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SERVICE MANUAL COMMAND PRO CS SERIES 4

1. CS8 5 spec 92 aste ete ee ens Fuel Tank Fuel Tank Fastener Screws Torque Ignition Spark Plug Type NGK Champion tinea Champion oce e entier ee Reda s Spark Plug Gap Spark Plug 2 2 Ignition Module Air Gap 66 005 66 015 2 5986 2 5990 HEURE 75 005 75 015 mm 2 9530 2 9533 in 78 00 78 02 mm 3 0709 3 0717 in 78 00 78 02 3 0709 3 0717 mE 85 00 85 02 mm 3 3465 3 3472 in Section 1 Safety and General Information 56 005 56 015 mm 2 2049 2 2053 in E He PRO 56 15 mm 2 211 in MO EM 66 15 mm 2 604 in MS i 75 15 mm 2 959 in mo 78 65 mm 3 096 in cies EN CER 78 65 mm 3 096 in 85 65 mm 3 372 in 0 05 0 002 20 N m 177 in Ib eT 50 36 ft Ib 0 1 0 004 5 3 N m 47 7 lb 16 141 in Ib aS 65 N m 48 ft Ib BOUE READER 65 N m 48 ft Ib cR 120 N m 85 ft Ib MMC 120 N m 85 ft Ib E 8 12 N m 71 106 in Ib 5 8 hex Kohler Part No 66 132 01 S Aum om 0 76 mm 0 030 in 20 N m 14 7 ft Ib 177 in Ib T 0 4 0 6 mm 0 015 0 023 in www mymowerparts com Kohler Engine Parts C
2. 15 995 16 000 mm 0 6297 0 6299 in CS8 5 spec 95xxxx 17 995 18 000 mm 0 7084 0 7086 in CS8 5 92 19 995 20 000 mm 0 7872 0 7874 in 5510512 ie nib tu toti 19 995 20 000 mm 0 7872 0 7874 in Max Wear Limit GS4 S6 cai dnd Aue ieee i 15 98 mm 0 6291 in CS8 5 JSK e ceste 17 98 mm 0 7079 in CS8 5 spec 92 19 98 mm 0 7866 in ed acetic tbe dg due 19 98 mm 0 7866 in Top Compression Ring to Groove Side Clearance 0 04 0 08 mm 0 0016 0 003 in Middle Compression Ring to Groove Side Clearance 0 02 0 06 0 0008 0 0024 0 03 0 07 0 0012 0 0028 Top Compression Ring Gap E E 0 2 0 4 mm 0 008 0 016 in C98 5 speC 95X00 eee a a 0 25 0 4 mm 0 010 0 016 in CS8 5 spec 92 0 2 0 4 mm 0 008 0 016 in tap edu iaa e Er RO HE re D di o Oca 0 2 0 4 mm 0 008 0 016 in CS Ve EUN 0 25 0 4 mm 0 010 0 016 in 1 14 www mymowerparts com 2 DS NH 2 Da NH Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 1 Safety and General Information Middle Compression Ring End G
3. Engine Uses Excessive Amount Of Oil Incorrect oil viscosity type Overfilled crankcase Clogged breather Worn or broken piston rings Worn cylinder bore Worn valve stems valve guides DOU Go mm 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 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 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 Checkthe air cleaner cover and base for damage or indications of improper fit or sealing 3 2 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 Check the carbu
4. Water Vacuum Pressure Cylinder Leakdown Ignition System Tester Contact your Kohler Distributor for price and availability Ignition System Tester Spark Tester 25 455 01 S can be used to test the ignition system on all Kohler engines except those that have CD ignition Water Manometer Vacuum Pressure Tester The water manometer 25 761 02 S and vacuum pressure tester 25 761 22 5 are used for testing crankcase vacuum They can also be used for testing exhaust back pressure and for adjusting some gaseous fuel regulators Cylinder Leakdown Tester 25 761 05 S Oylinder Leakdown Tester is a valuable alternate to a compression test on these engines By pressurizing the combustion chamber from an external air source this tool can determine if valves or rings are leaking Instructions for using this tester are found on page 3 4 of this manual Rocker Arm Crankshaft Tool If you don t have a spanner wrench to lift the rocker arms or to turn the crankshaft you can make a tool for doing this out of an old junk connecting rod Kohler Part No D enses feces NU 3226 DEN Obtain locally 25 761 02 5 oram 25 761 22 S DER EN NER 25 761 05 S E 25 455 01 S Find a used connecting rod from a 10
5. Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 10 Internal Components CS8 5 CS10 CS12 Valve Specifications Head Diameter 32 0 mm 1 26 in 27 0 mm 1 06 in Stem Diameter 5 948 5 963 mm 5 940 5 955 mm 0 2342 0 2348 in 0 2339 0 2344 in Length 88 1 mm 3 47 in 87 9 mm 3 46 in Face Seat Width 0 7 0 9 mm 0 0276 0 0354 in 0 7 0 9 mm 0 0276 0 0354 in Face Seat Limit 1 4 mm 0 055 in 1 4 mm 0 055 in Face Seat Angle Insert Area 90 90 Valve Stem Bend Limit 0 01 mm 0 0004 in 0 01 mm 0 0004 in 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 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 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
6. Figure 9 64 Removing Cover from Reduction Housing 4 Remove the ring gear output shaft assembly See Figure 9 65 Figure 9 62 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 63 Figure 9 65 Removing Ring Gear Shaft 5 Ifthe reduction housing requires removal from the closure plate remove the four mounting screws and separate the two castings Figure 9 63 Loosening Reduction Housing Cover Screws 3 Remove the cover from the reduction housing assembly Figure 9 66 Removing Housing Mounting Screws 9 15 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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 67 Separate Reduction Housing from Closure Plate Figure 9 68 CS4 CS6 6 1 Reduction Assembly Components 7 Checkthe reduction system bearings for wear or excessive play See Figure 9 62 If bearing removal is required use an internal bearing puller to remove the housing bearings An arbor press should be used for removal o
7. Section 3 Troubleshooting Kohler Part No 25 761 05 S is a relatively simple inexpensive leakdown tester for small engines The tester includes a quick disconnect for attaching the adapter hose and a holding tool Test the cylinder leakdown as follows 1 Run engine for 3 5 minutes to warm it up 2 Remove spark plug and air filter from engine 3 Rotate crankshaft until piston of cylinder being tested is at top dead center of the compression stroke You will need to hold engine in this position while testing a If the PTO end of the crankshaft is accessible the holding tool supplied with the tester can be used Loosen the holding tool screws and expand the opening Slide the tool onto the crankshaft as close as possible to the PTO face of the crankcase If the slot in the tool can be aligned with one of the holes on the PTO face find a bolt of appropriate length and thread size Insert the bolt through the slot and thread it into the selected hole to prevent the tool from moving Tighten the screws to lock the holding tool onto the crankshaft If a PTO face hole is not accessible tighten the screws to lock the holding tool onto the crankshaft Insert the end of a 3 8 breaker bar into the slot so the handle of the breaker bar is perpendicular to the crankshaft b If the 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 h
