm 0 008 0 024 in ESOS 8 tie 5 6 6 still reer er orem 0 2 0 65 mm 0 0079 0 0256 in A o o E T E 0 2 0 65 mm 0 0079 0 0256 in 1 10 Section 1 Safety and General Information Connecting Rod cont Connecting Rod to Piston Pin Running Clearance seee 0 006 0 025 mm 0 0002 0 0001 in Piston Pin End I D New E 16 006 16 020 mm 0 6301 0 6307 in SCC TIKKO seer siren ce asnret acs penneneindetonseawep A 18 006 18 020 mm 0 7089 0 7094 in Ger AON Gol Uh PD 6 6 6 8 Cee ee rer rere eer neem Cae err rT ne 20 006 20 020 mm 0 7876 0 7882 in Eo VEA T ENEE E E E E E 20 006 20 020 mm 0 7876 0 7882 in Max Wear Limit Bo A o o e E 16 10 mm 0 634 in Me e e eee eee te 18 10 mm 0 713 in E A TTT 20 10 mm 0 791 in ESTO prestan E EE S naipes 20 10 mm 0 791 in Connecting Rod Journal End I D New ES eee o O eesti E E 28 000 28 015 mm 1 1023 1 1029 in Be 0 299 AA o oo umes Gaponsseaeens 32 000 32 015 mm 1 2598 1 2604 in Euro 72 0 6 0 6 AAA NU A 36 000 36 015 mm 1 4173 1 4179 in A E E A T 36 000 36 015 mm 1 4173 1 4179 in Max Wear Limit E E OA 28 115 mm 1 1069 in II A UI 32 115 mm 1 2644 in ESOO ria iia 36 115 mm 1 4219 in E O A ase eaeanaiee 36 115 mm 1 4219 in Cr
57. SERVICE MANUAL KOHLER COMMAND PRO CS 4 12 75 HP HORIZONTAL CRANKSHAFT KOHLER ENGINES Contents Section 1 Safety and General Information sss ssss sss esse sss sese esse essen enen enen eenn Section 2 1001 AMAS ca i a a a A AEA AAAA RRi Section 3 Troubleshooting sss sss ssss sss sese s cesses enen nenen enen eenn Section 4 Air Cleaner and Air Intake System Section 5 Fuel System and Governor Section 6 Lubrication System Section 7 Retractable Starter Section 8 Electrical System and Components Section 9 Disassembly Section 10 Internal Components Seccion Ti ReassemDIy aan Section 1 Safety and General Information Safety Precautions To ensure safe operations please read the following statements and understand their meaning Also refer to your equipment owner s manual for other important safety information This manual contains safety precautions which are explained below Please read carefully A WARNING Warning is used to indicate the presence of a hazard that can cause severe personal injury death or substantial property damage if the warning is ignored A CAUTION Caution is used to indicate the presence of a hazard that will or can cause minor personal injury or property damage if the caution is ignored NOTE Note is used to notify people of installation operation or maintenance information that is important but not hazard related For Your Safety These pre
58. STG CS12ST CS12S CS12ST CS12TG CS12STG CS12TG CS12STG CS12STG CS12STG CS12SG CS12STG CS12T CS12S CS12STG CS12TG CS12STG CS12TR CS12T CS12ST CS12STR CS12STG CS12ST CS12STG CS12STG 11 24 941501 941502 941503 941504 941505 941506 941507 941508 941509 941510 941511 941512 941513 941515 941516 941517 941518 941519 941520 941521 941601 941602 941603 941604 941605 941606 941607 941608 941609 941610 941611 941612 941613 941615 941616 941617 941618 941619 941620 941621 941622 941623 941624 941625 941626 941627 941628 941629 941630 941631 941632 Figure Number Hole Position G Z GQ 4 E EMM GQ QQ G GQ GQ WW Application Governed 3 3 1 3 3 3 1 3 3 3 2 2 4 4 1 3 4 4 3 Application Governed BO GGG WO BW Y Figure Hole Number Position CS12T CS12ST CS12T CS12TR CS12ST CS12TG 941633 941634 941635 941636 941637 941638 Spring Hole Position Figure 11 91 CS8 5 spec 95xxxx Spring Hole Position Sa H o lt A Figure 11 90 CS8 5 spec 92xxxx CS10 CS12 E E TE a epr jj Section 11 Reassembly Connect Electrical Leads and Install Electric Starter If So Equipped CS8 5 spec 92xxxx CS10 CS12 with Inertia Drive Starters 1 Mount the electric starter with the control panel and solenoid attached onto the crankcase Install and torque the two
59. a ridge reamer to remove it before attempting to remove the piston Remove Camshaft and Tappets 1 Remove the camshaft from the crankcase 2 Carefully remove the connecting rod and piston assembly from the cylinder bore See Figure 9 85 Figure 9 83 Removing Camshaft and Tappets 2 Remove and mark the tappets Figure 9 85 Removing Piston Remove Connecting Rod with Piston and Rings 1 Remove the two hex flange screws securing the connecting rod cap Remove the rod cap 9 19 Section 9 Disassembly Remove Crankshaft 1 Carefully remove the crankshaft from the crankcase Figure 9 86 Removing Crankshaft Remove Governor Cross Shaft 1 Remove the hitch pin and plain washer from the governor cross shaft See Figure 9 87 Figure 9 87 Removing Governor Cross Shaft Hitch Pin 2 Remove the cross shaft out through the inside of the crankcase Figure 9 88 Removing Governor Cross Shaft with Inner Washer 9 20 Remove Flywheel End Main Bearing and Oil Seal 1 Remove the front oil seal from the crankcase See Figure 9 89 Figure 9 89 Oil Seal Removed 2 Remove the front main bearing from the crankcase using an arbor press See Figure 9 90 Figure 9 90 Removing Main Bearing with Press Remove Balance Shaft Bearing 1 Remove the balance shaft bearing using an internal bearing puller Section 10 Internal Components This section covers the operation inspection and repair recondit
60. aining ring into the groove of the armature shaft Squeeze it with a pliers to compress it into the groove It must fit into the recess in the end of the spring holder 4 Use a solvent to thoroughly clean any dirt or old Figure 8 38 Installing Retaining Ring lubricant from the splines Starter Disassembly 5 Inspect the splines and drive components for 1 wear or damage If the splines are damaged it will be necessary to replace the starter The drive components are available as individual service parts if any of them are worn or damaged E 6 Apply a small amount of molybdenum disulfide lubricant to the splines 7 Install the drive pinion spring and spring holder collar onto the armature shaft 8 26 Remove the retaining ring spring holder collar spring and drive pinion assembly from the armature shaft Refer to Starter Drive Service Disconnect the solenoid lead from the starter terminal Hold the lower jam nut from turning with a wrench while loosening the top nut to prevent damaging internal components See Figure 8 39 The solenoid may be removed or left in place Section 8 Electrical System and Components Figure 8 39 Removing Solenoid Lead Figure 8 42 Removing End Cap with Brush Plate 3 Scribe or mark a small line from the starter frame 6 Pull the armature out of the starter frame to each end cap to serve as match marks for reassembly later See Figure 8 40 Brush Inspection Replacement
61. all the serviced precleaner over the element Position the element precleaner assembly on the base and secure with the wing nut Reinstall the air cleaner cover and tighten securely See Figure 4 5 Heavy Duty Cyclonic Cleaner Place the precleaner over the element and install it as an assembly into the cover housing Insert the small end first into the housing so the larger end with the foam seal is out visible Secure with the wing nut if used Secure the cover housing with the latches See Figure 4 11 Air Cleaner Components Whenever the air cleaner cover is removed or the paper element or precleaner is serviced check the following Standard Air Cleaner Make sure the element cover is not bent distorted or damaged Make sure the wing nut and rubber sleeve seal on the base stud are in place and in good condition ensuring the element is sealed against leakage Some models the seal is fixed If the air cleaner element has a foam seal on the bottom make sure it is in good condition and not damaged See Figure 4 12 4 4 Heavy Duty Cyclonic Air Cleaner Make sure the main housing lower swirl dirt chamber mounting hardware and latches are not damaged bent or broken affecting the sealing ability and operation of air cleaner housing Clean and check all components as well as the airflow passages Air Cleaner Base Make sure the air cleaner base is secured tightly to carburetor and not cracked bent or damaged pr
62. aner Unhook the latches and remove the housing assembly from the mounting base Remove the wing nut some models securing air cleaner precleaner assembly or pull the complete filter assembly out of the housing Remove the precleaner from the paper element Service the precleaner 2 Do not wash the paper element or use pressurized air as this will damage the element Replace a dirty bent or damaged element with a genuine Kohler element Handle new elements carefully do not use if the sealing surfaces are bent or damaged Figure 4 10 4 3 Section 4 Air Cleaner and Air Intake System 3 When servicing the air cleaner check the air cleaner base and cover housing assembly Make sure it is secure and not bent or damaged On a heavy duty air cleaner unsnap the latches and clean out the lower swirl dirt chamber See Figure 4 9 Make sure the air slots in the upper section of the housing and in the lower chamber are open See Figure 4 10 Clean and inspect all components for damage or improper fit Replace any components which are bent or damaged Reassemble the lower chamber heavy duty air cleaners NOTE Before the air cleaner is reassembled make sure the rubber seal is in position on the stud standard only Also inspect the foam seal on the base of the filter element do not use if the condition of either is questionable in any way Replace it with a new part before reassembling 4 Standard Air Cleaner Inst
63. aner housing See Figure 4 17 Foam Air Cleaner Element Figure 4 17 Foam Air Cleaner Element Details 3 Wash the foam element in warm water with detergent Rinse the element thoroughly until all traces of detergent are eliminated Squeeze out all excess Water do not wring Allow the element to air dry 4 Lightly oil the element with new engine oil Squeeze element to evenly distribute the oil and remove any excess 4 5 Section 4 Air Cleaner and Air Intake System 5 When servicing the foam air cleaner element clean and check the air cleaner case and outer cover for damage distortion or an improper seal Replace any components which are bent or damaged 6 Make sure the square metal fitting plate is properly positioned within the case See Figure 4 17 7 Reinstall the outer cover and secure with the two screws See Figure 4 16 NOTE Do not operate engine without the air cleaner element excessive piston and or cylinder wear may result 4 6 Air Intake Cooling System To ensure proper cooling make sure the grass screen cooling fins and other external surfaces of the engine are kept clean at all times Every 100 hours of operation more often under extremely dusty or dirty conditions remove the blower housing and other cooling shrouds Clean the cooling fins and external surfaces as necessary Make sure the cooling shrouds are reinstalled NOTE Operating the engine with a blocked grass sc
64. anisiotannccdsrnensinnenines 0 1 mm 0 004 in Notes 1 Values are in Metric units Values in parenthesis are English equivalents Lubricate threads with engine oil prior to assembly 2 Measure 5 mm 0 197 in above the bottom of the piston skirt at right angles to the piston pin 3 Measure 10 mm 0 394 in above the bottom of the piston skirt at right angles to the piston pin Oil Drain Plugs Tightening Torque N m in Ib Into Aluminum Model 17 150 CS4 CS6 20 177 CS8 5 CS10 CS12 Torque Conversions N m in lb x 0 113 N m ft Ib x 1 356 in lb N m x 8 85 ft lb N m x 0 737 Section 2 Tools amp Aids Certain quality tools are designed to help you perform specific disassembly repair and reassembly procedures By using tools designed for the job you can properly service engines easier faster and safer In addition you ll increase your service capabilities and customer satisfaction by decreasing engine downtime Here is the list of tools and their source Separate Tool Suppliers Kohler Tools SE Tools Design Technology Inc Contact your source 415 Howard St 768 Burr Oak Drive of supply Lapeer MI 48446 Westmont IL 60559 Phone 810 664 2981 Phone 630 920 1300 Toll Free 800 664 2981 Fax 810 664 8181 Tools Balance Gear Timing Tool K amp M Series Kohler 25 455 06 S To hold balance gears in timed position when assembling engine Formerly Y 357 Camshaft Endplay Plate
65. ankcase Closure Plate Fastener Torque aa A A e E 22 N m 195 in lb A ote acute se A TTET 30 N m 265 in lb Oil Drain Plugs Torque coe TTT 17 N m 150 in Ib eee ee o O E T E ET A 20 N m 177 in lb Crankshaft PC Tay CG E E EE 0 04 mm 0 0015 in End Play Threaded Pump Shaft Models Only sss 0 0 0 2 mm 0 0 0 007 in Flywheel End Main Bearing Journal O D New E carpe tse tose on ta acces Anson A A 52 mm 2 047 in ot oa ct 15 0 6 0 0 Penne herent enn T nee Meme ee eee ee 52 mm 2 047 in Ge ao T 80 mm 3 149 in C A o o o a A E 80 mm 3 149 in Max Wear Limit E A A T A E A 52 05 mm 2 0492 in RO e o 0 8 0 E E A A E E A 52 05 mm 2 0492 in A e cla 80 05 mm 3 1515 in H PO O 0 E 80 05 mm 3 1515 in Section 1 Safety and General Information Crankshaft cont PTO End Main Bearing Journal O D New De A rr ner E E 52 mm 2 047 in ESO SPSS SOON ROME eer ee eT rn er errr ar ee rrr ee 52 mm 2 047 in COS SPEE 20 0 0 0 y q PORO OO IO 72 mm 2 834 in A sanecsentss 72 mm 2 834 in Max Wear Limit oa O COMER A A 52 05 mm 2 0492 in Bo e a 09 6 6 6 4 Emer OPEP on 52 05 mm 2 0492 in Be PE OOO E EE 72 05 mm 2 836 in A A 72 05 mm 2 836 in Connecting Rod Journal O D New A A o o 27 969 27 984 mm 1 011 1 017 in ESOS PSS IO OOO states odios 31 969 31 984 mm 1 2586 1 2592 in Me AE FOO Po Ur N 35 969 35 984 mm 1 4161 1 4167 in e a PAAA tate AEE cere tone N OE EE E 35 969 35 984 mm 1 4161
66. are not regulated Be aware however that the cylinder head will require more frequent service Gasoline Alcohol blends Gasohol up to 10 ethyl alcohol 90 unleaded gasoline by volume is approved as a fuel for Kohler engines Other gasoline alcohol blends are not approved Gasoline Ether blends Methyl Tertiary Butyl Ether MTBE and unleaded gasoline blends up to maximum of 15 MTBE by volume are approved as a fuel for Kohler engines Other gasoline ether blends are not approved Section 1 Safety and General Information Maintenance Instructions A WARNING Accidental Starts Disabling engine Accidental starting can cause severe injury or death Before working on the engine or equipment EN disable the engine as follows 1 Disconnect the spark plug lead s 2 Disconnect negative battery cable from battery Maintenance Schedule These required maintenance procedures should be performed at the frequency stated in the table They should also be included as part of any seasonal tune up e Fill fuel tank Section 5 Daily or Before e Check oil level Section 6 Starting Engine e Check air cleaner for dirty loose or damaged parts Section 4 e Check air intake and cooling areas clean as necessary Section 4 Every 25 Hours e Service precleaner element Replace if necessary Every 50 Hours e Service solid foam element Replace if necessary e Change oil Section 6 e Replace air cleaner element Section 4 e Remove co
67. arter NOTE If the starter does not crank the engine shut off the starter immediately Check the condition of the inline fuse and do not make further attempts to start the engine until the condition is corrected NOTE Do not drop the starter or strike the starter housing Doing so can damage the starter Starter Removal and Installation Refer to the Disassembly and Reassembly sections for starter removal and installation procedures Troubleshooting Guide Starting Difficulties Batter 1 Check the specific gravity of battery If low recharge or replace y battery as necessary 1 Check fuse condition Wiring 2 Clean corroded connections and tighten loose connections 3 Replace wires in poor condition and with frayed or broken insulation Starter Switch 1 Check the switch or solenoid operation If starter cranks normally or Solenoid replace the faulty components Battery 1 Check the specific gravity of battery If low recharge or replace battery as necessary 1 Check for corroded connections poor ground connection Problem Starter Does Not Energize Starter Energizes But Turns Slowly 1 Check for excessively dirty or worn brushes and commutator Clean using a coarse cloth not emery cloth 2 Replace brushes if excessively or unevenly worn 1 Make sure the clutch or transmission is disengaged or placed in neutral This is especially important on equipment with hydrostatic drive The transmission must be
68. arts from pulley Carefully inspect the components for wear cracks and or damage Replace all worn or damaged components Use only genuine Kohler replacement parts as specified in the parts manuals All components shown in Figure 7 1 are available as service parts Do not use nonstandard parts Install pawl springs CS8 5 12 only and pawls onto pawl studs of pulley All parts must be dry Pawl Spring Figure 7 6 6 Position the drive plate over the pawls aligning the actuating slots in the plate with the raised sections on each drive pawl Torque the center screw to 5 6 N m 44 53 in lb Rotate the pulley by hand and check operation See Figure 7 7 7 3 Section 7 Retractable Starter Drive Plate 9 Figure 7 7 Drive Plate and Pawl Details 7 Rehook the slack in rope into notch of pulley and rotate the pulley counterclockwise viewed from pawl side to re tension the spring approximately 4 full turns on CS4 and CS6 6 approximately 5 full turns on CS8 5 12 Recoil Spring Pulley and or Housing 7 Replacement Disassembly Release spring tension and remove the handle and starter rope Refer to Rope Replacement Unscrew the center screw and lift off the drive plate The screw will be captured within plate by the clip on backside Carefully note the positions of the pawls and pawl springs CS8 5 12 only before removing them Remove the parts from the starter pulley Ro