8. www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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 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 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
9. Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 uae 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 Maintenance free operation Strong spark output Stable controlled ignition timing The system consists of the following components Amagnet assembly which is permanently affixed to the flywheel ATCI module which mounts on the engine crankcase An engine stop switch which grounds the module to stop the engine Aspark plug Electric Start Engines also contain An electric starter motor A3 position starter switch Astarter solenoid Wiring harness with fuse 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 t
10. Bids Engine is still usable but there is some wear present Customer should start planning for overhaul or replacement Rings and or cylinder have considerable wear Engine should be reconditioned or replaced www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Go Back CS4 12 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 replaceable 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 1 Standard Dual Element Air Cleaner 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 compon
11. Ib Figure 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 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 11 Reassembly Figure 11 53 Torquing Mounting Screws Install Stator and Wire Shield If So Eq 1 uipped Align stator holes with mounting bosses of 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 to 5 8 N m 44 70 in Ib Figure 11 55 Stator Screws Torque Sequence 11 14 2 Route the stator leads along the formed channel and out through the hole in the crankcase casting 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 Ib See Figure 11 56 Figure 11 56 Installing Shield 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
12. Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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 Connectthe fuel line to the shut off valve and secure with the clamp Figure 11 109 CS8 5 12 Adjusting Governor Install Fuel Tank CS4 CS6 CS8 5 spec 92xxxx CS10 CS12 1 Ifthe 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 as shown and thread it into the throttle control bracket Torque the four M8 screws to 27 31 N m 238 274 in Ib and the single M6 screw to 8 12 N m 71 106 in Ib See Figure 11 112 11 28 www mymowerparts com Kohler Engi
13. The correct float height is determined by the design of the inlet needle and float There is no provision for physical adjustment 9 Checkto 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 Lift out the float and inlet needle Slide the inlet needle and clip off of the float tab www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 d Check components for contamination wear or damage See Figure 5 6 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 Grooved Wear 2 Figure 5 6 Inlet Needle and Seat Wear Damage 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 damage it as it is not available as a service part a Useathin flat blade screwdr
14. 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 If there is fuel at the tip of the spark plug fuel is a Disconnect and ground the spark plug lead reaching the combustion chamber b Close the choke on the carburetor c Crank the engine several times If there is no fuel at the tip of the spark plug d Remove the spark plug and check for fuel at check for fuel flow from the fuel tank Test 3 the tip Check for fuel flow from the tank to the If fuel does flow from the line check for a carburetor problem in the carburetor dirt gum varnish etc a Remove the fuel line from the inlet fitting of the carburetor If fuel does not flow from the line check for a b Hold the line below the bottom of the tank clogged fuel cap vent inlet filter shut off valve Open the shut off valve and observe flow Screen filter and or fuel line 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 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 5 2 www mym
15. 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 3a across stator leads using an ohmmeter 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 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 is 0 08 0 26 ohms the stator is OK If the resistance is 0 ohms the stator is
16. lf 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 direction Test Conclusion 1 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 If spark is now present check for a shorted lead in the kill circuit or a faulty switch step 7 If there is still no spark go to step 3 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 iginition 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 igintion 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 t
17. shorted Replace stator If the resistance is infinity ohms stator is open Replace stator 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 8 15 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 8 Electrical System and Components Battery General A 12 volt battery not furnished with a minimum current rating of 160 CS4 CS6 or 200 CS8 5 12 cold cranking amps should be sufficient for cranking most electric start engine models The actual cold cranking requirement depends on engine size application and starting temperatures Cranking requirements increase as temperatures decrease and battery capacity shrinks Refer to the operating instructions of the equipment this engine powers for specific battery requirements If the battery charge is not sufficient to turn over the engine recharge the battery Battery Maintenance Regular maintenance is necessary to prolong battery life A WARNING Explosive Gas Batteries produce explosive hydrogen gas while being charged To prevent
18. 13 Installing Piston Using a Ring Compressor Install the connecting rod cap to the connecting 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 3 Lubricate cylinder bore piston piston pin and 1 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 2 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 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 Lubricate the camshaft bearing surfaces and cam lobes as well as the camshaft bore in the crankcase with engine oil www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 3 Rotate the crankshaft to TDC so the timing mark dimple on crankgear smaller gear is in the 4 o clock position Install the camshaft into the crankcase aligning the timing marks on the tw
19. 2 engine two or three revolutions and then turn it up against compression when highest pull force or 3 The fuel system must be completely emptied or cranking force is required the gasoline must be treated with a stabilizer to prevent deterioration If you choose to use a 5 Store the engine in a clean dry place 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 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 1 Safety and General Information F 347 00 13 661 A 5 16 24 qty 5 14 mm 551 deep 384 25 15 128 321 50 Straight PTO 12 657 143 00 5 630 162 00 6 378 Spark Plug RS 5 719 14 962 Oil Fill Oil Drain Plug 5 Mounting Face 9 0 354 dia 2 9 0x14 0 354x 551 slot aty 2 Dimensions in millimeters Inch equivalents shown Figure 1 5 Typical Engine Dimensions CS4 and CS6 1 6 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 1 Safety and General Information 452 90 17 831 7 tug don 127 00 E 5 256 5 000 dia 5 16 24 aty 4 18 mm 709 deep 3 8 16 aty 4 454 00 17 874 445 85
20. HP or larger engine Remove and discard the rod cap If itis a Posi Lock rod you will also need to remove the studs If itis a Command rod you will need to grind off the aligning steps so the joint surface is flat Find a 1 long capscrew with the correct thread size to match the threads in the connecting rod Obtain a flat washer with the correct 1 0 to slip on the capscrew and an O D of approximately 1 Kohler Part No 12 468 05 S can be used if you don t have the right size on hand Assemble the capscrew and washer to the joint surface of the rod as shown in Figure 2 1 Figure 2 1 Rocker Arm Crankshaft Tool 2 1 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 2 Special Tools Flywheel Holding Tool A flywheel holding tool must be used to remove and reinstall the flywheel The flywheel holding tool shown below is illustrated in template form on page 2 3 and may be fabricated locally for use in the field The tool is not available from Kohler Figure 2 2 Using Flywheel Holding Tool 2 2 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Template for Flywheel Holding Tool Material needed 9 mm or 3 8 thick steel 25 mm or 1 wide 14 2 3 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 2 Special Tools 2 4 www mymowerparts com Kohler Engine Parts Call K amp T 606
21. 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 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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 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
22. O D New CSE CSG 52 2 047 CS8 5 spec 95 52 2 047 CS8 5 SpeC 92XXxX s e d nh 80 mm 3 149 in 80 mm 3 149 in Max Wear Limit 554 6 Pe edie Oa utes ea n edad 52 05 mm 2 0492 in 88 5 SDeC ODXOO0 Rote iu 52 05 mm 2 0492 in CS8 5 spec 92 80 05 mm 3 1515 in 52510 12 80 05 mm 3 1515 in PTO End Main Bearing Journal O D New 294 050 att ato tele bor emi tut tated 52 mm 2 047 in CS8 5 spec 95 52 2 047 98 5 Spec 920000 totae CR rade 72 mm 2 834 in CS 10 12 1 5 nt Sum ai 72 mm 2 834 in Max Wear Limit CSE tail ttu LEE otn t 52 05 mm 2 0492 in 288 5 5 95 00 IR pene pen 52 05 mm 2 0492 in CS8 5 spec 92 72 05 2 836 in 910 12 inde e Med ette 72 05 mm 2 836 in Connecting Rod Journal O D New ue n 27 969 27 984 mm 1 011 1 017 in CS8 5 spec 95xxxx 31 969 31 984 mm 1 2586 1 2592 in 288 5 Spec tt edet E EE 35 969 35 984 mm 1 4161 1 4167 in GST0 12 Octo tes cca dette ius a raha 35 969 35 984 mm 1 4161 1
23. 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 11 6 and 11 7 Note Verify that correct installation has been made at this time www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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 7 CS8 5 12 Installing Hitch Pin Install Crankshaft 1 Carefully slide the flywheel end of the crankshaft through the main ball bearing and seal Figure 11 10 Piston Installation Details Figure 11 8 Installing Crankshaft www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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 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 6 Figure 11
24. 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 Service solid foam element Replace if necessary Change Section 6 e Replace air cleaner element Section 4 e Remove cooling shrouds and clean cooling areas Section 4 Every 100 Hours Check all fittings and fasteners Section 1 Clean fuel shut off valve filter Replace if necessary Section 5 Check muffler screen spark arrestor Clean replace if necessary Check spark plug condition and gap Replace if necessary Section 8 Check and adjust valve clearance when engine is cold Section 11 Annually or Check and adjust idle speed Section 5 Every 300 Hours Service starter motor drive if so equipped Section 7 Have combustion chamber decarbonized Perform these maintenance procedures more frequently under extremely dusty dirty conditions 2 a Kohler Engine Service Dealer perform this service Storage If the engine will be out of service for two months or To empty the system run the engine until the tank more use the following storage procedure and system are empty 1 Clean the exterior surfaces of the engine 4 Remove the spark plug Add one tablespoon of engine oil into the spark plug hole Install the plug 2 Change the oil while the engine is still warm from but do not connect the plug lead Crank the operation See Change on page 6