69. ays maintain the proper oil level in the crankcase Never operate the engine with the oil below the low oil level NOTE Just because you can see oil in the crankcase doesn t mean the level is in the safe range Bring the level up to the point of overflowing the filler neck Oil Sentry Some engines are equipped with an Oil Sentry oil monitor When the oil level falls below the safe level the engine stops automatically Unless you refill with oil the engine will not start again See Figure 6 3 Figure 6 3 Oil Sentry Operation 6 2 NOTE If the engine stalls or does not start turn the engine switch to the on position and attempt to start the engine If the oil warning light flickers for a few seconds the engine oil is insufficient Add oil and restart NOTE Make sure the oil level is checked BEFORE EACH USE and is maintained up to the point of overflowing the filter neck Change Oil For a new engine change oil after the first 20 hours of operation Thereafter change oil after every 100 hours of operation For an overhauled engine use 10W 30 weight service class SG SH SJ or higher oil for the first 5 hours of operation Change the oil after this initial run in period Refill with service class SG SH SJ or higher oil as specified in the Viscosity Grades table on page 6 1 Change the oil while the engine is still warm The oil will flow more freely and carry away more impurities Make
70. b on the cross shaft the exposed threads in the tower causing the shaft to rotate when the engine speed changes See Figure 5 9 One end of the cross shaft i Sonic tne qasziein car pure orcleancnto protrudes through the side of the closure plate remove any deposits and blow it dry with Through external linkage attached to the cross shaft compressed air the rotating action is transmitted to the throttle lever of the carburetor c Reinstall it in the tower and thread it in until R When the engine is at rest and the throttle control is in the fast position the tension of the governor 12 Reinstall the main jet and install the bowl gasket spring holds the throttle plate open When the engine in the groove Reassemble the bowl to the 1s Operating the BOVETNOL gear assembly a rotating carburetor with the screw removed in step 7 the force applied by the regulating pin against the Poston the bolso tie den screurwill be cross shaft tends to close the throttle plate The accessible after the carburetor is mounted to the governor spring tension and the force applied by the engine regulating pin are in equilibrium during operation holding the engine speed constant 13 Use the reverse of steps 1 5 to reinstall the carburetor on the engine 5 7 Section 5 Fuel System and Governor When a load is applied and the engine speed and governor gear speed decreases the governor spring tension moves the governor lever to open t
71. bolt to 8 N m 70 8 in lb on CS4 CS6 10 N m 88 5 in Ib on CS8 5 CS10 CS12 Governor Shaft VE Mounting Bolt Figure 5 11 CS8 5 spec 92xxxx CS10 and CS12 Governor Adjustment Figure 5 12 CS8 5 spec 95xxxx Governor Adjustment High Idle Speed Adjustment The recommended maximum no load high idle speed for the CS engines is 3750 RPM 100 RPM for tapered shaft models and 3800 RPM 100 RPM for all others The actual high idle speed depends on the application Refer to the equipment manufacturer s instructions for specific information The high idle speed is set by turning the throttle stop screw on the throttle lever bracket assembly in or out See Figures 5 13 to 5 15 and follow the procedures below 1 Start the engine and allow it to warm up Place the throttle control lever into the fast or high idle position 2 Check the engine speed with a tachometer 3 To increase the high idle speed turn the high idle speed adjusting screw out counterclockwise while applying light pressure to the throttle control lever in the counterclockwise direction away from the carburetor To decrease the high idle speed turn the high idle speed adjusting screw in clockwise until the desired engine speed is attained Jc Screw Figure 5 13 CS4 CS6 Throttle Lever Throttle Stop Screw Details Throttle Lever Section 5 Fuel System and Governor VAG a L A l tT OO DO SR
72. c 95xxxx remove the five screws and washers securing the fuel tank support to the crankcase and the single screw into the throttle control bracket Lift off the fuel tank support See Figure 9 11 Figure 9 11 CS8 5 spec 95xxxx Fuel Tank Support Remove External Governor Throttle and Choke Linkage 1 Carefully lift up and unhook the choke link and spring from the choke lever on the carburetor CS8 5 CS10 and CS12 only The choke link may stay connected on CS4 and CS6 engines Figure 9 14 Removing Governor Lever and Linkage 3 On CS8 5 spec 95xxxx remove the single hex flange screw securing the throttle control bracket to the crankcase See Figure 9 15 Figure 9 12 Disconnecting Choke Link and Dampening Spring from CS8 5 CS12 Carburetor 2 Loosen the hex flange screw securing the governor lever to the governor shaft Mark which hole location the governor spring is in Lift off the y governor lever with throttle linkage and spring Figure 9 15 Removing Control Bracket on CS8 5 attached unhooking the governor spring from the spec 95xxxx throttle lever Unhook the throttle linkage and dampening spring from the carburetor throttle shaft 9 4 Remove Carburetor A WARNING Gasoline may be present in the carburetor and fuel system Gasoline is extremely flammable and its vapors can explode if ignited Keep sparks open flames and other sources of ignition away from the engine 1 Remove th
73. cautions should be followed at all times Failure to follow these precautions could result in injury to yourself and others amp WARNING A WARNING amp WARNING Accidental Starts can cause severe injury or death Disconnect and ground spark plug lead before servicing Accidental Starts Disabling engine Accidental starting can cause severe injury or death Before working on the engine or equipment disable the engine as follows 1 Disconnect the spark plug lead s 2 Disconnect negative battery cable from battery Rotating Parts can cause severe injury Stay away while engine is in operation Rotating Parts Keep hands feet hair and clothing away from all moving parts to prevent injury Never operate the engine with covers shrouds or guards removed Hot Parts can cause severe burns Do not touch engine while operating or just after stopping Hot Parts Engine components can get extremely hot from operation To prevent severe burns do not touch these areas while the engine 1s running or immediately after it 1s turned off Never operate the engine with heat shields or guards removed 1 1 Section 1 Safety and General Information A WARNING Explosive Fuel can cause fires and severe burns Do not fill the fuel tank while the engine is hot or running Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containe
74. ctronic Ignition System 18 Amp Charging System Rectified Only Oil Sentry TM System Recoil Start Figure 8 14 Main Switch Oil Oil Warning Sentry Unit R B Light w LO Ignition Module Carb Fuel Shut Off Heater Solenoid Electronic Ignition System Starter __ Stator Solenoid Battery 10 Amp Charging System 2 Spark W start with Rectifier Regulator and Plug S A Electric e Ground Ground Ground Ground Start Inertia Drive Starter Special Generator Application Options Figure 8 15 er Motor 8 13 Section 8 Electrical System and Components Oil Warning Main Switch Unit B Ground B BW F a Jon BW Sentry Light Engine A Y Ground Y Ignition Starter Solenoid ER W i oi T dni TY Solenoid Shift Sentry E Startor Motor Plu Lead 9 Ground Ground Ground Ground 10 Amp Charging System with Rectifier Regulator and Oil Sentry System Solenoid Shift Electric Starter Figure 8 16 B EUSE 2041 O Paga Engine Ground RW Lor T Starter Solenoid he del W ar z Starter i j I Solenoid Shift w Starter Motor Ground Ground Ground Oil Sentry Light 18 Amp Charging System with Rectifier Regulator and Oil Sentry System Solenoid Shift Electric Starter and Provisions for Charge Lamp Figure 8 17 8 14 Section 8 Electrical System and Components Oil Warning Main Switch Light Engine Ground es I
75. cuits with an ohmmeter terminal of the battery Connect the other end to the terminal of the red white solenoid lead Use a known good fully charged battery and When negative jumper cable is touched to jumper cables to test starter motor Be sure the crankcase or starter housing starter motor Starter transmission is in neutral and PTO is off should operate If it does continue with step 5 Motor Does Inertia Drive Starters Remove the heavy lead If starter does not operate refer to the servicing Not Operate from the post terminal on the starter Connect one procedures for the starter motor and check out With Key end of the positive jumper cable to the post the brushes and armature Repair or replace as Switch terminal and connect the other end to the positive required terminal of the battery Solenoid Shift Starters Connect one end of the positive jumper cable to the positive brush lead attached to the lower stud terminal of solenoid Connect the other end to the positive terminal of the battery Connect one end of the negative jumper cable to the negative terminal of the battery Touch the other end of the negative jumper cable to a bare surface on the crankcase or to the starter housing Inertia Drive Starters Disconnect the leads from a The resistance of the energizing coil should the starter solenoid and remove it from the starter be at least 3 4 ohms If the meter reading is for testing See Figure 8 33 on page 8 25 less than 3
76. d noiselessly and there is no evidence of scoring erooving etc on the races or bearing surfaces the bearings can be reused Figure 10 4 Cam Lobe Checking B Inspect the crankshaft keyways If worn or chipped Cam Lobe Dimension B replacement of the crankshaft will be necessary Intake Exhaust CS4 CS6 22 0 0 05 mm 22 0 0 05 mm Inspect the crankpin for score marks or metallic 0 87 0 002 in 0 87 0 002 in pickup Slight score marks can be cleaned with crocus cloth soaked in oil If wear limits as stated in CS8 5 CS10 26 08 0 05 mm 26 08 0 05 mm Specifications and Tolerances are exceeded it will be CS12 1 03 0 002 in 1 03 0 002 in necessary to replace the crankshaft Measure the camshaft journals which fit in the ball Crankcase bearings for wear using a micrometer Compare with specifications listed Inspection and Service Check all gasket surfaces to make sure they are free of gasket fragments Gasket surfaces must also be free of deep scratches or nicks Check the cylinder bore for wear scoring or vertical scratches In severe cases unburned fuel can cause scuffing and scoring of the cylinder wall it washes the necessary lubricating oils off the piston and cylinder wall As raw fuel seeps down the cylinder wall the piston rings make metal to metal contact with the wall Scoring of the cylinder wall can also be caused by localized hot spots resulting from blocked coo
77. e prevent deterioration If you choose to use a stabilizer follow the manufacturers recommendations and add the correct amount for the capacity of the fuel system Fill the fuel tank with clean fresh gasoline Run the engine for 2 3 minutes to get stabilized fuel into the carburetor 1 5 Section 1 Safety and General Information er ii Din UUU 347 00 13 661 373 00 14 685 5 16 24 qty 5 14 mm 551 deep 66 00 2 598 6 378 384 25 15 128 321 50 Straight PTO 12 657 143 00 gt 5 630 100 00 a 162 00 3 937 6 378 Spark Plu j S 5 719 380 03 14 962 Oil Fill Oil Drain Plug AN Mounting Face i 9 0x14 0 354x 551 slot qty 2 f 44 50 1 752 37 00 j 80 00 i i i a 1 457 3 150 Dimensions in millimeters Inch equivalents shown in Figure 1 5 Typical Engine Dimensions CS4 and CS6 1 6 Section 1 Safety and General Information 454 00 17 874 a 445 85 17 553 452 90 17 831 133 50 OTEK 5 256 x 165 10 6 500 5 000 dia KOER dia 5 16 24 qty 4 5 16 24 qty 2 18 mm 18 mm 709 deep 709 deep 3 8 16 qty 4 146 08 18 mm 709 deep 5 751 dia 110 4 a dia 90 50 103 00 3 563 49550 4 055 7 697 417 50 Straight PTO 16 437 187 50 7 382 118 34 205 00 152 00 ehe 298 00 4 659 8 071 4 659
78. e air cleaner base gasket from the two mounting studs 2 Pull the carburetor outward and off the mounting studs 3 Remove the outer gasket spacer block and inner gasket from the studs Figure 9 16 Removing Carburetor Gaskets and Spacer If you want to remove the carburetor without disturbing the governor lever mounting proceed as follows 1 Gently hold the governor lever in the full throttle left clockwise position 2 Pull the carburetor outward and off the mounting studs Tilt the carburetor and disconnect the throttle link and dampening spring from the throttle lever See Figure 9 17 Section 9 Disassembly Figure 9 17 Removing Carburetor Without Governor Lever Removal Remove Retractable Starter 1 Remove the hex flange screws securing the retractable starter to the blower housing See Figure 9 18 Figure 9 18 Removing Starter Mounting Screws 9 5 Section 9 Disassembly Remove Blower Housing 1 Remove the hex flange screws securing the blower housing The screw in the upper right hand position may also secure a ground lead on some models See Figures 9 20 and 9 21 NOTE On models with electric starters loosening or removing the starter cover panel mounting screws will allow easier access to the screw in the upper right hand position Figure 9 19 CS8 5 CS10 and CS12 Blower Housing Screws Figure 9 20 CS4 CS6 Silver Screw with Ground Lead 9 6 Mounting Screw
79. e stator to DC voltage while also monitoring and controlling the battery voltage There are two different rectifier regulators which are used an 18 amp and a 7 10 amp assembly Although externally similar the internal circuits differ and the two should not be interchanged 8 18 18 Amp Rectifier Regulator The 18 amp rectifier regulators contain a 6 terminal plug in configuration illustrated in Figure 8 23 The upper center terminal is the control or monitor terminal through which the regulator monitors battery voltage This terminal is connected internally to SCRs which are turned on and off as required controlling the battery voltage between 14 and 15 volts The connection between the B charge lead and the monitor terminal lead is made within the wiring harness The lower center terminal serves as a connection for a pilot lamp circuit to indicate when the charging system is functioning Monitor Terminal Red B Charge Red Pilot Lamp Stator AC Leads White Terminal Figure 8 23 18 Amp Rectifier Regulator 7 10 Amp Rectifier Regulator The 7 10 amp rectifier regulators contain a 5 terminal plug in configuration See Figure 8 24 with two differences from the 6 terminal 18 amp system Battery voltage is monitored by the internal circuitry of the rectifier regulator instead of through the lead connection at the upper center location The terminal in the upper center location serves no function No lower cent
80. ead in the kill circuit or a faulty switch step 7 If there is still no spark go to step 3 Engine Will 8 4 Not Start Trace the blue lead from the Oil Sentry control module Disconnect the bullet connector where it joins the lead from the Oil Sentry float switch black with gray sleeve Repeat spark test again Connect a jumper lead from the blue lead terminal to a bare spot on the crankcase ground Turn the ignition switch on crank the engine and observe the red LED indicator lamp a If the indicator lamp was not flashing trace the black manual start models or black white electric start models lead from the ignition switch Separate the bullet connector where the switch lead joins the double red harness lead Crank the engine again observing the red LED indicator lamp Set an ohmmeter to the Rx1 scale and zero the meter Connect one ohmmeter lead to the Oil Sentry float switch lead black with gray sleeve and touch the other lead to a bare spot on the crankcase ground Drain the oil from the crankcase and repeat the test a If continuity was indicated with and without oil above check if the insulation has been scraped off the float switch lead With the float switch removed connect one ohmmeter lead to the float switch lead terminal and connect the other lead to mounting bracket Test resistance with the switch in the normal position and inverted Repeat test 2 or 3 times in each direc
81. eal Figure 11 8 Installing Crankshaft Section 11 Reassembly Install Connecting Rod with Piston and Rings 1 Ifthe piston and or connecting rod has been changed or removed make sure the following is correct before installing Figure 11 9 a The locating mark on piston is down See Figure 11 10 Figure 11 10 Piston Installation Details Section 11 Reassembly b The connecting rod offset is down and oil hole is in the 3 o clock position Match marks should align as shown with dipper down See Figure 11 11 Match Marks Figure 11 11 Connecting Rod Details 2 Stagger the piston rings in the grooves until the end gaps are 120 apart See Figure 11 12 The oil ring rails should also be staggered Figure 11 12 Piston Ring Gap Positioning 3 Lubricate cylinder bore piston piston pin and piston rings with engine oil Compress the rings using a piston ring compressor 4 Lubricate the crankshaft journal and connecting rod bearing surfaces with engine oil 5 Make sure V stamping on piston is facing down toward the base of the engine Use a hammer handle with a rubber grip and gently tap the piston into the cylinder as shown in Figure 11 13 Be careful that the oil ring rails do not spring free between the bottom of the ring compressor and the top of the cylinder Figure 11 13 Installing Piston Using a Ring Compressor 6 Install the connecting rod cap to the connecting