25. Spring AY XN Drive Pawl Spring Pulley 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 KOHLER 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 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 7 Retractable Starter 2 Pullthe 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 Ibs 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 2 Pullthe 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 Pull the knot end out of the handle untie the knot and slide the handle off 4 Hold the pulley firmly and untie the slip knot Allow the pulley to rotate slowly as the spring tension is released 7 2 5 When all spring tension on the st
26. a chance to reach normal operating temperatures Replace corroded valves www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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 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 sho
27. 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 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 8 16 2 Keep the cables terminals and external surfaces of the battery clean A build up of corrosive acid or grime on the external surfaces can cause the battery to self discharge Self discharge occurs rapidly when moisture is present 3 Wash the cables terminals and external surfaces with a mild baking soda and water solution Rinse thoroughly with clear water NOTE Do allow the baking soda solution to enter the cells as this will destroy the electrolyte Battery Test To test the battery you will need a DC voltmeter Perform the following steps See Figure 8 20 1 Connect the voltmeter across the battery terminals 2 Crank the engine If the battery drops below 9 volts while cranking the battery is discharged or faul
28. 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 contact 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
29. 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 r Expander Gap Install Top Rail in This Direction Over Expander Gap Start Rail as Indicated 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 marking Using a piston ring expander install this ring in the middle groove with the 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 marks running and side clearances Refer to Section 1 Specificatio
30. brush holder Reinstall the springs Starter Service Clean drive lever and armature shaft Apply Kohler electric starter drive lubricant Part No 52 351 01 S to lever and shaft Starter Reassembly 1 2 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 the retaining ring and locks the collar into position See Figure 8 51 Figure 8 51 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 52 Figure 8 52 Installing Armature 8 27 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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 ea
31. caused by localized hot spots resulting from blocked cooling fins or from inadequate or contaminated lubrication Measure the cylinder bore using an inside micrometer Figure 10 5 Camshaft Journal Checking or bore gauge See Figure 10 6 Compare readings with specifications in Section 1 Camshaft Journal Specifications CS4 CS6 14 95 mm 0 589 in CS8 5 C910 15 965 15 990 mm 0 6285 0 6295 in 10 3 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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
32. 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 Return Spring Engine in Operation H 1H r ee P pde Decomp Weight Figure 10 1 ACR Operation Details 10 1 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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 engines without ACR 6 Engines with ACR can be sta
33. 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 battery as necessary Starter 1 Check fuse condition Does Not Wiring 2 Clean corroded connections and tighten loose connections Energize 3 Replace wires in poor condition and with frayed or broken insulation Starter Switch 1 Checkthe switch or solenoid operation If starter cranks normally or Solenoid replace the faulty components Battery 1 Checkthe specific gravity of battery If low recharge or replace battery as necessary 1 Check for corroded connections poor ground connection 1 Check for excessively dirty or worn brushes and commutator Starter Clean using a coarse cloth not emery cloth Energizes 2 Replace brushes if excessively or unevenly worn Tunis 1 Make sure the clutch or transmission is disengaged or placed in Slowly ue neutral This is especially important on equipment with hydrostatic drive The transmission must be exactly in neutral to prevent resistance which could keep the engine from starting 2 Checkfor seized engine components such as the bearings connecting rod and piston Transmission or Engine 8 17 www mymowerparts com Koh
34. 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 housing and electric starter cover panel www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 11 Reassembly Figure 11 2 Installing Bearing in Closure Plate Figure 11 4 Installing Governor Shaft 3 Usea 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 2mm 0 08 in Figure 11 3 Installing Oil Seal Install Governor Cross Shaft 1 Install the governor shaft seal with the 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 3 Figure 11 5 Installing Outer Washer Install the second flat washer onto the shaft
35. it must be reset to the specified height as shown in Figure 10 20 Governor Gear Shaft Housing Surface Figure 10 20 Governor Shaft Position Details Exposed Shaft Length A CS4 CS6 29 2 0 2 mm 1 149 0 007 CS8 5 CS10 36 0 0 6 mm 1 417 20 023 in CS12 10 13 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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 Excessive Figure 10 21 wear Standard Figure 10 22 Sprocket Wear Inspection on CS4 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 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 Clean and inspect al
36. 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 a new 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 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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 Ib 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 coa
37. on boot only to prevent damage to spark plug lead Figure 9 1 Disconnecting Spark Plug Lead 9 1 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 9 Disassembly Turn Fuel Shut Off Valve to Off Position 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 Drain Plug 2 Allow ample time for the oil to drain from the crankcase 3 Onengines 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 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 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 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 9 Disassemb
38. points to remember when servicing piston rings 1 Ifthe 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 reuse 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 15 Measuring Piston Ring Side Clearance Figure 10 14 Measuring Piston Ring End Gap 10 11 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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 4 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 loss of oil control will result Top Ring 2nd Ring Has R Marking Cil Ring Place one end of a rail
39. qt 5510442 ect Oen 1 1 L 1 2 U S qt Fuel Tank Capacity 94 CSG i iet aia P RI 3 9 L 4 1 U S qt GS8 5 Sp8C 5 eter tei eee tpe eee 6 0 L 6 3 U S qt CS8 5 spec 92 6 9 L 7 3 U S qt 6 9 L 7 3 U S qt Angle of Operation Maximum At Full Oil Level All Directions 20 Air Cleaner Base Bolt Torque 2 n e ated tet Ca i eere HE eese 5 8 Nem 44 71 in Ib Base Nut Torque CSF CSG E 5 8 N m 44 71 in Ib CS8 5 spec 95xxxx noaie aia aa EE a aa 5 8 N m 44 71 in Ib 698 5 6 92 i iced dide nee dentes 10 12 N m 88 106 in Ib CSTO M ME 10 12 N m 88 106 in Ib Camshaft End PI8y iie cie e ede ee P eee deinde e 0 05 mm 0 0020 in Bore 1 0 Max Wear Limit 594 0590 mui tet fc E et 14 95 mm 0 583 in CSB 5812 st teh aee pi rell at ettet tese 15 95 mm 0 627 in Camshaft Bearing Surface O D Max Wear Limit 96 Ae rU e ILLE 15 05 0 592 16 05 mm 0 649 in Carburetor Fuel Bowl Retaining Screw Torque iui bett 7 N m 62 in Ib 99 524 o oS 9 N m 79 in Ib Throttle Choke Plate Screws 2 1 5 2 5 13 22 in Ib Connecting Rod Connecting Rod Fastener Torqu
40. spark plug to 20 N m 177 in Ib Wire Gauge Spark Plug Ground Electrode 0 76 mm 0 030 in Gap Figure 8 1 Servicing Spark Plug 8 1 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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 an 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 www mymowerparts com
41. the positions of the pawls and pawl springs CS8 5 12 only before removing Remove parts 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 Ibs Rotate the pulley by hand and check operation See Figure 7 7 7 3 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 7 Retractable Starter Figure 7 7 Drive Plate and Pawl Details 8 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 approximately 5 full turns on CS8 5 12 Recoil Spring Pulley and or Housing Replacement Disassembly Figure 7 8 Retractable Starter Pawl Assembly Details 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 ten
42. 1 66 Tightening Cylinder Head Screws Figure 11 67 Cylinder Head Screws Torquing Sequence Install Push Rods Rocker Arms Studs and Rocker Shaft NOTE Push rods should always be installed in the original location 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 11 17 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 11 Reassembly Figure 11 68 Installing Push Rods 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 Ib See Figure 11 69 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 Figure 11 70 CS4 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 Figures 11 71 and 11 72 Figure 11 71 CS8 5 spec 92xxxx CS10 CS12 Assembling Rocke
43. 12 Install and tighten the two thru bolts 13 Make sure the dust cover is in place on solenoid Figure 8 59 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 58 Figure 8 58 Installing Thru Bolts 8 29 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 8 Electrical System and Components 8 30 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Go Back CS4 12 Section 9 Disassembly 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 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
44. 17 553 423 50 16 673 70 00 2 756 165 10 6 500 dia 916 24 qty 2 18 mm 709 deep 146 08 5 751 dia 18 mm 709 dee 99 110 00 4 331 dia 90 50 z 3 563 195 50 7 697 103 00 4 055 417 50 Straight 16 437 118 34 4 659 99 00 298 00 11 732 8 071 Spark Plug Oil Oil Drain Plug Mounting Face NS 11 00 433 dia qty 2 11 00x27 433x1 063 slot aty 2 65 00 2 559 16 00 630 37 00 1 457 62 00 102 00 I 2 441 4 016 Figure 1 6 Typical Engine Dimensions CS8 5 spec 92xxxx CS10 and CS12 Dimensions in millimeters Inch equivalents shown 1 7 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 1 Safety and General Information 431 00 16 968 156 00 6 142 165 1 6 50 110 4 33 424 00 16 693 90 50 103 00 3 563 1 4 055 5 16 24 18 mm 709 deep aty 2 3 8 16 18 mm 709 deep 195 50 5 16 24 18 mm 709 deep aty 4 aty 4 7 697 380 00 14 961 183 00 7 205 11 00x27 00 433x1 063 slotted hole aty 2 7 11 433 hole 2 16 00 630 433 hole aty 2 00 2 32 21500 2d Dimensions in millimeters 7 Inch equivalents shown Figure 1 7 Typical Engine Dimensions CS8 5 spec 95xxxx 1 8 w
45. 2 all except models Figure 11 87 CS8 5 spec 92xxxx CS10 CS12 C312 60H72 Governor Lever Installation 512 50HZ Figure 11 90 CS8 5 spec 92xxxx CS10 CS12 3 Connect the throttle link and the shorter end of Spring Hole Position 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 CS8 5 spec 95xxxx all except 50HZ G model Figure 11 91 CS8 5 spec 95xxxx Spring Hole Position Figure 11 88 CS8 5 spec 95xxxx CS10 CS12 Governor Linkage Connected to Governor Arm Hole Position CS6 all except 60HZ Figure 11 89 CS4 CS6 Spring Hole Position 11 23 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 11 Reassembly Connect Electrical Leads and Install Electric Starter If So Equipped 7 5 92 10 12 Mount the electric starter with the control panel and solenoid attached onto the crankcase Install and torque the two hex flange screws to 30 N m 265 in Ib 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 Figu
46. 2xxxx CS10 and CS12 Upper Right Hand Mounting Screw 2 Pull the blower housing off Figure 9 20 CS4 CS6 Silver Screw with Ground Lead Figure 9 23 Removing the Blower Housing 9 6 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 9 Disassembly 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 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 On CS8 5 spec 95xxxx remove the two screws securing the control panel and mounting bracket for the electrical components See Figure 9 28 F