82. em Seal 5 If the cylinder head is being replaced the carburetor mounting studs can be removed by using the air cleaner base nuts locked together See Figure 9 45 Figure 9 45 Removing Carburetor Mounting Studs Section 9 Disassembly Remove Flywheel NOTE Whenever possible an impact wrench should be used to loosen the flywheel retaining nut A flywheel strap wrench or an approved holding tool see Section 2 may also be used to hold the flywheel when loosening or tightening the flywheel retaining nut Always use a puller to remove the flywheel from the crankshaft Do not strike the flywheel or crankshaft as these parts could become cracked or damaged NOTE Some electric start flywheels require the ignition module be taken off first or loosened to remove the flywheel from crankshaft See Figure 9 46 Perform Remove Ignition Module prior to Step 1 if applicable Figure 9 46 Electric Start Flywheel Mo Configuration Some models dul 1 Remove the flywheel retaining nut washer and drive cup See Figures 9 47 and 9 48 Figure 9 47 Removing Flywheel Nut using an Impact Wrench 9 11 Section 9 Disassembly Remove Ignition Module 1 Remove the two hex flange screws securing the ignition module to the crankcase See Figure 9 51 Figure 9 48 Removing Flywheel Nut Using Holding Tool 2 Remove the flywheel from the crankshaft using a puller See Figure 9 49 and 9 50 Figure 9 51 Removing
83. epth 2 mm 0 079 in Figure 8 46 Commutator Mica Depth Armature Coil 1 Use an ohmmeter set to the Rx1 scale Touch the probes between two different segments of the commutator and check for continuity See Figure 8 47 Test all the segments Continuity must exist between all or the armature is defective Check for continuity between the armature coil segments and the commutator segments See Figure 8 47 There should be no continuity If continuity exists between any two the armature is defective Check armature windings insulation for shorting See Figure 8 47 A Armature Coil Continuity Check Figure 8 47 Armature Checking Section 8 Electrical System and Components Starter Reassembly 1 Position the thrust washer in the recess inside the drive end cap Install cover gasket on housing flange if removed previously Figure 8 50 Installing Frame 4 With the brushes and brush springs in place on brush plate align the tabs and install the brush plate in commutator end cap Insert the positive Figure 8 48 Installing Thrust Washer and Gasket brush stud with plastic support through hole in the end cap from the inside out Install the 2 Carefully apply one or two drops of oil to the O Ring fiber washer metal washer and inner hex bronze bushing in the drive end cap and wipe jam nut Tighten nut to secure but do not away any excess Insert the armature shaft overtighten or damage to the
84. er pilot lamp terminal exists on the 7 10 amp rectifier regulator B Charge Ground Black Stator AC Leads a White Figure 8 24 7 10 Amp Rectifier Regulator Floating Isolated Terminal Rectified Only Non Regulated Systems Some engines are equipped with a rectified only non regulated charging system with output ranging from 0 2 amp to 18 amps The rectifier is normally connected to the engine with a matching wiring harness and secured to the equipment with a single mounting screw Grounding is achieved through the wiring harness In certain other applications the rectifier may be integrated within the basic engine wiring harness The rectifier converts AC voltage coming from the stator to DC voltage only The 3 amp rectifier is shown in Figure 8 25 DC Voltmeter A AS Battery Section 8 Electrical System and Components Figure 8 25 3 Amp Rectifier Rectifier Regulator SE S Ss 2 7 Plugin Connector Connect Tester Leads to Female Bullet Connector Red Wire Ammeter Ground Lead Black Stator AC Leads White Figure 8 26 Connections for Testing Charging Systems 8 19 Section 8 Electrical System and Components Troubleshooting Guide Battery Charging System NOTE Zero ohmmeters on each scale to ensure accurate readings Voltage tests should be made with engine running at 3600 RPM no load Battery must be fully charged Check the specific gravity of battery If low
85. euse old rings 3 Before installing the rings on the piston place the top two rings each in turn in its running area in the cylinder bore and check end gap See Figure 10 14 This gap should be a maximum of 0 9 mm 0 035 in in a used cylinder bore and 0 2 mm 0 4 mm 0 008 0 016 in in a new cylinder bore Figure 10 14 Measuring Piston Ring End Gap Section 10 Internal Components 4 After installing the new rings on the piston check piston to ring side clearance Maximum recommended side clearance is Top ring 0 04 0 08 mm 0 0016 0 0033 in 2nd ring CS4 CS6 0 02 0 06 mm 0 0008 0 0024 in CS8 5 12 0 03 0 07 mm 0 0012 0 0028 in Piston Ring Side Clearance Limit 0 1 mm 0 004 in If side clearance is greater than specified a new piston must be used Refer to Figure 10 15 Figure 10 15 Measuring Piston Ring Side Clearance 10 11 Section 10 Internal Components Install Piston Rings To install piston rings proceed as follows NOTE Rings must be installed correctly Ring installation instructions are usually included with new ring sets Follow instructions carefully Use a piston ring expander to install rings Install the bottom oil control ring first and the top compression ring last 2nd Ring Has R Marking 1 Oil Control Ring Bottom Groove Place the expander in the lowest groove The ends of the expander must butt Do not allow the ends to overlap incorrect tension and a l
86. eventing a proper seal Breather Tube Make sure the breather tube is in good condition and connected to the air cleaner base or adapter and the breather cover Replace the tube if it is cracked or damaged Figure 4 12 Foam Seal Figure 4 13 Cutaway View CS8 5 spec 95xxxx engines use an air cleaner base with a serviceable rubber base pad to seal the air filter element on the bottom See Figure 4 14 Make sure the pad is installed clean and in good condition Figure 4 14 Serviceable Rubber Base Pad Foam Air Cleaner Element Figure 4 15 Foam Air Cleaner Configuration Check the air cleaner daily or before starting the engine Check for buildup of dirt and debris along with loose or damaged components NOTE Operating the engine with loose or damaged air cleaner components could allow unfiltered air into the engine causing premature wear and failure Every 50 hours of operation wash and reoil the foam air cleaner element more often under extremely dusty or dirty conditions Replace the foam element with a new genuine Kohler element if deteriorated or damaged in any way Section 4 Air Intake and Air Cleaner System To service the foam element perform the following steps 1 Remove the two screws and the outer air cleaner cover housing See Figure 4 16 Mounting Screw A x MA Mounting Screw Figure 4 16 Mounting Details 2 Remove the foam element from the air cle
87. f the carburetor b Hold the line below the bottom of the tank Open the shut off valve and observe flow Carburetor General The CS engines use fixed jet MIKUNI carburetors The fixed main jet carburetor is designed to deliver the correct fuel to air mixture to the engine under all 5 2 2 If there is fuel at the tip of the spark plug fuel is reaching the combustion chamber If there is no fuel at the tip of the spark plug check for fuel flow from the fuel tank Test 3 If fuel does flow from the line check for a problem in the carburetor dirt gum varnish etc If fuel does not flow from the line check for a clogged fuel cap vent inlet filter shut off valve screen filter and or fuel line s operating conditions The high idle mixture is set at the factory and cannot be adjusted The low fuel adjusting needle is also set at the factory and normally does not need adjustment NOTE Carburetor adjustments should be made only after the engine has warmed up 4 Fuel leaks from carburetor Section 5 Fuel System and Governor Troubleshooting Carburetor Related Causes Possible Cause Probable Remed 1 Engine starts hard runs roughly or stalls at idle speed Engine runs rich Indicated by black sooty exhaust smoke misfiring loss of speed and power governor hunting or excessive throttle opening Engine runs lean Indicated by misfiring loss of speed and power governor hunt
88. fferent specification series 92xxxx and 95xxxx The design features of 92xxxx spec no engines are identical to CS10 and CS12 engines and share the same service procedures The 95xxxx spec no engines incorporate certain design differences from the 92xxxx spec no series All service and repair information unique to the 95xxxx spec no series will be listed and covered separately 1 3 Section 1 Safety and General Information Oil Recommendations Using the proper type and weight of oil in the crankcase is extremely important as is checking oil daily and changing oil regularly Failure to use the correct oil or using dirty oil causes premature engine wear and failure Oil Type Use high quality detergent oil of API American Petroleum Institute service class SG SH SJ or higher Select the viscosity based on the air temperature at the time of operation as shown below RECOMMENDED SAE VISCOSITY GRADES C L L 5W 20 SW 30 a a EAN 10W 30 POSI EE I O EI ee E Kohler 10W 30 100 E 30 40 TEMPERATURE RANGE EXPECTED BEFORE NEX OIL CHANGE Synthetic oils should not be used Figure 1 3 Viscosity Grades Table NOTE Using other than service class SG SH SJ or higher oil or extending oil change intervals longer than recommended can cause engine damage A logo or symbol on oil containers identifies the API service class and SAE viscosity grade See Figure 1 4 S Figure 1 4 Oil Container Log
89. fter Honing Proper cleaning of the cylinder walls following boring and or honing is very critical to a successful overhaul Machining grit left in the cylinder bore can destroy an engine in less than one hour of operation after a rebuild The final cleaning operation should always be a thorough scrubbing with a brush and hot soapy water Use a strong detergent that is capable of breaking down the machining oil while maintaining a good level of suds If the suds break down during cleaning discard the dirty water and start again with more hot water and detergent Following the scrubbing rinse the cylinder with very hot clear water Dry it completely and apply a light coating of engine oil to prevent rusting Closure Plate and Crankcase 1 Clean the sealing surfaces of the closure plate and crankcase of all gasket material NOTE Do not scrape the surfaces when cleaning as this will damage the surfaces and could cause leaks The use of a gasket removing solvent or aerosol spray is recommended Figure 10 8 Removing Gasket with Aerosol Spray Measuring Piston to Bore Clearance Before installing the piston into the cylinder bore it is necessary that the clearance be accurately checked This step is often overlooked and if the clearances are not within specifications engine failure will usually result NOTE Do not use a feeler gauge to measure piston to bore clearance it will yield inaccurate measurements Always use a m
90. ge Adjust the carburetor settings as required Low idle speed should be set to 2000 RPM 150 or application Torque hex flange nuts to specifications CS4 CS6 6 8 N m 53 71 in 1b CS8 5 12 18 22 N m 159 195 in Ib 2 Make sure the maximum engine speed does not exceed Torque hex flange screw to sss aa A Pear tae Type Engine Speed Maximum CS8 5 12 15 N m 133 in 1b Type Engine Speed Tapered Shaft Models 3750 100 RPM 3800 100 RPM Adjust the throttle choke and or high speed stop screw as necessary See Figures 11 118 11 119 and 11 120 on page 11 32 Refer also to Fuel System and Governor section Figure 11 117 Torquing Muffler Mounting Screws 11 31 Section 11 Reassembly avia amp Pd Figure 11 118 CS4 CS6 High Speed Stop Screw Figure 11 120 CS8 5 spec 95xxxx High Speed Stop Screw A y Pi E La HHT K N i 5 L 4 Figure 11 119 CS8 5 spec 92xxxx CS10 CS12 High Speed Stop Screw 11 32 KOHLER ENGINES FOR SALES AND SERVICE INFORMATION IN U S AND CANADA CALL 1 800 544 2444 ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 FORM NO TP 2503 B ISSUED 12 99 REVISED 8 06 LITHO IN U S A 1PTP 2503 B 6 50531 4966 3
91. gnition pea Solenoid Module JE Valve i Starter Oil Sentry 4 Gauge B Starter Solenoid l 5 J E Solenoid Battery Shift Stater Motor L Ground OPTIONAL Ground Ground Ground Ground AAA EEA E TES E E 0 4 or 2 Amp Charging System Rectified Only and Oil Sentry System Solenoid Shift Electric Starter Optional Solenoid Valve Some Models Figure 8 18 Qil Warning Unit Qil F Sentry Engine A Light Ground Ignition Module _ Starter i Solenoid a Mea Solenoid Starter sad Battery S Motor Ground Ground Ground Cm som TTT Ground a o 3 G 18 Amp Charging System with Rectifier Regulator and Oil Sentry System Solenoid Shift Electric Starter and Provisions for Charge Lamp Spec Specific Ignition Switch and Wiring Harness Connectors Figure 8 19 8 15 Section 8 Electrical System and Components Oil Warning Main Switch Unit Engine Ground Ignition Module m Startor Ground Ground Ground Solenoid Shift Starter Motor Ground No Charging System Operational Off Battery Oil Sentry System Solenoid Shift Electric Starter Figure 8 20 Ignition Module Ground Ground Stop Switch Recoil Start No Oil Sentry System Stop Switch Only Ground Figure 8 21 8 16 Section 8 Electrical System and Components Oil Warning Unit Ground b Oil Sentry Sp Light Ignition Module Spark S
92. gure 11 49 Installing Counter Gear Assembly 5 Lubricate the bearing surfaces with oil and install the output shaft gear assembly into the cover See Figure 11 50 Figure 11 52 Installing Cover 11 13 Section 11 Reassembly Figure 11 53 Torquing Mounting Screws Figure 11 55 Stator Screws Torque Sequence Install Stator and Wire Shield If So 2 Route the stator leads along the formed channel Equipped and out through the hole in the crankcase casting 1 Align stator holes with mounting bosses of 3 Install the protective wire shield over the channel and secure in place with the M6x1 0 screw Torque screw to 10 N m 88 5 in 1b See Figure 11 56 crankcase so the leads are at the 1 o clock position and toward the crankcase Install the four M6 shoulder screws and torque the screws in sequence shown as applicable to 5 8 N m 44 70 in lb Figure 11 56 Installing Shield 11 14 Install Flywheel A WARNING Damaging Crankshaft and Flywheel Can Cause Personal Injury Using improper procedures to install the flywheel can crack or damage the crankshaft and or flywheel This not only causes extensive engine damage but can also cause personal injury since broken fragments could be thrown from the engine Always observe and use the following precautions and procedures when installing the flywheel NOTE Before installing the flywheel make sure the crankshaft taper and flywheel hub are clean dry a
93. gure 9 72 Figure 9 72 Removing Output Shaft Gear from Cover Section 9 Disassembly 5 Remove the counter gear from the closure plate Remove the screw and washer securing the crank gear and slide the gear off of the crankshaft splines See Figure 9 73 Pry Tap Pads Figure 9 75 CS4 CS6 Closure Plate Mounting Screws Figure 9 73 Removing Counter Gear and Crank Gear 6 Remove the dowel pins and gasket Clean the gasket surfaces with a cleaning solvent or aerosol type gasket remover Do not nick or scrape the sealing surfaces See Figure 9 74 Figure 9 76 CS8 5 CS12 Closure Plate Mounting Screws 2 Locate the pry tap pads on the closure plate See Figures 9 75 and 9 76 These areas permit separation of the closure plate from the crankcase with a flat screwdriver or by tapping lightly with a plastic hammer NOTE Do not pry on the gasket surface of the Figure 9 74 Removing Dowel Pins and Gasket crankcase or closure plate as this can cause damage and leakage 7 Check the reduction system bearings for wear or excessive play See Figure 9 63 If bearing removal is required use an internal bearing puller to remove the housing bearings An arbor press should be used for removal of the others Remove Closure Plate 1 Remove the hex flange screws securing the closure plate to the crankcase six on CS4 and CS6 eight on CS8 5 CS12 See Figures 9 75 and 9 76 9 17 Section 9 Disassembly F
94. he retaining ring and locks the collar into position See Figure 8 62 Section 8 Electrical System and Components Figure 8 62 Lock Collar around Retaining Ring 5 Install the thrust washer onto the armature shaft and lightly lubricate the end of the shaft with drive lubricant 6 Position the lubricated drive lever around the drive pinion assembly and insert the assembly into the drive end cap Seat the pivot section of drive lever into the corresponding section within the housing See Figure 8 63 Figure 8 63 Installing Armature 8 33 Section 8 Electrical System and Components 7 Mount the brush holder to rear of starter frame Install the four brushes into the corresponding slots Then carefully work set each of the four brush springs into position behind the brushes Slide the rubber insulating grommet onto the small corresponding plastic tab on frame See Figure 8 64 Figure 8 66 Tool on end of Armature 10 Carefully slide the frame with the brush plate assembly down over the tool and onto armature and drive end cap aligning the cutout with lever section on top The rubber insulating grommet should also be up See Figure 8 67 Figure 8 64 Mounting Brush Holder to Frame NOTE Maintain pressure on the insulator while installing so the springs do not come out 8 Position the insulator over the brushes and springs Hold it firmly in place so the springs do not come out See Figure 8 65