47. 4167 in Max Wear Limit niae e eene ade 27 9 mm 1 098 in 58 eras 31 9 1 2559 CS8 5 spec 92 35 9 mm 1 4134 in QS10 12 irit eb eiie ent einn 35 9 mm 1 4134 in Crankshaft Runout Either 80 0 02 mm 0 0008 in itte doa 0 04 0 0016 1 12 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Cylinder Bore Cylinder Bore I D New stessi CSO cise CS8 5 spec 95xxxx CS8 5 spec 92xxxx C919 Max Wear Limit COSA isi essen ries n in t RE d 90 So fic scan CS8 5 spec 95 CS8 5 spec 92xxxx CSIO stt Fete fett tu e ted gor EI Max Out of Round Cylinder Head Cylinder Head Bolt Torque CS4 6S0 t sinet a Re Max Out of Flatness Electric Starter Thru Bolt Case Torque CS8 5 12 tiunt eec th nere Mounting Bolts To Block Torque OSB 5212 inis sese eta Flywheel Flywheel Retaining Screw Torque 054 056 need e e ce etd CS8 5 spec 5
48. 678 9623 or 606 561 4983 Go Back CS4 12 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 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 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 Faulty cylinder head gasket Faulty carburetor Engine Starts Hard 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 Engine Will Not Crank drive is engaged Battery if equipped is discharged Safety interlock switch is engaged Loose or faulty wires or connections Fault
49. 900 ENTUM 65 900 mm 74 898 tee bere 77 898 mm 77 898 VEREOR 84 898 mm mu 0 2 0 4 mm 0 008 0 016 in d 0 25 0 4 mm 0 010 0 016 in rom 0 2 0 4 mm 0 008 0 016 in 0 2 0 4 mm 0 008 0 016 in mem 0 25 0 4 mm 0 010 0 016 in 0 2 0 4 0 0079 0 0157 dne dat 0 2 0 7 mm 0 0079 0 028 in 2 2037 2 2043 in 2 597 2 598 in 2 9509 2 9527 in 3 0691 3 0708 in 3 0691 3 0708 in 3 3446 3 3464 in 2 2 2 20 in 2 60 in 2 9487 in 3 0669 in 3 0669 in 3 3424 in 2 ec peste 0 015 0 040 mm 0 0006 0 0016 in ped 0 002 0 066 mm 0 0001 0 0026 in PES 10 88 in Ib C 30 N m 22 ft Ib 5 22 N m 195 Ib 22 N m 195 Ib DENS 65 N m 48 ft Ib 48 ft Ib uM 6 5 N m 57 in Ib ee 7 Nm 62 in Ib 10 N m 88 in Ib 7 62 in Ib www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 1 Safety and General Information Throttle Control Throttle Control Lever Fastener Torque ae cc 7 9 62 80 Ib 9 11 N m 80 97 Ib Valve Cover Valve Cover Fastener Torque CS4 10 N m 88 in Ib 23 biet c et dte tud 11 N m 97 in Ib Valves and Valve Lifters Intake Valve Stem to Va
50. Before installing the flywheel make sure the crankshaft taper and flywheel hub are clean dry and 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 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 11 Reassembly 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 Figure 11 58 Clean and Dry Flywheel Hub 2 Install the flywheel onto the crankshaft being careful not to shift the woodruff key 3 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 4 Useaflywheel holding tool and torque wrench to 1 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 Figure 11 60 Tightening Flywheel Nut Install Ignition Module Turn the flywheel so the magnet is away from the location where the igniti
51. Components This section covers the operation service and repair of the electrical systems and electrical system components Spark Plug Engine misfire or starting problems are often caused by a spark plug that is in poor condition or has an improper gap setting This engine uses the following spark plugs Type The original spark plug is an NGK BPRAES The Champion equivalent of that spark plug is RN14YC The service replacement is Champion RC14YC Kohler Part No 66 132 01 S Equivalent alternate brand spark plugs can also be used 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 3 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 a new plug as necessary 1 Before removing the spark plug clean the area around the base of the plug to keep dirt and debris out of the engine 2 Remove the plug and check its condition Replace the plug if worn or reuse is questionable NOTE Do clean the spark plug in a machine which uses abrasive grit Some grit could remain on in the spark plug and enter the engine causing extensive wear and damage 3 Check the gap using a wire feeler gauge Adjust the gap to 0 76 mm 0 030 in by carefully bending the ground electrode See Figure 8 1 4 Reinstall the spark plug into the cylinder head Torque the
52. Drive Plate Center Screw Clip Starter Pawl Dog CS8 5 12 Repair Kit Contains 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
53. FOR SAFETY MAINTENANCE SPECS AND ADJUSTMENTS FOR SALES AND SERVICE IN US CANADA CALL 1 800 544 2444 KOHLERENEIMES KOHLER CO KOHLER WI USA Ref Small Off Road Engines Figure 1 2 Explanation of Engine Identification Numbers CS8 5 engines have been produced in two different 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 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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 RECOMMEHOED SAE VIZCOZITY GRADEER riri Figure1 3 Viscosity Grades Table NOTE Using other than service class SG SH SJ or higher oil or extendin
54. 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 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 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 9 Disassembly 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 the air cleaner base gasket from the two mounting studs Pull the carbu
55. 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 44 51 ft Ib 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 24 177 212 in Ib See Figures 11 30 and 11 31 Figure 11 32 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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 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 CS4 CS6 10 88 5 in Ib Figure 11 33 CS8 5 12 Installing Counter Gear and CS8 5 12 30 N m 265 in Ib Output Shaft Gear Assembly 5 Install the dowel pins into their respect
56. Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 CoMMAND CS SERIES 4 12 HP HORIZONTAL CRANKSHAFT KOHLER Smees ro RUN C www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Contents Section 1 Safety and General Information Section 2 Special Tools e PPP Section 3 Troubleshooting Section 4 Air Cleaner and Air Intake System 1 22 Section 5 Fuel System and Governor da EOUS UE REIS CE E YR UR Section 5 Lubrication System Section 7 Retractable Starter Section 8 Electrical System and Components Section 9 BIET E1101 e AREE tom Section 10 Internal Componenlis c rre rn nnne Xon tiu ouo nnmnnn nnnm san nan nau nanan Section 11 Reassenibly I aad www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Go Back CS4 12 Section 1 Safety and General Information Safety Precautions To insure 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 WARNING Warning is used to indicate the presen
57. Make sure all fasteners are tightened securely Use appropriate torque values and sequences when necessary 3 Piston blowby or leaky valves Confirm by Recondition piston rings cylinder bore valves and inspecting components valve guides 4 Restricted exhaust Repair replace restricted muffler exhaust system Compression Test 5 Move the throttle control to the full wide open A compression test or a cylinder leakdown test may be position Be sure the choke is off performed to check the condition of an engine Insufficient compression pressure will result in a 6 Crank engine over using recoil or electric starter performance loss and may indicate leaking valves or and check results damaged worn piston rings Standard Compression Pressure Test the compression as follows 400 600 kPa 57 85 psi with ACR mechanism in operation 1 Check perform valve clearance adjustment Cylinder Leakdown Test 2 Start engine if possible and run for 3 5 minutes to A cylinder leakdown test can be a valuable alternative warm it up then stop to a compression test especially on engines with ACR By pressurizing the combustion chamber from an 3 Disconnect and ground spark plug lead Remove external air source you can determine if the valves or the spark plug rings are leaking and how badly 4 Install adapter and compression tester into spark plug hole 3 3 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983
58. Mounting Screws 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 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 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 clos
59. Parts Call K amp T 606 678 9623 or 606 561 4983 Section 1 Safety and General Information 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 engine S designates slanted cylinder configuration and 6 designates horsepower A suffix letter designates a specific version as follows A Model No Command Engine Slanted Cylinder Horsepower 4 4HP 6 6 HP 8 5 8 5 HP 10 10HP 12 12HP Spec No Engine Model Code Model 54 56 58 5 300 CS10 CS12 CS8 5 250 cc 911509 Serial No Year Manufactured Code Year 1998 1999 2000 28 23701265 Variation of Basic Engine Factory Code 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 IMPORTANT ENGINE INFORMATION THIS ENGINE MEETS U S EPA PHASE 1 AND 2000 2001 CALIFORNIA EMISSION CONTROL REGULATIONS FOR SORE FAMILY MODEL NO SPEC NO DISPL CC SERIAL NO CS6ST 911509 2823701265 REFER TO OWNER S MANUAL
60. Remove Crankshaft 1 Carefully remove the crankshaft from the crankcase Figure 9 87 Removing Governor Cross Shaft with Inner Washer Remove Flywheel End Main Bearing and Figure 9 85 Removing Crankshaft Oil Seal 1 Remove the front oil seal from the crankcase Remove Governor Cross Shaft See Figure 9 88 1 Remove the hitch pin and plain washer from the governor cross shaft See Figure 9 86 Figure 9 88 Oil Seal Removed Figure 9 86 Removing Governor Cross Shaft Hitch Pin 2 Remove the cross shaft out through the inside of the crankcase 9 20 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 9 Disassembly 2 Remove the front main bearing from the crankcase using an arbor press See Figure 9 89 Figure 9 89 Removing Main Bearing with Press Remove Balance Shaft Bearing 1 Remove the balance shaft bearing using an internal bearing puller 9 21 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 9 Disassembly 9 22 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Go Back CS4 12 Section 10 Internal Components This section covers the operation inspection and repair reconditioning 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
61. Some engines are equipped with a 3 or 18 amp rectified non regulated charging system The rectifier is connected to the engine with a matching wiring harness Grounded through the wiring harness the rectifier module is secured to the equipment with a single mounting screw The rectifier converts the AC voltage coming from the stator to DC voltage only The 3 amp rectifier is shown in Figure 8 18 DC Voltmeter Figure 8 18 3 Amp Rectifier Rectifier Regulator afl Plug in Connector Connect Tester Leads to Female Bullet Connector Red Wire Ground Lead Black Stator Leads White Figure 8 19 Connections for Testing Charging Systems 8 14 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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 recharge or replace battery as necessary 1 No Charge to Battery Battery Continuously Charges at High Rate Refer to Figure 8 19 Separate the bullet 1 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
62. all K amp T 606 678 9623 or 606 561 4983 Section 1 Safety and General Information Ignition Module Mounting Screws 2 10 N m 88 in Ib Stator Mounting Screw Torque ooh ond nd di Seb ta us frutta 5 8 N m 44 70 in Ib Muffler Muffler Torque Flange Nuts amp Bracket Bolts CIA CS dE CEP 8 12 N m 71 106 in Ib CS8 5212 eit tib dio aii ere dites eas 18 22 159 195 in Ib Cil Sentry Oil Sentry Float Switch Torque sssssssseeenee 10 N m 88 in Ib Piston Piston Rings and Piston Pin Piston to Piston Pin Clearance 6524056 OR ee eed siue Hs 00 0 002 0 018 mm 0 0001 0 0007 in 288 5712 coge i CL FAT eee 0 004 0 020 mm 0 0002 0 0008 in Piston Pin Bore 1 0 New CS4 0S0 iud Hae t EC d du ted aad dl 16 002 16 013 mm 0 6300 0 6304 in CS8 5 spec 95xxxx nennen nnne 18 004 18 015 mm 0 7088 0 7093 in CS8 5 SPEC 9230000 1 tec e nd a 20 004 20 015 mm 0 7876 0 7880 in CS10 12 iet i tr pre RE 20 004 20 015 mm 0 7876 0 7880 in Max Wear Limit CS4 S65 teens 16 03 0 6311 CS8 5 spec 5 e dads doa 18 03 mm 0 7098 in CS8 5 spec 92 20 03 0 7886 in 5510 12 1 2 et aec a e ak eet ee 20 03 mm 0 7886 in Piston Pin O D New CS4 0S06