95. he throttle plate wider This allows more fuel into the engine increasing engine speed This action occurs very rapidly so a reduction in speed is hardly noticed As the speed reaches the governed setting the governor spring tension and the force applied by the regulating pin will again be in equilibrium This maintains the engine speed at a relatively constant level The governed speed setting is determined by the position of the throttle control It can be variable or constant depending on the application Figure 5 9 Governor System Initial Adjustment Make this initial adjustment whenever the governor lever is loosened or removed from the cross shaft To ensure proper setting make sure the throttle linkage is connected to the governor lever and to the carburetor throttle lever certain engine components removed for clarity of illustration Governor Adjustment 1 Close the fuel shut off valve 2 Remove the air cleaner outer cover Then either reposition the fuel tank to access governor shaft and lever joint or disconnect the fuel line and remove the tank from the engine NOTE Make sure the carburetor is mounted and secured in place when adjustment is being made checked 3 Loosen the governor lever mounting bolt 4 Move the governor lever clockwise until it stops 5 Rotate the governor shaft clockwise until it stops 5 8 6 Hold both in this position and tighten the governor lever bolt Torque the
96. icrometer Section 10 Internal Components For CS4 CS6 x 5 mm 0 197 in For CS8 5 12 x 10 mm 0 394 in Figure 10 9 Measuring Piston Diameter Use the following procedure to accurately measure the piston to bore clearance 1 Use a micrometer and measure the diameter of the piston at location indicated above the bottom of the piston skirt and perpendicular to the piston pin See Figure 10 9 2 Use an inside micrometer telescoping gauge or bore gauge and measure the cylinder bore Take the measurement approximately 40 mm 1 6 in below the top of the bore and perpendicular to the piston pin 3 Piston to bore clearance is the difference between the bore diameter and the piston diameter step 2 minus step 1 Flywheel Inspection Inspect the flywheel for cracks and the flywheel keyway for damage Replace flywheel if cracked Replace the flywheel the crankshaft and the key if flywheel key is sheared or the keyway damaged Inspect the ring gear for wear cracks or damage Kohler does not provide ring gears as a serviceable part Replace the flywheel if the ring gear is damaged 10 5 Section 10 Internal Components Cylinder Head and Valves Inspection and Service Carefully inspect the valve mechanism parts Inspect the valve springs and related hardware for excessive wear or distortion Check the valves and valve seat area for evidence of deep pitting cracks or distortion Check clearance of the
97. igure 9 77 Separating Closure Plate From Figure 9 79 Removing Governor Gear Crankcase 6 Remove the crankshaft seal See Figure 9 80 Steps 3 7 should be performed only if further disassembly or servicing in the respective areas is necessary 3 Remove the two hex flange screws mounting the oil sentry gauge and the single screw holding the wire shield in place See Figure 9 78 Grommet Figure 9 80 Removed Crankshaft Seal 7 Press out the crankshaft bearing using an arbor press Use an internal bearing puller to remove the balance shaft bearing Figure 9 78 Removing Shield and Oil Sentry 4 Pull the grommet out of the cutout in the casting and remove the oil sentry gauge Note the routing of the wire 5 Remove the governor gear flyweight assembly by carefully applying upward pressure with two small screwdrivers between the gear and the closure plate bosses This will unseat the retaining ring from the groove allowing removal of the gear and mounting components by pulling upward Do not pry against the gasket surface Note the placement and order of all parts See Figure 9 79 Figure 9 81 Bearing Removal Using a Press 9 18 Section 9 Disassembly Remove Balance Shaft If So Equipped 1 Pull the balance shaft out of the crankcase Figure 9 84 Removing Connecting Rod Bolts NOTE If a carbon ridge is present at the top of the Figure 9 82 Removing Balance Shaft cylinder bore use
98. ill flicker for a few seconds when attempting to start and the engine will not start See Figure 8 2 Bring Level Up To Point of Overflow A Proper Oil Level Low Oil Level Figure 8 2 Cutaway Showing Proper Oil Level Oil Sentry systems typically consist of the following components e An oil warning control unit black box e An oil level float switch e An indicator light 8 3 Section 8 Electrical System and Components Troubleshooting Guide Ignition and Oil Sentry Systems Before testing be certain all electrical leads are connected and crankcase oil is at the point of overflowing the filler neck If tester is firing ignition system is good Install a new spark plug and try to start engine If it still will not start check other possible causes fuel compression etc If tester does not fire go to step 2 Disconnect the cap from the spark plug and attach it to the terminal end of spark tester Kohler Part No 25 455 01 S Attach tester spring clip to a good ground not to the spark plug Turn ignition key switch on and crank the engine while observing the firing tip of the tester On electric start engines remove the starter cover panel Locate the black white kill lead coming from the ignition module inside the blower housing Disconnect the bullet connector where the kill lead plugs into the harness Repeat the spark test step 1 If spark is now present check for a shorted l
99. ing or excessive throttle opening Troubleshooting Checklist If engine troubles are experienced that appear to be fuel system related check the following areas before 1 Low idle fuel mixture speed improperly adjusted Adjust the low idle speed RPM then adjust the low idle fuel needle Clogged air cleaner Clean or replace Choke partially closed during operation Check the choke lever linkage to ensure choke is operating properly Low idle fuel mixture is improperly adjusted Adjust low idle fuel needle Float level is too high Separate carburetor bowl from carburetor body check float setting against specification Replace float if required Dirt under the fuel inlet needle Remove needle clean needle and seat and blow out with compressed air Bowl vent pilot jet or air bleeds plugged Remove low idle fuel adjusting needle Clean vent ports and air bleeds Blow out all passages with compressed air Leaky cracked or damaged float Submerge float to check for leaks Low idle fuel mixture is improperly adjusted Adjust low idle fuel needle Float level is too low Separate carburetor bowl from carburetor body check float setting against specification Replace float if required Idle holes plugged dirt in fuel delivery channels Remove low idle fuel adjusting needle Clean main fuel jet and all passages blow out with compressed air Float level too high See Remedy 2d D
100. ing Spring the studs 11 27 Section 11 Reassembly Install Air Cleaner Base and Element 1 Install the air cleaner base gasket onto the mounting studs Attach the breather hose onto the air cleaner base connection port Then install the air cleaner base onto the studs Connect the opposite end of the breather hose to the valve cover Secure the base with the two hex flange nuts on the mounting studs and the one or two hex flange screw s into the support bracket s depending on the model involved See Figures 11 104 11 105 and 11 106 On models using a separate rubber seal between the air filter element and base install or make sure the rubber seal for the air cleaner is clean installed and in good condition See Figure 11 106 Torque hex flange nuts to CS4 CS6 5 8 N m 44 71 in Ib CS8 5 12 10 12 N m 88 106 in Ib Torque hex flange screw s to 5 8 N m 44 71 in Ib Figure 11 104 CS4 CS6 Installing Air Cleaner Base Figure 11 105 CS8 5 12 Installing Air Cleaner Base 11 28 Rubber Seal Figure 11 106 CS8 5 Air Cleaner Base and Rubber Seal Some Models 2 Make sure the seal is on the air cleaner base stud fixed on some models See Figures 11 104 11 105 and 11 106 Install the filter element with precleaner and secure with the wing nut Do not install the outer air cleaner cover and knob at this time Figure 11 107 Installing Air Filter Element Precleaner and Wing
101. ing two M6x1 0 hex flange screws Route the wire lead and seat the grommet in the cutout as shown in Figure 11 18 Figure 11 16 CS8 5 12 Aligning Crankshaft and Camshaft Timing Marks Install Balance Shaft CS8 5 12 If So Equipped 1 Position the crankshaft so the timing mark dimple on the larger crankgear is in the 8 o clock position Figure 11 18 Oil Sentry Gauge Mounting and Lead Routing Details Section 11 Reassembly Ze Figure 11 19 Tightening Mounting Screws Install shield for lead and secure with the M6x1 0 hex flange screw Torque all three screws to 10 N m 88 5 in 1b See Figure 11 19 Install Closure Plate Assembly 1 Check to make sure the sealing surfaces of the crankcase and closure plate are clean and free of nicks burrs Install the two dowel pins into the locations shown in the crankcase Install the new closure plate gasket dry onto the dowel pins Make sure the governor lever is facing towards the right cylinder side Completed assembly before closure plate is installed should look like Figures 11 20 and 11 21 Figure 11 20 CS4 CS6 Internal Details Figure 11 21 CS8 5 12 Internal Details 57 Install the closure plate to the crankcase Carefully seat the ends of the camshaft and balance shaft into their mating bearings Rotate the crankshaft slightly to help engage the governor gear teeth On pump threaded crankshaft models only install two or
102. ioning of major internal engine components The following components are not covered in this section they are covered in their own sections Air Cleaner Section 4 Carburetor amp External Governor Section 5 Retractable Starter Section 7 Ignition Charging amp Electric Starter Section 8 Clean all parts thoroughly Only clean parts can be accurately inspected and gauged for wear or damage There are many commercially available cleaners that will quickly remove grease oil and grime from engine parts When such a cleaner is used follow the manufacturer s instructions and safety precautions carefully Make sure all traces of the cleaner are removed before the engine is reassembled and placed into operation Even small amounts of these cleaners can quickly break down the lubricating properties of engine oil Refer to A Guide to Engine Rebuilding TP 2150 A for additional information Measurement Guide TP 2159 B and Engine Inspection Data Record TP 2435 are also available use these to record inspection results Automatic Compression Release ACR These engines are equipped with an Automatic Compression Release ACR mechanism ACR lowers compression at cranking speeds to make starting easier Operation The ACR mechanism consists of a spring loaded arm and sliding pin mounted to the camshaft When the engine is rotating at low cranking speeds 600 RPM or less the arm holds the pin so it protrudes above the heel of the exhaust
103. irt under fuel inlet needle See Remedy 2e Bowl vent plugged Blow out with compressed air Carburetor bowl gasket leaks Replace gasket e Make sure the air cleaner base and carburetor are securely fastened to the engine using gaskets in good condition adjusting or disassembling the carburetor Make sure the fuel tank is filled with clean fresh gasoline Make sure the fuel cap vent and inlet filter are not blocked and operating properly Make sure fuel is reaching the carburetor This includes checking the fuel shut off valve screen filters and fuel lines for restrictions e Make sure the air cleaner element is clean and all air cleaner components are fastened securely e Make sure the ignition system governor system exhaust system and throttle and choke controls are operating properly If after checking all items listed above the engine is hard to start runs roughly or stalls at low idle speed it may be necessary to adjust or service the carburetor 9 3 Section 5 Fuel System and Governor Adjustments General NOTE Carburetor adjustments should be made only after the engine has warmed up The carburetor is designed to deliver the correct fuel to air mixture to the engine under all operating conditions The high idle mixture is set at the factory and cannot be adjusted The low idle fuel adjusting needle is also set at the factory and has a limiting cap It normally does not need adjustment
104. k the oil level Note if the oil level is within the operating range on the dipstick or if it is low or overfilled e Check the condition of the oil Drain the oil into a container the oil should flow freely Dark dirty and or thick oil could indicate infrequent maintenance or overheating Check for metal chips and other foreign particles Sludge is a natural by product of combustion a small accumulation is normal Excessive sludge formation could indicate the oil has not been changed at the recommended intervals the incorrect type or weight of oil was used overrich carburetion or weak ignition to name a few NOTE It is good practice to drain oil at a location away from the workbench Be sure to allow ample time for complete drainage Cleaning the Engine After inspecting the external condition of the engine clean the engine thoroughly before disassembling it Also clean individual components as the engine is disassembled Only clean parts can be accurately inspected and gauged for wear or damage There are many commercially available cleaners that will quickly remove grease oil and grime from engine parts When such a cleaner is used follow the manufacturer s instructions and safety precautions carefully Make sure all traces of the cleaner are removed before the engine is reassembled and placed into operation Even small amounts of these cleaners can quickly break down the lubricating properties of engine oil Ba
105. laceable high density paper element surrounded by an oiled foam precleaner See Figures 4 1 and 4 2 Servicing information for these two styles is on pages 4 1 through 4 4 The third design does not use a paper element just the foam See Figure 4 14 Servicing information for the third design is on page 4 5 The heavy duty air cleaner assemblies also contain a lower swirl chamber which separates the dirt particles from the incoming air for extended service intervals Figure 4 2 Heavy Duty Cyclonic Air Cleaner Service Check the air cleaner daily or before starting the engine Check for buildup of dirt and debris along with loose or damaged components NOTE Operating the engine with loose or damaged air cleaner components could allow unfiltered air into the engine causing premature wear and failure Figure 4 1 Standard Dual Element Air Cleaner Figure 4 3 Removing Cover Knob Standard 4 1 Section 4 Air Cleaner and Air Intake System Figure 4 5 Standard Element Precleaner Assembly 6 Figure 4 6 Heavy Duty Element Precleaner Assembly Figure 4 7 Removing Standard Precleaner Precleaner Service If so equipped wash and reoil the precleaner every 25 hours of operation more often under extremely dusty or dirty conditions 4 2 1 To service the precleaner perform the following steps Remove the air cleaner cover knob standard air cleaner or unsnap the latches heavy duty air cleaner and
106. lange screws On CS4 and CS6 engines secure the ground lead with the silver screw in the upper right hand location See Figures 11 96 11 97 and 11 98 Torque the screws to 7 N m 62 in Ib Figure 11 97 CS4 CS6 Silver Screw and Ground Lead Location 11 26 Figure 11 98 CS8 5 spec 92xxxx CS10 CS12 Blower Housing Installed 2 Attach the electric starter cover panel if so equipped to the right tank support with the three phillips head screws and one flange nut See Figure 11 99 Figure 11 99 CS8 5 spec 92xxxx CS10 CS12 Attaching Electrical Starter Cover Panel Install Carburetor 1 Install anew carburetor spacer gasket onto the carburetor studs followed by the carburetor spacer and another spacer gasket See Figure 11 100 Figure 11 100 Carburetor Spacer and Gaskets 2 Tilt the carburetor to hook the throttle link and dampening spring into the hole s of the throttle lever See Figures 11 101 and 11 102 Figure 11 101 CS4 CS6 Assembling Linkage S 4 Push the carburetor and linkage all the way onto Section 11 Reassembly Figure 11 102 CS8 5 12 Assembling Linkage CS8 5 12 Connect Z end of choke link and dampening spring to choke lever on blower housing or control bracket Then connect the angled end of the link and spring into the holes of the choke lever on the carburetor as shown in Figure 11 103 Figure 11 103 CS8 5 12 Attaching Choke Link and Dampen
107. ling fins or from inadequate or contaminated lubrication Measure the cylinder bore using an inside micrometer or bore gauge See Figure 10 6 Compare readings with specifications in Section 1 Figure 10 5 Camshaft Journal Checking Camshaft Journal Specifications 15 965 15 990 mm 0 6285 0 6295 in 10 3 Section 10 Internal Components Figure 10 6 Measuring Cylinder Bore If the cylinder bore is badly scored excessively worn tapered or out of round resizing is necessary Use a measuring device inside micrometer etc to determine the amount of wear refer to the Specifications Tolerances and Special Torque Values in Section 1 then select the nearest suitable oversize of either 0 25 mm 0 010 in or 0 50 mm 0 020 in Resizing to one of these oversizes will allow usage of the available oversize piston and ring assemblies Initially resize using a boring bar then use the following procedures for honing the cylinder Honing While most commercially available cylinder hones can be used with either portable drills or drill presses the use of a low speed drill press is preferred as it facilitates more accurate alignment of the bore in relation to the crankshaft crossbore Honing is best accomplished at a drill speed of about 250 RPM and 60 strokes per minute After installing coarse stones in hone proceed as follows 1 Lower hone into bore and after centering adjust so that the stones are in contac
108. listed See Figure 10 10 for the individual model involved Determine whether the valve stem or the guide is responsible for the excessive clearance The valve guides are not replaceable Valve Seat Inserts The valve seats are not replaceable If the seats become badly pitted worn or distorted the inserts can be reconditioned Use a standard valve seat cutter see Figure 10 11 and cut seat to dimensions shown in Figure 10 10 Valve details illustration Figure 10 11 Standard Valve Seat Cutter Lapping Valves Reground or new valves must be lapped in to provide proper fit Use a hand valve grinder for final lapping Lightly coat valve face with fine grade of grinding compound then rotate valve on seat with grinder Continue grinding until smooth surface is obtained on seat and on valve face Thoroughly clean valve and cylinder head in soap and hot water to remove all traces of grinding compound After drying apply a light coating of SAE 10 oil to prevent rusting Intake Valve Stem Seal These engines use a valve stem seal on the intake valve Always use a new seal when the intake valve is removed from the cylinder head The seal should be replaced if deteriorated or damaged in any way Never reuse an old seal Figure 10 12 Valve Stem Seal 10 9 Section 10 Internal Components Pistons and Rings Inspection Scuffing and scoring of pistons and cylinder walls occurs when internal temperatures approach the melti
109. m the flywheel as possible then tighten the screws just enough to hold it in position 3 Route the ignition module lead as shown in Figure 11 61 or 11 62 4 Rotate the flywheel in a clockwise direction until the magnet is under the legs of the ignition module 5 Insert a 0 5 mm 0 020 in flat feeler gauge between each leg of module and magnet Loosen the screws allowing the magnet to draw the module against the gauge s Push against module to hold legs tight against the feeler gauge s while tightening screws Tighten the lower screw first Torque screws to 10 N m 88 5 in 1b See Figures 11 61 and 11 62 11 16 Figure 11 62 CS8 5 12 Setting Air Gap 6 Rotate the flywheel back and forth checking to make sure the magnet does not strike the module Connect the kill lead to the terminal Assemble Cylinder Head 1 Lubricate all the valve train components with engine oil Pay particular attention to the lip of the valve stem seal valve stems and valve guides Figure 11 63 Intake Valve Stem Seal NOTE The engine utilizes a valve stem seal on the 2 intake valve Always use a new seal when valves are installed in the cylinder head Replace the seal if it is deteriorated or damaged in any way Never reuse an old seal Install the valves valve springs and retainers into their respective locations in the cylinder head Compress each valve spring retainer assembly with a valve spring compressor and lock
110. main body and remove the bowl gasket from the body 8 Place the carburetor in an inverted position Lift up the float so that the tip of the float valve lightly contacts the float arm See Figure 5 5 Measure the float height from the casting surface as illustrated in Figure 5 6 Float height for the CS4 and CS6 is 16 mm 0 63 in Float height for the CS8 5 CS10 and CS12 is 14 9 mm 0 59 in Install a float kit if the float height is incorrect Float Kit Contains Float Gasket bowl Gasket bowl screw Pin float Gasket intake Gasket air cleaner base 5 6 LLA Figure 5 5 Float Height Position Figure 5 6 Measuring Float Height A CAUTION Do not bend the float in an attempt to reset the height The correct float height is determined by the design of the inlet needle and float There is no provision for physical adjustment 9 Check to see if the fuel inlet needle or seat is dirty obstructed or worn a Remove the main jet from the side of the tower b Grab the exposed end of the float pin with a needle nose pliers and pull it out c Lift out the float and inlet needle Slide the inlet needle and clip off of the float tab d Check components for contamination wear or damage See Figure 5 7 Use carburetor cleaner to clean out any dirt or contamination Use a float kit if the inlet needle or float is damaged or worn If the inlet seat is damaged or worn the carburetor must be replaced
111. mbly 4 Remove the two electric starter mounting bolts See Figures 9 29 and 9 30 Figure 9 31 Inertia Drive Starter and Control Panel Removed Figure 9 29 Removing Inertia Drive Starter Mounting Bolts Starter Mounting Bolts d Figure 9 30 Starter Bolts on Models with Solenoid Shift Starters Figure 9 32 Solenoid Shift Starter and Control Panel Removed 5 Remove the starter motor wiring harness and control panel housing from the engine Components may be further disassembled if required See Figures 9 31 9 32 and 9 33 Figure 9 33 Control Panel and R H Tank Bracket 9 8 Remove Left Fuel Tank Bracket 1 Remove the left fuel tank mounting bracket by removing the two screws Figure 9 34 and 9 35 Washers are used on the CS4 and CS6 only Figure 9 34 CS4 CS6 Left Side Tank Mounting Bracket Details Figure 9 35 CS8 5 spec 92xxxx CS10 and CS12 Left Side Tank Mounting Bracket Details Remove Valve Cover Breather Air Shroud on Head Assembly and Push Rods Remove the four hex flange screws securing the valve cover The air cleaner support bracket CS8 5 12 may be mounted off two of the screws or directly to cylinder head Remove the support bracket and note the locations of all the screws See Figures 9 36 and 9 37 Section 9 Disassembly Figure 9 36 Removing Valve Cover Screws on Models with Attached Support Bracket Support Bracket Screws Figure 9 3
112. move the blower housing and remove the ignition module With the kill lead and spark plug cap removed test resistance from the small spade terminal to the core of the spark plug lead wire Set an ohmmeter to the Rx1 scale and zero the meter Test the ignition key switch as follows a On manual start engines trace the two black leads from the on off switch and separate them from any connections Connect the ohmmeter leads to the switch leads and check for continuity in both switch positions On electric start engines trace the four leads red red white black black white from the key switch and separate them from any connections Connect the ohmmeter leads to the black and black white leads and check for continuity in all three switch positions Then connect the ohmmeter leads to the red and red white leads and test again in all three switch positions No Continuity Resistance of the cap should be 4 6 K ohms Resistance should be 9 5 12 9 K ohms If resistance is not in this range replace the module Continuity should be indicated when and only when switch is in the off position Replace switch for any other results Continuity should be indicated between the black and black white leads only when the key switch is in the off position There should be continuity between the red and red white leads only in the start position Replace switch for any other results 8 5 Section 8 Electrical System and
113. n lb switch wiring harness oil sentry control module starter and warning light attached based on model spec involved Figure 11 81 CS4 CS6 Mounting Left Fuel Tank Support Figure 11 83 CS4 CS6 Mounting Right Fuel Tank Support 11 21 Section 11 Reassembly Figure 11 84 CS8 5 Spec 92xxxx 10 CS 12 Mounting Right Fuel Tank Support CS8 5 spec 95xxxx Align and mount the throttle control bracket to the top of the crankcase with the hex flange screw Make sure the hole in the bracket for mounting the base pan is aligned with the threaded hole in the crankcase Torque the screw to 10 13 N m 88 106 in 1b On retractable start engines mount the Oil Sentry control module to the crankcase and attach the eround lead to the same mounting screw Torque the screw to 10 12 N m 88 106 in 1b On electric start engines mount the bracket with control panel attached to the crankcase using the two hex flange head screws Torque the screws to 10 12 N m 88 106 in 1b 3 Check that the ground leads are secured at the bracket locations as shown in Figures 11 83 through 11 85 CS8 5 12 Reattach the ignition system ground lead to the crankcase boss adjacent to the governor shaft See Figure 11 85 or to the control module mounting bolt location based on model involved 11 22 Figure 11 85 CS8 5 12 Ground Lead Location Install Governor Lever Throttle Link Throttle and Governor Springs 1
114. n engine operating under normal conditions will have light tan or gray colored deposits If the center electrode is not worn a plug in this condition could be set to the proper gap and reused Carbon Fouled Soft sooty black deposits indicate incomplete combustion caused by a restricted air cleaner overrich carburetion weak ignition or poor compression 8 2 Worn On a worn plug the center electrode will be rounded and the gap will be greater than the specified gap Replace a worn spark plug immediately Wet Fouled A wet plug is caused by excess fuel or oil in the combustion chamber Excess fuel could be caused by a restricted air cleaner a carburetor problem or operating the engine with too much choke Oil in the combustion chamber is usually caused by a restricted air cleaner a breather problem or internal engine wear Overheated Chalky white deposits indicate very high combustion temperatures This condition is usually accompanied by excessive gap erosion Lean carburetor settings an intake air leak or incorrect spark timing are normal causes for high combustion temperatures Electronic TCI Transistor Controlled Ignition System These engines are equipped with a dependable electronic TCI system providing e Maintenance free operation e Strong spark output e Stable controlled ignition timing The system consists of the following components e A magnet assembly which is permanently affi
115. n the pivot portion of the drive 1 Remove flange nut and disconnect the braided lever and remove the drive lever and armature wire from lower main solenoid terminal from the drive end cap See Figure 8 60 2 Remove the two hex flange nuts securing the NOTE When removing the lever and armature solenoid and carefully separate the solenoid be careful not to lose the thrust washer from the starter assembly the front end of solenoid must be lifted slightly to permit disengagement from drive lever in starter See Figure 8 58 Figure 8 60 Removing Drive Lever and Armature 9 The stop collar is held in place by being snapped over the retainer from the bottom up The Figure 8 58 Starter with Solenoid Removed retainer is positioned in a groove in the armature shaft To access the retainer the stop collar must 3 Remove the two thru bolts be pushed back or down towards the drive pinion See Figure 8 61 4 Remove the commutator end cap from the starter frame and the rubber insulating grommet 5 Carefully remove the insulator and brush springs from the brush holder 6 Lift the four brushes out of their corresponding slots and remove the brush holder 7 Remove the frame from around the armature and drive end cap See Figure 8 59 Figure 8 61 Starter Drive and Stop Components 10 With the stop collar dislodged the retainer can be removed from the armature shaft Do not reuse the retainer 11 Remove the drive
116. nd Recoil Start Figure 8 4 Ignition Module Stop Switch 9 Wire Lead B Electronic Ignition System Y with Oil Sentry System Recoil Start Ground Figure 8 5 8 8 Wiring Color Codes _ Y Yellow L Y w Brown Green Gy Oil Sentry Gauge Lead Black w Gray Shielding Oil Warning Unit Ground B E Oil Sentry Gauge Section 8 Electrical System and Components Oil Warning Unit N R Stop Switch E BW a Oil SentryTM B Light Oil V Sentry E T Wire Lead Gauge Y Ignition Module Ground s Sy Spark Electronic Ignition System 7 Amp Plug 5 Ground Unregulated Charging System with gt Oil Sentry System Recoil Start Ground Ground Figure 8 6 Oil Warning Unit BW i K y BW B Ground Oil Sentry y Light Wire Lead g Eng oe 7 x Ground W W B Ignition Module Oil Sentry O Gauge S E Ground W W Stator W W Ground Spark Ground Plug Solenoid Starter A Ground Electronic Ignition System 7 Amp Charging System with Rectifier Regulator and Oil Sentry System Electric Start Inertia Drive Starter Rectifier Regulator Starter Y Motor Ground Ground Figure 8 7 8 9 Section 8 Electrical System and Components Con oi on Star B R OO E Ap AL OO Warning Unit R BW d Y a L d E BW Ne Ground a Oil Sentry B Light Wire Lead Engine T x a Ground B Ignition
117. nd completely free of lubricants The presence of lubricants can cause the flywheel to be over stressed and damaged when the flange screw is torqued to specifications Figure 11 57 Clean and Dry Taper of Crankshaft NOTE Make sure the flywheel key is installed properly in the keyway The flywheel can become cracked or damaged if the key is not installed properly 1 Install the woodruff key into the keyway of the crankshaft Make sure that the key is properly seated and parallel with taper of shaft Section 11 Reassembly Figure 11 58 Clean and Dry Flywheel Hub Zi 4 Install the flywheel onto the crankshaft being careful not to shift the woodruff key Install the drive cup with grass screen if so equipped engaging it with the flywheel Hold in position and install the large flat washer and hex nut Finger tighten to keep cup engaged Figure 11 59 Carefully Align Keyway to Key Use a flywheel holding tool and torque wrench to tighten flywheel nut Torque the hex nut to CS4 CS6 CS8 5 spec 95xxxx 65 N m 48 ft Ib CS8 5 spec 92xxxx CS10 CS12 120 N m 88 ft Ib 11 15 Section 11 Reassembly Figure 11 60 Tightening Flywheel Nut Install Ignition Module 1 Turn the flywheel so the magnet is away from the location where the ignition module will be installed 2 Install the ignition module loosely to the bosses with the two hex flange screws Move the module as far away fro
118. ng point of the piston Temperatures high enough to do this are created by friction which is usually attributed to improper lubrication and or overheating of the engine Normally very little wear takes place in the piston boss piston pin area If the original piston and connecting rod can be reused after new rings are Stuck Broken Rings installed the original pin can also be reused but new piston pin retainers are required The piston pin is included as part of the piston assembly if the pin boss in the piston or the pin are worn or damaged a new piston assembly is required Ring wear failure is usually indicated by excessive oil consumption and blue exhaust smoke When rings fail oil is allowed to enter the combustion chamber where it is burned along with the fuel High oil consumption can also occur when the piston ring end gap is incorrect because the ring cannot properly conform to the cylinder wall under this condition Oil control is also lost when ring gaps are not staggered during installation When cylinder temperatures get too high lacquer and varnish collect on the piston causing the rings to stick which results in rapid wear A worn ring usually takes on a shiny or bright appearance Scratches on rings and pistons are caused by abrasive material such as carbon dirt or pieces of hard metal Detonation damage occurs when a portion of the fuel charge ignites spontaneously from heat and pressure shortly after ignition
119. o Refer to Section 6 Lubrication System for detailed oil check and oil change procedures 1 4 Fuel Recommendations A WARNING Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent General Recommendations Purchase gasoline in small quantities and store in clean approved containers A container with a capacity of 2 gallons or less with a pouring spout is recommended Such a container is easier to handle and helps eliminate spillage during refueling Do not use gasoline left over from the previous season to minimize gum deposits in your fuel system and to insure easy starting Do not add oil to the gasoline Do not overfill the fuel tank Leave room for the fuel to expand Fuel Type For best results use only clean fresh unleaded gasoline with a pump sticker octane rating of 87 or higher In countries using the Research method it should be 90 octane minimum Unleaded gasoline is recommended as it leaves less combustion chamber deposits Leaded gasoline may be used in areas where unleaded is not available and exhaust emissions
120. oling shrouds and clean cooling areas Section 4 Every 100 Hours e Check all fittings and fasteners Section 1 e Clean fuel shut off valve filter Replace if necessary Section 5 e Check muffler screen spark arrestor Clean replace if necessary e Check spark plug condition and gap Replace if necessary Section 8 e Check and adjust valve clearance when engine is cold Section 11 Annually or e Check and adjust idle speed Section 5 Every 300 Hours e Service starter motor drive if so equipped Section 7 e Have combustion chamber decarbonized Perform these maintenance procedures more frequently under extremely dusty dirty conditions 2Have a Kohler Engine Service Dealer perform this service Sto rage To empty the system run the engine until the If the engine will be out of service for two months or tank and system are empty more use the following storage procedure 4 Remove the spark plug Add one tablespoon of 1 Clean the exterior surfaces of the engine engine oil into the spark plug hole Install the plug but do not connect the plug lead Crank the 2 Change the oil while the engine is still warm engine two or three revolutions and then turn it from operation See Change Oil on page 6 2 up against compression when highest pull force or cranking force is required 3 The fuel system must be completely emptied or the gasoline must be treated with a stabilizer to 5 Store the engine in a clean dry plac
121. ort bracket off the two right side valve cover locations or to the cylinder head boss locations based upon the model involved using the two longer screws Torque all the screws to 10 12 N m 88 106 in 1b See Figure 11 79 and 11 80 Figure 11 77 CS4 CS6 Cylinder Air Shroud Mounting Bolt Location 8 Position the spark plug lead within the corresponding cutout in the air shroud Figure 11 79 CS8 5 12 Torquing Valve Cover Screws 11 20 Section 11 Reassembly Figure 11 80 CS8 5 12 Torquing Screws Figure 11 82 CS8 5 spec 92xxxx CS10 CS12 Mounting Left Fuel Tank Support Install Fuel Tank Supports If So Equipped Throttle Lever Wiring 2 Assemble the right fuel tank support and eg c i TM attached electrical components to the crankcase ie Switch and Oil Sentry bosses Mount the throttle control bracket off the ontrol Moauie flywheel side screw as shown in Figures 11 83 CS4 CS6 CS8 5 spec 92xxxx CS10 CS12 and 11 84 Install a flat washer under the head of 1 Attach the left fuel tank support to the crankcase screw on PTO side only Torque screws to bosses with the two hex flange screws and flat CS4 CS6 22 26 N m 195 230 in Ib washers under the heads CS4 and CS6 only CS8 5 spec 92xxxx CS10 CS12 27 31 N m Torque screws to 238 274 in lb CS4 CS6 22 26 N m 195 230 in Ib CS8 5 spec 92xxxx CS10 CS12 27 31 N m The fuel tank support may have the ignition 237 274 i
122. oss of oil control will result Place one end of a rail between the upper side of the expander and groove and wind into position Be careful that the end of rail does not scratch the piston Repeat this procedure with the second rail on the lower side of the expander Position rail gaps 90 from the expander gap and 180 from each other Check the assembly to ensure freedom of movement in the groove See Figure 10 16 Expander Gap Install Top Rail in This Direction Over Expander Gap Start Rail as Indicated el Sl atts Expander Gap Install Top Rail in This Direction Over Expander Gap Start Rail as Indicated Expander Gap Figure 10 16 Oil Control Ring Details 10 12 2 Middle Compression Ring Locate and identify the compression ring with the R marking Using a piston ring expander install this ring in the middle groove with the R up towards the top of the piston See Figure 10 17 Figure 10 17 Middle Compression Ring 3 Top Compression Ring Using a piston ring expander install the compression ring with no markings into the top groove It is symmetrical in design so it may be installed with either side up 4 Stagger position the two compression rings so the end gaps are spaced 120 apart as well as from the expander gap See Figure 10 18 Figure 10 18 Ring Gap Positioning Connecting Rods Inspection and Service Check bearing area big end for excessive wear score mark
123. ower jam nut from turning with a wrench while tightening the top nut to prevent damaging the internal components See Figure 8 55 Reinstall the protective boot over the connection If the solenoid was removed from the starter reinstall it at this time and connect the starter lead to the lower large terminal See Figure 8 56 8 30 Section 8 Electrical System and Components Solenoid Shift Electric Starter The following subsection covers the solenoid shift electric starter Much of the information in the proceeding subsection relates to this type starter also so it is not repeated here A Nippendenso solenoid shift starter is used Operation Solenoid Shift Starter When power is applied to the starter the electric solenoid moves the drive pinion out onto the drive shaft and into mesh with the flywheel ring gear When the pinion reaches the end of the drive shaft it rotates the flywheel and cranks the engine When the engine starts and the start switch is released the starter solenoid is deactivated the drive lever moves back and the pinion moves out of mesh with the ring gear into the retracted position Thrust Washer e ad Retainer Starter FZ Stop Collar 28 Brushes Assembly ie it yl Holder Insulator Commutator End Cap Thru Bolt Figure 8 57 Nippendenso Solenoid Shift Starter 8 31 Section 8 Electrical System and Components Starter Disassembly 8 Pull outward o
124. pecified height as shown in Figure 10 20 Governor Gear Shaft Housing o Surface Figure 10 20 Governor Shaft Position Details Exposed Shaft Length A CS4 CS6 29 2 0 2 mm 1 149 0 007 in CS8 5 CS10 peas 36 0 0 6 mm 1 417 0 023 in 10 13 Section 10 Internal Components Governor Reassembly 1 Install one thrust washer onto the governor shaft followed by the governor gear flyweight assembly 2 Start the retaining clip over the end of the shaft 3 Raise the gear up on the shaft sufficiently to install the other thrust washer and governor regulating pin under the outer fingers of the flyweights See Figure 10 21 Figure 10 21 Installing Governor Gear Assembly 4 Push the governor regulating pin down until the retaining ring locks into place in the shaft groove Governor gear should now be retained on shaft and operate freely Check gear and flyweight operation Gear Reduction Assemblies Clean and inspect all components for wear and damage Remove the housing gasket and dowel pins then clean the gasket surfaces with a cleaning solvent or aerosol type gasket remover Do not nick or scrape the sealing surfaces a Inspect all sprocket gear teeth for excessive wear If teeth are worn to a point the gear s sprocket s and chain CS4 and CS6 should be replaced See Figure 10 22 10 14 NAA Excessive wear Standard Figure 10 22 Sprocket Wear Inspection on CS4
125. pinion assembly from the armature for servicing replacement 12 Clean all parts and the splines on the armature as necessary Figure 8 59 Disassembled Starter 8 32 Brush Replacement The brushes in the starter are part of the starter frame The brush kit Kohler Part No 52 221 01 S contains four replacement brushes and springs If replacement is necessary all four brushes should be replaced 1 Remove brushes from brush holder and remove brush holder from frame Cut the brush lead wire at the edge of the post with a pair of nippers File off burrs on the post The replacement brushes have a solid portion on them which should be crimped on the post Solder the crimped portion to the post Replace the brush holder in the frame and place the brushes in the brush holder Reinstall the springs Starter Service Clean drive lever and armature shaft Apply Kohler electric starter drive lubricant See Section 2 to lever and shaft Starter Reassembly La Za Install the drive pinion onto the armature shaft Slide the stop collar onto the armature shaft below the retaining ring groove Make sure the recessed side of the stop collar is up Position a new retainer in the groove of armature shaft and carefully tighten with a pliers to secure NOTE Always use a new retainer Do not nick or damage armature shaft Use an open end wrench and slide the stop collar up until the recessed section encases t
126. r ignition switch Faulty electric starter or solenoid electric start Pawls not engaging in drive cup retractable start Seized internal engine components Engine Runs But Misses 1 E 3 SEO PT pe Dirt or water in the fuel system Spark plug lead loose Loose wires or connections that intermittently short the kill terminal of ignition module to ground Engine overheated Faulty ignition module Faulty spark plug Carburetor malfunction Engine Will Not Idle 1 eee Ta Restricted fuel cap vent Dirt or water in the fuel system Faulty spark plug Idle fuel adjusting needle improperly set Idle speed adjusting screw improperly set Low compression Stale fuel and or gum in carburetor Engine Overheats 1 T eS Air intake grass screen cooling fins or cooling shrouds clogged Excessive engine load Low crankcase oil level High crankcase oil level Faulty carburetor Engine Knocks 1 2 3 4 Excessive engine load Low crankcase oil level Old improper fuel Internal wear or damage 3 1 Section 3 Troubleshooting Engine Loses Power 1 Low crankcase oil level High crankcase oil level Dirty air cleaner element Dirt or water in the fuel system Excessive engine load Engine overheating Faulty spark plug Low compression Exhaust restriction et eS Engine Uses Excessive Amount Of Oil 1 Incorrect oil viscosity type Overfilled crankcase Clogged breather
127. r pulley is released remove the rope from the pulley Tie a single knot in one end of the new rope Rotate the pulley counterclockwise to pre tension the spring approximately 4 full turns of pulley on CS4 and CS6 approximately 5 full turns of pulley on CS8 5 12 Rotate the pulley until the rope hole in pulley is aligned with the rope guide bushing of the starter housing NOTE Do not allow the pulley spring to unwind Enlist the aid of a helper if necessary Feed the unknotted end of the rope through the rope hole in the starter pulley and rope guide bushing of the housing See Figure 7 5 Figure 7 5 Installing Rope 10 11 12 Tie a slip knot approximately 12 from the free end of rope Hold the pulley firmly and allow it to rotate slowly until the slip knot reaches the guide bushing of the housing Slip the handle onto the rope Tie a single knot at the end of the rope Untie the slip knot and pull on the handle until the rope is fully extended Slowly retract the rope into the starter If the spring is properly tensioned the rope will retract fully and the handle will stop against the starter housing Pawl Dogs Replacement Only partial disassembly of the starter is necessary to replace the pawls Pawl repair kits are available which include the following components CS4 and CS6 Pawl Repair Kit Contains Drive Plate Center Screw Clip Starter Pawl Dog CS8 5 12 Pawl Repair Kit Contain
128. recharge or replace battery as necessary Battery Continuously Charges at High Rate 8 20 I Refer to Figure 8 26 Separate the bullet connector in the red lead from the rectifier regulator Connect an ammeter from the female terminal to the positive terminal of the battery Connect a DC voltmeter from the female terminal to the negative terminal of the battery Leave the other rectifier regulator leads connected in the normal manner Run the engine at 3600 RPM and read the voltage on the voltmeter If voltage is 14 0 volts or more place a minimum load of 5 amps on battery to reduce voltage Observe ammeter NOTE Turn on lights if 60 watts or more or place a 2 5 ohm 100 watt resistor across battery terminals Separate the bullet connectors in the AC white leads Connect an AC voltmeter across the stator leads female terminals With engine running at 3600 RPM measure the AC output from the stator With engine stopped measure the resistance across stator charging leads using an ohmmeter Compare the meter reading obtained against the specified range based on the charging system involved With the engine stopped measure the resistance from each stator lead to ground using an ohmmeter Perform same test as step 1 above If voltage is 14 0 15 0 volts and charge rate increases when load is applied the charging system is OK and the battery was fully charged If voltage is less than 14 0 volts or
129. reen dirty or plugged cooling fins and or cooling shrouds removed will cause engine damage due to overheating Section 5 Fuel System and Governor Description A WARNING Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent Fuel System Components The typical fuel system includes the following components Fuel Tank Shut off Valve with Screen Filter Fuel Tank Inlet Filter Carburetor Fuel Line Operation The fuel from the tank is moved through the shut off valve screen filter and fuel lines by gravity Fuel then enters the carburetor float bowl and is drawn into the carburetor throat There the fuel is mixed with air This fuel air mixture is then burned in the engine combustion chamber Fuel Recommendations General Recommendations Purchase gasoline in small quantities and store in clean approved containers A container with a capacity of 2 gallons or less with a pouring spout is recommended Such a container is easier to handle and helps eliminate spillage during refueling e Do not use gasoline left over from the previous season
130. remove the cover housing See Figures 4 3 and 4 4 Remove the precleaner from the filter element If element is not secured to the air cleaner base with a wing nut remove the filter element and precleaner from the cover housing as an assembly before separating See Figures 4 5 and 4 6 Wash the precleaner in warm water with detergent Rinse the precleaner thoroughly until all traces of detergent are eliminated Squeeze out excess water do not wring Allow the precleaner to air dry Saturate the precleaner with new engine oil Squeeze out all excess oil Install the precleaner over the paper element If the element was not secured with a wing nut some heavy duty air cleaners install the element precleaner assembly small end first into the cover housing Reinstall the air cleaner cover housing assembly Secure with the knob or latches Section 4 Air Intake and Air Cleaner System Figure 4 11 Installing Heavy Duty Cover Housing Figure 4 8 Removing Heavy Duty Precleaner Paper Element Service Every 100 hours of operation more often under extremely dusty or dirty conditions check the paper element Replace the element as necessary Follow these steps 1 Standard Air Cleaner Loosen the air cleaner cover knob and remove the cover Remove the wing nut and lift off the air cleaner element with precleaner Remove the precleaner from the paper element Service the precleaner Heavy Duty Cyclonic Air Cle
131. ricted exhaust 4 Repair replace restricted muffler exhaust system Compression Test Cylinder leakdown tester is a simple and inexpensive A compression test or a cylinder leakdown test may be tester for small engines The tester includes a quick performed to check the condition of an engine disconnect for attaching the adapter hose and a Insufficient compression pressure will result in a holding tool performance loss and may indicate leaking valves or damaged worn piston rings Test the cylinder leakdown as follows Test the compression as follows 1 Run engine for 3 5 minutes to warm it up 1 Check perform valve clearance adjustment 2 Remove spark plug and air filter from engine 2 Start engine if possible and run for 3 5 minutes 3 Rotate crankshaft until piston of cylinder being to warm it up then stop tested is at top dead center TDC of the compression stroke You will need to hold engine 3 Disconnect and ground spark plug lead Remove in this position while testing the spark plug a Ifthe PTO end of the crankshaft is accessible 4 Install adapter and compression tester into spark the holding tool supplied with the tester can plug hole be used Loosen the holding tool screws and expand the opening Slide the tool onto the 5 Move the throttle control to the full wide open crankshaft as close as possible to the PTO position Be sure the choke is off face of the crankcase If the slot in the tool can be aligned with one of the holes
132. rs in well ventilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent A WARNING Cleaning Solvents can cause severe injury or death Use only in well ventilated areas away from ignition sources Flammable Solvents Carburetor cleaners and solvents are extremely flammable Keep sparks flames and other sources of ignition away from the area Follow the cleaner manufacturer s warnings and instructions on its proper and safe use Never use gasoline as a cleaning agent 1 2 A WARNING Carbon Monoxide can cause severe nausea fainting or death Avoid inhaling exhaust fumes and never run the engine in a closed building or confined area Lethal Exhaust Gases Engine exhaust gases contain poisonous carbon monoxide Carbon monoxide is odorless colorless and can cause death if inhaled Avoid inhaling exhaust fumes and never run the engine in a closed building or confined area A WARNING Aa Uncoiling Spring can cause severe injury Wear safety goggles or face protection when servicing retractable starter Spring Under Tension Retractable starters contain a powerful recoil spring that is under tension Always wear safety goggles when servicing retractable starte
133. rs and carefully follow instructions in the Retractable Starter Section 7 for relieving spring tension Explosive Gas can cause fires and severe acid burns Charge battery only in a well ventilated area Keep sources of ignition away Explosive Gas Batteries produce explosive hydrogen gas while being charged To prevent a fire or explosion charge batteries only in well ventilated areas Keep sparks open flames and other sources of ignition away from the battery at all times Keep batteries out of the reach of children Remove all jewelry when servicing batteries Before disconnecting the negative ground cable make sure all switches are OFF If ON a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or gasoline vapors are present 4h CAUTION K Electrical Shock can cause injury Do not touch wires while engine is running Electrical Shock Never touch electrical wires or components while the engine is running They can be sources of electrical shock Engine Identification Numbers When ordering parts or in any communication involving an engine always give the Model Specification and Serial Numbers of the engine The engine identification numbers appear on a decal or decals affixed to the engine shrouding See Figure 1 1 An explanation of these numbers is shown in Figure 1 2 Model Designation Model CS6ST for example C designates Command
134. s Figure 9 21 Cover Panel Mounting Screws Upper Mounting Screw Figure 9 22 CS8 5 spec 92xxxx CS10 and CS12 Upper Right Hand Mounting Screw 2 Pull the blower housing off Figure 9 23 Removing the Blower Housing Remove Right Fuel Tank Bracket if so equipped Switch Bracket Electric Starter and Housing Cover Panel Assembly 1 Disconnect the wiring harness bullet connectors for the oil sentry and ignition module Remove the mounting screw securing the ground lead See Figures 9 24 and 9 25 Disconnect the rectifier regulator lead connections if used Figure 9 24 CS8 5 spec 92xxxx CS10 and CS12 Ground Lead Location Figure 9 25 CS8 5 spec 95xxxx Ground Lead Location 2 Remove the two front fuel tank bracket not used on CS8 5 spec 95xxxx mounting screws attaching the throttle lever mechanism switch and oil sentry light bracket On electric start engines the electrical control panel housing will also be included Note the washer used on PTO side screw only See Figure 9 31 Section 9 Disassembly Figure 9 26 CS4 CS6 Right Tank Bracket Mounting Details Figure 9 27 CS8 5 spec 92XXXX CS10 and CS12 Right Tank Mounting Bracket Details Electric Start Engines Only 3 Remove the two screws securing the control panel and mounting bracket for the electrical components See Figure 9 28 Figure 9 28 Removing Control Panel Screws 9 7 Section 9 Disasse
135. s 1 Drive Plate Center Screw Pawl Dog Spring Clip Starter Pawl Dog Disassembly A WARNING Spring Under Tension Do not remove the center screw from starter until the spring tension is released Removing the center screw before releasing spring tension or improper starter disassembly can cause the sudden and potentially dangerous release of the spring Follow these instructions carefully to ensure personal safety and proper starter disassembly Make sure adequate face protection is worn by all persons in the area 1 Release recoil spring tension by CS4 CS6 Loosen the center screw approximately 1 turn Rotate the pulley against spring tension until the pulley rope hole with knot is adjacent to outlet in housing Lift up the slack in rope between pulley and housing slowly allow the pulley to unwind releasing the spring tension Count the number of rotations for reassembly later CS8 5 12 Rotate the pulley against spring tension until the cutout in pulley is adjacent to outlet in housing Lift up the slack in rope through the cutout and slowly allow pulley to unwind releasing spring tension Count the number of rotations for reassembly later Section 7 Retractable Starter Unscrew the center screw and lift off the drive plate The center screw will be captured by the clip around the shoulder on backside of plate Note the positions of the pawls and pawl springs CS8 5 12 only before removing Remove p
136. s running and side clearances Refer to Section 1 Specifications Tolerances and Special Torque Values Replace rod if scored or excessively worn Governor Gear Inspection and Service Inspect the governor gear teeth look for any evidence of worn chipped or cracked teeth Check the condition of flyweights and pivot pins for wear or damage Movement must be free but not sloppy If any of these conditions or problems are noted the governor gear must be replaced Removal The governor gear is held onto the governor gear shaft by a small retaining clip located near the center section of the gear within the flyweight assemblies The mounting of the governor gear also retains the governor regulating pin and thrust washer in place The gear can be removed by using two small screwdrivers and carefully applying upward pressure from beneath the gear and against the bosses in the closure plate Do not pry against or nick damage the gasket surface of the closure plate See Figure 10 19 Figure 10 19 Governor Gear Removal Section 10 Internal Components Governor Shaft Position In Closure Plate The governor shaft is pressed into the closure plate to a specified height and normally should not require removal or servicing The position is critical to proper operation of the governor gear and the entire governor assembly If for any reason the mounted position of the governor shaft is changed or affected it must be reset to the s
137. shaft on CS4 CS6 Figure 9 59 Removing Screw from Crankshaft on CS8 5 CS12 5 Remove the reduction components a On CS4 and CS6 leave the chain intact and pull out the two sprockets as an assembly See Figure 9 60 Note the position of the wave washer and remove it from the output shaft Also remove the thrust washer from the end of the crankshaft See Figure 9 61 9 14 Figure 9 60 Removing Sprockets and Chain on CS4 CS6 Figure 9 61 Thrust Washer Behind Crank Sprocket on CS4 CS6 b On CS8 5 12 remove the crankshaft gear counter gear and output shaft gear assembly See Figure 9 62 Figure 9 62 CS8 5 CS12 Disassembled Reduction Assembly 6 Check the reduction system bearings for wear or excessive play See Figure 9 63 If bearing removal is required use an internal bearing puller to remove the housing bearings An arbor press should be used for removal of the others Figure 9 63 Checking Bearing Play 6 1 Reduction Assemblies CS4 and CS6 1 Remove any drive coupling and the key from the reduction output shaft Clean the shaft and keyway of any burrs damage 2 Remove the four reduction cover mounting screws Use a flat pan to catch oil when the screws are removed and the cover is separated See Figure 9 64 Figure 9 64 Loosening Reduction Housing Cover Screws 3 Remove the cover from the reduction housing assembly Section 9 Disassembly Figure 9 65 Removing Co
138. sic Engine Tests Crankcase Vacuum Test A partial vacuum should be present in the crankcase when the engine is operating at normal temperatures Pressure in the crankcase normally caused by a clogged breather can cause oil to be forced out at oil seals gaskets or other available spots Crankcase vacuum is best measured with water manometer or vacuum pressure tester see Section 2 Complete instructions are provided in the kits Test the crankcase vacuum following the instructions with the engine running at high idle speed above 3500 RPM Section 3 Troubleshooting 1 The engine should have a minimum of 4 in of 2 Refer to the following chart for possible causes vacuum A vacuum less than 4 in is usually due and solutions to internal wear or a bad gasket or seal allowing air to leak into the crankcase A pressure is usually due to a problem with the breather Low No Crankcase Vacuum or Pressure in Crankcase Possible Cause en 1 Crankcase breather clogged or inoperative 1 Disassemble breather clean parts thoroughly reassemble and recheck pressure Seals and or gaskets leaking Loose or Replace all worn or damaged seals and gaskets improperly torqued fasteners Make sure all fasteners are tightened securely Use appropriate torque values and sequences when necessary Piston blowby or leaky valves Confirm by Recondition piston rings cylinder bore valves and inspecting components valve guides Rest
139. stem The recommended 7 N m 62 in lb valve to rocker arm clearance for both intake and exhaust is 0 1 mm 0 004 in 5 Use a new Champion RN14YC Champion RC14YC Kohler Part No 66 132 01 S or equivalent spark plug 6 Set gap to 0 76 mm 0 030 in Install the spark plug in the cylinder head and torque to 20 N m 177 in 1b Figure 11 73 CS4 CS6 CS8 5 spec 95xxxx Adjusting Valve to Rocker Arm Clearance c Adjust clearance as required by loosening the locknut and turning the adjuster Turn clockwise to decrease clearance Figure 11 75 Installing and Torquing New Spark Turn counterclockwise to increase Plug clearance On CS8 5 spec 92xxxx CS10 CS12 Hold the adjuster up when making adjustment 11 19 Section 11 Reassembly Install Valve Cover 1 Install a new valve cover gasket onto the cylinder head 2 Install the valve cover assembly CS4 CS6 CS8 5 spec 95xxxx Install the four hex flange screws and torque to 10 12 N m 88 106 in 1b Figure 11 76 Installing Cylinder Air Shroud 7 Install the cylinder air shroud Matching the alignment slot on the ends with the corresponding raised groove in the crankcase CS4 CS6 Install and torque the single M6x1 0 mounting screw to 10 N m 88 5 in Ib See Figure 11 77 Figure 11 78 CS4 CS6 CS8 5 spec 95xxxx Torquing Valve Cover Screws CS8 5 12 Install the four valve cover screws Mount the air cleaner base supp
140. stops rotating and the drive pinion is held in the retracted position by the Figure 8 31 Testing Hold In Coil Solenoid Contact anti drift spring Continuity Starter Drive Service Inertia Drive Electric Starters Every 300 hours of operation or annually whichever This subsection covers the operation troubleshooting occurs first clean and lubricate the splines on the and repair of the inertia drive permanent magnet starter drive shaft If the drive pinion is worn or has electric starter chipped or broken teeth it must be replaced It is not necessary to completely disassemble the starter to service the drive components Service the drive as follows 0 Retaining 07 Ring Drive Pinion Hn Figure 8 32 Inertia Drive Starter Spring J Spring Holder Collar Post Terminals Figure 8 34 Drive Components Red White Cg 1 Remove the starter from the engine 2 Push back the spring holder collar to expose the retaining ring on the armature shaft which secures the drive components Remove the retaining ring using either of the Kohler retaining ring removal tools Figure 8 33 Solenoid Details 8 25 Section 8 Electrical System and Components Figure 8 35 Removing Retaining Ring Figure 8 37 Installing Drive Components 3 Remove the spring holder collar spring and 8 drive pinion assembly from the armature shaft Figure 8 36 Disassembled Drive Components Install a new ret
141. sure the engine is level when filling checking and changing the oil Change the oil as follows 1 To keep dirt and debris out of the engine clean the area around the oil fill check plug before removing it 2 Remove the oil drain plug and oil fill check plug Be sure to allow ample time for complete drainage 3 Reinstall the drain plug Make sure it is tightened to 17 6 N m 13 ft Ib torque 4 Fill the crankcase with new oil of the proper type up to the point of overflowing the filler neck Refer to Oil Type on page 6 1 Always check the level before adding more oil 5 Reinstall the oil fill check plug and tighten securely Section 6 Lubrication System NOTE To prevent extensive engine wear or damage always maintain the proper oil level in the crankcase Never operate the engine with the oil level below the low oil level Figure 6 6 CS8 5 12 Right Oil Fill Level Plug Location Figure 6 4 CS4 CS6 Right Oil Fill Level Plug Location Figure 6 7 CS8 5 12 Left Oil Fill Level Plug Location Figure 6 5 CS4 CS6 Left Oil Fill Level Plug Location 6 3 Section 7 Retractable Starter A WARNING Spring Under Tension Retractable starters contain a powerful recoil spring that is under tension Always wear safety goggles when servicing retractable starters and carefully follow instructions in this section for relieving spring tension Pawl Repair Kit Starter o Handle Drive
142. t with the cylinder wall Use of a commercial cutting cooling agent is recommended 2 With the lower edge of each stone positioned even with the lowest edge of the bore start drill and honing process Move the hone up and down while resizing to prevent the formation of cutting ridges Check the size frequently NOTE Keep in mind the temperatures caused by honing may cause inaccurate measurements Make sure the bore is cool when measuring 10 4 3 When the bore is within 0 064 mm 0 0025 in of desired size remove the coarse stones and replace with burnishing stones Continue with the burnishing stones until within 0 013 mm 0 0005 in of desired size and then use finish stones 220 280 grit and polish to final size A crosshatch should be observed if honing is done correctly The crosshatch should intersect at approximately 20 off the horizontal Too flat an angle could cause the rings to skip and wear excessively too steep an angle will result in high oil consumption See Figure 10 7 Figure 10 7 Cylinder Bore Crosshatch after Honing 4 After resizing check the bore for roundness taper and size Use an inside micrometer telescoping gauge or bore gauge to take measurements The measurements should be taken at three locations in the cylinder at the top middle and bottom Two measurements should be taken perpendicular to each other at each of the three locations See Figure 10 6 Clean Cylinder Bore A
143. tate the pulley clockwise 1 2 to 1 full turn this will ensure the spring is disengaged from the starter housing Carefully lift the pulley out of the recoil housing while reaching through the spokes of the pulley to keep the spring from coming out of the pulley Wearing adequate eye face protection carefully remove the spring from the pulley cavity Clean all parts including the starter spring cavity in pulley and recoil housing of all old grease and dirt Inspect all parts for wear or damage and replace as required Figure 7 8 Retractable Starter Pawl Assembly Details Figure 7 9 Disassembled Retractable Starter Reassembly A WARNING Spring Under Tension 1 Do not remove the center screw from starter until the spring tension is released Removing the center screw before releasing spring tension or improper starter disassembly can cause the sudden and potentially dangerous release of the spring Follow these instructions carefully to ensure personal safety and proper starter disassembly Make sure adequate face protection is worn by all persons in the area 7 4 Generously lubricate the recoil spring with a commercially available bearing grease Engage the outer spring hook into the pulley slit opening then carefully wind the spring counterclockwise into the drum of the pulley from larger to smaller diameter Carefully install pulley into recoil housing engaging the spring hook with starter ho
144. tator Ground Plug Ground Ground Rectifier Regulator 10 Amp Charging System Recoil Start Only Oil Sentry System Figure 8 22 8 17 Section 8 Electrical System and Components NOTE Observe the following guidelines to avoid damage to the electrical system and components e Make sure the battery polarity is correct A negative ground system is used e Make sure all ground connections are secure and in good condition e Disconnect both battery cables before doing electrical welding on the equipment powered by the engine Also disconnect other electrical accessories in common ground with the engine e Prevent the stator AC leads from touching or shorting while the engine is ruming This can damage the stator Stator The stator is mounted on the crankcase behind the flywheel Should the stator have to be replaced follow the procedures in Section 9 Disassembly Rectifier Regulator The rectifier regulator is connected to the engine with a matching wiring harness containing a plug in connector Grounded through the wiring harness the rectifier regulator is secured to the equipment in a suitable location with two mounting screws To replace it disconnect the plug and remove the two mounting screws NOTE When installing the rectifier regulator push the wiring harness plug into the regulator receptacle until it locks into place The rectifier regulator converts the AC voltage coming from th
145. the Ignition Module Screws Remove Stator and Protective Shield If So Equipped 1 Remove the mounting screw and protective shield over the stator leads See Figure 9 52 Figure 9 49 Using Puller to Remove Flywheel on CS8 5 CS12 Figure 9 50 Use External Type Puller to Remove Flywheel on CS4 CS6 3 Remove the flywheel key from keyway 9 12 Section 9 Disassembly 2 Remove the four hex flange shoulder screws securing the stator to the crankcase Remove the stator and pull the wires through the opening in the casting See Figure 9 53 Figure 9 55 Removing Reduction Housing Screws on CS8 5 CS12 3 Pull the reduction housing off the closure plate Figure 9 53 Removing Mounting Screws and Stator Remove Reduction Assembly If So Equipped 2 1 Reduction Assembly 1 Remove any drive coupling and the key from the reduction assembly output shaft Clean the shaft and keyway of any burrs damage 2 Remove the mounting bolts securing the reduction system housing onto the crankcase Place a flat pan or towel under the housing to Figure 9 56 Removing Reduction Housing on CS4 catch any remaining oil See Figures CS6 9 54 and 9 55 a Figure 9 57 Removing Reduction Housing on Figure 9 54 Removing Reduction Housing Screws CS8 5 CS12 on CS4 CS6 9 13 Section 9 Disassembly 4 Remove the screw and washer securing the crankshaft sprocket gear Figure 9 58 Removing Screw from Crank
146. this time Connect an adequate air source 70 100 psi to the tester Turn the regulator knob in the increase clockwise direction until the gauge needle is in the yellow set area at the low end of the scale Connect tester quick disconnect to the adapter Note the gauge reading and listen for escaping air at the carburetor intake exhaust outlet and crankcase breather Check your test results against the table below Leakdown Test Results Air escaping from crankcase breather sese eee bp AUT escaping om exhaust Syste ea Air escaping from CADUC essenin isi Gauge reading in low green Zone errata Gauge reading in moderate yellow Zone sss sese sese Gauge reading in high red zone mentar lid 3 4 PEP Defective rings or worn cylinder walls is Defective exhaust valve A Defective intake valve T Piston rings and cylinder in good condition E Engine is still usable but there is some wear present Customer should start planning for overhaul or replacement seen Rings and or cylinder have considerable wear Engine should be reconditioned or replaced Section 4 Air Cleaner and Air Intake System Air Cleaners General These engines are equipped with one of three air cleaner configurations the standard dual element air cleaner assembly an optional heavy duty cyclonic air cleaner assembly or a third design which uses an oiled solid foam element The first two styles have a rep
147. three of the fasteners securing the closure plate to the crankcase Check crankshaft end play using a dial indicator End play must be 0 0 0 2 mm 0 0 0 007 in If end play is not within the specified range shims are available in the following thicknesses 0 1 mm 0 0039 in 0 2 mm 0 007 in and 0 3 mm 0 011 in for CS4 and CS6 0 1 mm 0 0039 in 0 2 mm 0 007 in 0 3 mm 0 011 in and 0 4 mm 0 015 in for CS8 5 12 When proper end play has been established install all screws and torque in the sequence shown in Figure 11 22 or 11 23 On all other models install the hex flange screws securing the closure plate to the crankcase See Figure 11 22 or 11 23 Torque Screws to 22 N m 195 in Ib Figure 11 22 CS4 CS6 Closure Plate Torque Sequence Torque Screws to 30 N m 265 in Ib Figure 11 23 CS8 5 12 Closure Plate Torque Sequence Install Reduction System If So Equipped 2 1 Reduction Assemblies 1 If any bearings were removed press the new bearing s into the housing so the manufacturer s marks are visible Pre lube the bearings with engine oil on installation See Figures 11 24 and 11 25 Figure 11 24 CS4 CS6 Installing Bearing S 4 Section 11 Reassembly Figure 11 25 CS8 5 12 Installing Bearing Install a new oil seal into the cover to a depth of 2 mm 0 08 in See Figure 11 26 Apply a light coating of lightweight lithium grease to lip of seal 2mm 0
148. tion If spark is now present the control module or float switch is faulty Test the control module step 4 and the float switch step 5 If there is still no spark test the ignition module step 6 If the indicator lamp flashes during cranking the control module is functioning proceed to step 5 If the lamp was not flashing initially but did flash in step 4a the control module is good but the ignition switch is probably faulty Test the float switch step 5 and the ignition switch step 7 With the oil at the proper level no continuity should have been indicated After the oil was drained continuity should have been indicated If test results are other than specified remove the closure plate from the engine and remove the float switch for further testing 5a and 5b a Ifthe lead wire is bare allowing it to short repair with electrical tape or replace float switch Switch continuity should be as indicated in Figure 8 3 If not replace it Section 8 Electrical System and Components 6 Set an ohmmeter to the Rx1K or Rx10K scale and zero Connect one ohmmeter lead to the kill lead black white terminal and connect 6 Resistance of the ignition module should be 13 5 18 0 K ohms Engine Will Not Start Continuity Figure 8 3 the other lead into the spark plug cap a Remove the cap from the spark plug lead and test the resistance of the cap alone If resistances are other than specified re
149. ue E II eE EE EE ES 7 6 Num 5 6 ft lb ESO ZOO TI nidos 10 8 Num 8 ft lb Eso spec 9010000 2400 REM casio d iii 16 5 N m 12 1 ft 1b CISS PET E IHH REM aerea 19 66 N m 14 5 ft Ib EA AP e o PE ER 19 66 N m 14 5 ft Ib COI 5pc 94 IIx O 2000 BREM aaa 22 6 N m 16 7 ft Ib Col spec 941 6x 2400 RPM cisrtscdi aaa iciaera ticas 24 9 N m 18 4 ft lb Hydro 12 75 2400 RPM pts o 30 6 N m 22 6 ft lb Bore O E N E 56 0 mm 2 20 in E O ANA T 66 0 mm 2 60 in Eo E o E ene ee 75 0 mm 2 95 in Bs A A E en ene ene reer 78 0 mm 3 07 in A aaea E E A EE A E E A AAE 78 0 mm 3 07 in Y A E A E E E TEE OE E E 85 0 mm 3 35 in Stroke E A o E E TE AE E EET 50 0 mm 1 97 in LER 00 A E E EET 57 0 mm 2 44 in ojo ee Oy E enn E S 63 0 mm 2 48 in ETT A E A 63 0 mm 2 48 in Displacement En T EE E 123 cc 7 50 cu in A A A reas ase ceca ea eon E A A ET T 171 cc 10 43 cu in C38 DSC 09d 0 castes CU A aa 251 cc 15 30 cu in Be E o A T 301 cc 18 37 cu in o A o H 301 cc 18 37 cu in pe hs ee un OT UE O RO PA 357 cc 21 79 cu in Compression Ratio Ss EP O VASA e 1 AE T A E AT 8 3 1 NO SE E EE TEE E AE E E EEE aces 8 5 1 SD cae tesserae soca erence cosas eee scacencuesecteao amnasoscunoncuasoceat 8 3 1 EEE e T 8 1 1 A rr nr Sll Weight Approx CoE e A ias 15 4 kg 35 1b Eo 05 AAA uo 26 kg 57 2 1b En Ss 0 0 0 0 9 OIR E R 31 9 kg 70 5 lb L E A TE EE EAE E A ETEA 31 9 kg 70 5
150. urately inspected and gauged for wear or damage There are many commercially available cleaners that will quickly remove grease oil and grime from engine parts When such a cleaner is used follow the manufacturer s instructions and safety precautions carefully Make sure all traces of the cleaner are removed before the engine is reassembled and placed into operation Even small amounts of these cleaners can quickly break down the lubricating properties of engine oil Typical Disassembly Sequence The following sequence is suggested for complete engine disassembly The sequence can be varied to accommodate options or special equipment Disconnect spark plug lead Turn fuel shut off valve to off position Drain oil from crankcase Remove muffler and heat shield assembly Remove air cleaner assembly Remove fuel tank and fuel tank support Remove external governor throttle and choke linkage 8 Remove carburetor 9 Remove retractable starter 10 Remove blower housing 11 Remove right fuel tank bracket switch bracket electric starter and housing cover panel assembly 12 Remove left fuel tank bracket 13 Remove governor lever and throttle linkage 14 Remove valve cover breather air shroud cylinder head assembly and push rods oe a i 15 Remove flywheel 16 Remove ignition module 17 Remove stator and protective shield 18 Remove reduction assembly 19 Remove closure plate 20 Remove balance
151. using tab See Figure 7 10 NOTE Rotating pulley counterclockwise slightly will assist engagement Install the pawl springs CS8 5 12 only and pawls onto pawl studs of pulley Figure 7 10 Assembling Starter Pulley to Housing oy Mount drive plate over pawls onto pulley aligning the actuating slots in plate with the raised sections on each drive pawl Torque the screw to 5 6 N m 44 53 in 1b Rotate the pulley by hand and check operation See Figure 7 11 Section 7 Retractable Starter Figure 7 11 Torque Center Mounting Screw 6 Tension the spring and install the rope and handle as outlined in Steps 6 through 12 under Rope Replacement 7 Install the recoil starter to engine blower housing but do not fully tighten the mounting screws 8 Pull out on recoil handle rope to engage the pawls to the drive cup hold engaged and torque the mounting screws to 5 5 N m 47 7 in 1b See 4 Figure 7 3 7 5 Section 8 Electrical System and Components This section covers the operation service and repair NOTE Do not clean the spark plug in a machine of the electrical systems and electrical system which uses abrasive grit Some grit could components remain on in the spark plug and enter the engine causing extensive wear and Spark Plug damage Engine misfire or starting problems are often caused l l l by a spark plug that is in poor condition or has an 3 Check the gap using a bens feeler gauge
152. valve stems in guides See Figure 10 10 for valve details and specifications Figure 10 10 Valve and Valve Seat Measuring Locations CS4 CS6 Valve Specifications Dimension Time 19 0 mm 0 75 in 22 0 mm 0 87 in PB Stem Diameter 5302 i 55mm 0 22in c 64 5 mm 254 in A S T E 7 mm 0 0276 in 7 mm 0 067 in T Face Seat Angle Insert O O Valve Guide Guide Inside Diameter 5 5 mm 0 22 in 5 5 mm 0 22 in Stem to Guide Clearance 0 04 0 06 mm 0 0016 0 002 in 0 06 0 08 mm 0 002 0 003 in Valve Clearance 0 1 mm 0 004 in 0 1 mm 0 004 in Valve Seat Contact Width Std 0 7 mm 0 03 in 0 7 mm 0 03 in Limit 1 7 mm 0 067 in 1 7 mm 0 067 in Valve Stem Bend Limit 0 01 mm 0 0004 in 0 01 mm 0 0004 in 10 6 Section 10 Internal Components CS8 5 CS10 CS12 Valve Specifications 32 0 mm 1 26 in 27 0 mm 1 06 in pa EX Stem Diameter 5 948 5 963 mm 5 940 5 955 mm Apt msi mz Face Seat Limit 1 4 mm 0 055 in 1 4 mm 0 055 in Face Seat Angle Insert Area f 90 OS o Valve Guide Guide Inside Diameter 6 0 6 012 mm 0 2362 0 2367 in 6 0 6 012 mm 0 2362 0 2367 in Stem to Guide Clearance 0 037 0 064 mm 0 045 0 072 mm 0 00146 0 00252 in 0 00177 0 00283 in Valve Clearance 0 1 mm 0 004 in 0 1 mm 0 004 in Valve Seat Contact Width 0 7 mm 0 03 in 0 7 mm 0 03 in 1 7 mm 0 067 in 1 7 mm 0 067 in Valve Stem Bend Limit 0 01 mm 0 0004 in 0 01 mm 0 0004 in
153. ver from Reduction Housing 4 Remove the ring gear output shaft assembly See Figure 9 66 Figure 9 66 Removing Ring Gear Shaft 5 If the reduction housing requires removal from the closure plate remove the four mounting screws and separate the two castings Figure 9 67 Removing Housing Mounting Screws 9 15 Section 9 Disassembly 6 Remove the gasket s and clean the respective sealing surfaces with a cleaning solvent or aerosol type gasket remover Do not nick or scrape the sealing surfaces Figure 9 68 Separate Reduction Housing from Closure Plate Figure 9 69 CS4 CS6 6 1 Reduction Assembly Components 7 Check the reduction system bearings for wear or excessive play See Figure 9 63 If bearing removal is required use an internal bearing puller to remove the housing bearings An arbor press should be used for removal of the others 6 1 Reduction Assemblies CS8 5 CS10 and CS12 1 Remove any drive coupling and the key from the reduction assembly output shaft Clean the shaft and keyway of any burrs damage 2 Remove the six reduction cover mounting screws See Figure 9 70 9 16 Figure 9 70 Removing Housing Cover Screws 3 Remove the cover from the reduction assembly Place a flat drain pan or shop towel under the housing to catch any remaining oil Figure 9 71 Removing Housing Cover 4 Pull the output shaft gear assembly out of the housing cover or closure plate See Fi
154. volt power supply and two test leads Connect one lead to the flat spade S start terminal on the solenoid Momentarily connect the other lead to the lower large post terminal See Figure 8 28 When the connection is made the solenoid should energize audible click and the plunger retract Repeat the test several times If the solenoid fails to activate it should be replaced NOTE DO NOT leave the 12 volt test leads connected to the solenoid for any time over what is necessary for performing each of the individual tests Internal damage to the solenoid may otherwise occur Momentary Connection Only Figure 8 28 Testing Pull In Coil Plunger Actuation Test 2 Solenoid Pull In Coil Contact Continuity Test Use an ohmmeter set to the audible or Rx2K scale and connect the two ohmmeter leads to the two large post terminals Perform the preceding test 1 and check for continuity See Figure 8 29 The ohmmeter should indicate continuity if no continuity is indicated the solenoid should be replaced Repeat test several times to confirm condition 8 24 12 volt Test Leads Momentary Connection Only VOM Leads A Figure 8 29 Testing Pull In Coil Solenoid Contact Continuity Test 3 Solenoid Hold In Coil Function Test Connect one 12 volt test lead to the flat spade S start terminal on the solenoid and the other lead to the body or mounting surface of the solenoid Then manually push the plunger
155. w screws Torque the screws to 20 24 N m bearing s into the housing or cover so the 177 212 in Ib manufacturers marks are visible Pre lube the bearings with engine oil on installation 2 Install a new oil seal into the cover to a depth of 2 mm 0 08 in See Figure 11 40 Apply a light coating of lightweight lithium grease to the lip of the seal Figure 11 42 Torquing Housing Mounting Screws 6 Lubricate the teeth of the ring gear output shaft assembly with oil and install Engage teeth with splines on crankshaft and slide assembly into the bearing bore in the housing Figure 11 40 Oil Seal Installation Depth 3 Pre lube all bearing surfaces with engine oil 4 Install anew gasket between the reduction housing and closure plate Figure 11 43 Installing Ring Gear Output Shaft Assembly Figure 11 41 Installing Gasket and 6 1 Reduction Housing 11 11 Section 11 Reassembly 7 Install a new gasket dry onto the housing and attach the cover with the four mounting screws so the Oil Fill and Oil Level port locations are positioned exactly as shown Torque the screws to 20 24 N m 177 212 in lb Figure 11 44 Installing Cover Assembly Figure 11 45 Torquing Cover Mounting Screws 8 Add oil Use the same weight oil as in the engine Fill through the fill plug hole on top until oil is even with bottom of level plug hole on side Capacity 0 15 liter 5 02 fl oz 9 Install the
156. with the knob Figure 11 115 Installing Outer Air Cleaner Cover and Knob Install the Retractable Starter 1 Install the retractable starter using the hex flange screws Finger tighten the mounting screws only 2 Pull the rope handle to engage the pawls centering the starter to the drive cup Hold in this position and torque the mounting screws to 6 5 7 N m 57 62 in Ib Section 11 Reassembly Prepare the Engine for Operation The engine is now reassembled Before starting or operating the engine be sure to do the following 1 Make sure all hardware is properly torqued 2 Make sure the oil drain plugs and oil sentry control unit are tightened securely 3 Fill the crankcase with the correct oil Refer to the oil recommendations and procedures in the General Information and Lubrication System sections Figure 11 116 Engage Pawls and Torque Mounting 4 Reconnect the rectifier regulator if so equipped Screws Testing the Engine It is recommended that the engine be operated on a test stand or bench prior to installation on a piece of equipment Install Muffler 1 Install anew exhaust gasket onto the exhaust studs 2 Install the muffler and heat shield assembly 1 Install the hex flange screw with a flat washer through the front support bracket into the crankcase boss Set the engine up on a test stand Check gas and oil levels Start the engine and run for 5 10 minutes between idle and midran
157. xed to the flywheel e A TCI module which mounts on the engine crankcase e An engine stop switch which grounds the module to stop the engine e A spark plug Electric Start Engines also contain e An electric starter motor e A 3 position starter switch e A starter solenoid e Wiring harness with fuse e Rectifier Regulator Section 8 Electrical System and Components Operation As the flywheel rotates and the magnet assembly moves past the ignition module a low voltage is induced in the primary windings of the module When the primary voltage is precisely at its peak the module induces a high voltage in its secondary windings This high voltage creates a spark at the tip of the spark plug This spark ignites the air fuel mixture in the combustion chamber The timing of the spark is automatically controlled by the module Therefore other than periodically checking replacing the spark plug no maintenance timing or adjustments are necessary or possible with this system In the event starting problems should occur which are not corrected by replacing the spark plug refer to the Troubleshooting Guide for trouble analysis procedures Oil Sentry Control System Most engines are equipped with an Oil Sentry oil monitor control system When the oil level within the crankcase falls below the safe level the engine stops automatically Unless the oil level is brought up to the proper level the oil warning light w
158. y Light Wire Lead gt Ignition N Y Module Oil s Sentry U Gauge Ground a Ground Ground ug Ground O MN 4h CD L Q sanery Starter Solenoid Electronic Ignition System 1 6 Amp Charging Pa e 7 System Rectified Only Oil Sentry System 1 Electric Start Inertia Drive Starter Ground Ground Figure 8 11 8 11 Section 8 Electrical System and Components Oil Warning Unit BW d L 0 Bw Ground A B Light Oil V Sentry 19 T Gauge E Oil Sentry Y y OUH ietonail Models Spark Electronic Ignition System Oil Plug Sentry System with Indicator Light Grond Some Models Recoil Start Figure 8 12 y Engine Oil Ground Sentry TM l Light Ground l i Ignition Wire Lead Module Q Ground Sentry Gauge d N Spark i Ground amp Plug Ground Ground Electronic Ignition System 3 Amp Charging System Rectified Only Oil Sentry TM System Electric Start Solenoid Shift Starter Figure 8 13 8 12 Stop Switch BW Engine FA gt Ground Gr und Ignition Module Stator Ground Main Switch Wire Color BW B R_ Rw off O FO Battery Starting Motor Ground Section 8 Electrical System and Components Oil Warning Unit Engine Ground b Oil Sentry Gauge B Ignition W W H Module Oil a Als w w B R IR Stator W W ww a r s L Ele

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