63. 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 78 9 18 Figure 9 78 Removing Governor Gear 6 Remove the crankshaft seal See Figure 9 79 Figure 9 79 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 80 Bearing Removal Using a Press www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 9 Disassembly Remove Balance Shaft If So Equipped 1 Pull the balance shaft out of the crankcase Figure 9 83 Removing Connecting Rod Bolts NOTE carbon ridge is present at the top of the Figure 9 81 Removing Balance Shaft cylinder bore use 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 84 Figure 9 82 Removing Camshaft and Tappets 2 Remove and mark the tappets Figure 9 84 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 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 9 Disassembly
64. 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 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
65. ance specifications If the crankshaft turns easily and noiselessly and there is no evidence of scoring grooving etc on the races or bearing surfaces the bearings can be reused Figure 10 4 Cam Lobe Checking Inspect the crankshaft keyways If worn or chipped L Di ion B Dimension replacement of the crankshaft will be necessary CS4 CS6 22 0 0 05 mm 22 0 0 05 Inspect the crankpin for score marks or metallic 0 87 0 002 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 40 002 1 03 0 002 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
66. 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 FuelLine 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 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
67. ap C84 6S6 658 5 5 95 ii deter ee erectae eden CS8 5 spec 92 65 E E ER ici RU EE Oil Control Ring End Gap 054 056 098 5 12 Piston Thrust O D CS8 5 spec 95 CS8 5 spec 92xxxx aT RT Max Wear Limit SA iuit entia ed veda CS8 5 Spet ObXXXX CS8 5 spec 92xxxx GS 10 o niii tc ic QU EUN N A Piston Thrust Face to Cylinder Bore Running Clearance CS4 C 86 aset dac ce nen T Pe ea Leeds C98 5 125 ssi ttes tea Reduction System Case Mounting Bolt s Torque 84 656 wench eae ei ee anaes CS8 5 12 Crankshaft Gear Torque CS4 090 m o sd e audes CS8 5 spec 95xxxx CS8 5 spec 92 CST103l2 Retractable Starter Mounting Screws to Blower Housing Torque C 94 686 ieu Lebe hus aetna C98 5 12 cc Rocker Arm Stud Into Cylinder Head Torque inanem teu e Rs Adjusting Jam Nut Torque 2 E eese 55 975 55 990 mm T 65 975 65 990 mm 74 954 74 998 77 954 77 998 77 954 77 998 84 954 84 998 55
68. arter pulley is released remove the rope from the pulley 6 Tie a single knot in one end of the new rope 7 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 8 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 9 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 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 11 Slip the handle onto the rope Tie a single knot at the end of the rope 12 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 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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
69. ate align the tabs and install the brush plate in commutator end cap Insert the positive brush stud with plastic support through hole in the end cap from the inside out Install the O Ring fiber washer metal washer and inner hex jam nut Tighten nut to secure but do not overtighten or damage to the inside plastic support can occur Figure 8 40 Assembled Brush Plate Figure 8 41 Brush Plate and Terminal Components 8 23 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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 42 Figure 8 44 Assembling Starter Lead Figure 8 42 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 43 Figure 8 45 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 See Figure 8 17 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 43 Torquing Thru Bol
70. 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 Screw 11 Idle Fuel Needle with Limiter Cap Figure 5 1 Carburetor Adjustments www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Pilot Jet Screw Main Jet Main Nozzle Float Float Pin Float Gasket Drain Plug Spring Washer DONO O E ON gt Bowl Retaining Screw Float Bowl Clip Needle Assembly Spring Idle Fuel Adjusting Screw Limiter Cap Screw Figure 5 2 CS4 and CS6 Carburetor Exploded View 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 www mymowerparts com 6 11 H a2 Float Pin Clip Needle Assembly Spring Throttle Adjusting Screw Spring Idle Fuel Adjusting Screw Limiter Cap Screw Ball Figure 5 3 CS8 5 12 Carburetor Exploded View 5 5 Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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
71. 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 Figure 9 36 Removing Valve Cover Screws on CS8 5 spec 92xxxx CS10 and CS12 Support Bracket Screws Figure 9 37 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 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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 Mounting Screw Disassemble Cylinder Head 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 Figure 9 40 Remov
72. 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 Remove flywheel Remove ignition module Remove stator and protective shield Remove reduction assembly Remove closure plate Remove balance shaft assembly Remove camshaft and valve tappets Remove connecting rod with piston and rings Remove crankshaft Remove governor cross shaft 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
73. ce 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 warning 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 precautions should be followed at all times Failure to follow these precautions could result in injury to yourself and others amp WARNING WARNING A WARNING Accidental Starts can cause severe Rotating Parts can cause severe Hot Parts can cause severe burns injury or death injury Do not touch engine while operating Disconnect and ground spark plug Stay away while engine is in or just after stopping lead before servicing operation Accidental Starts Rotating Parts Hot Parts Disabling engine Accidental starting Keep hands feet hair and clothing Engine components get can cause severe injury or death away from all moving parts to extremely hot from operation To Before working on the engine or prevent injury Never operate the prevent severe burns do not touch equipment disable the engine as engine with covers shrouds or these areas while the engine is follows 1 Disconnect the spark guards removed running or immediately after it is plug lead s 2 Disconnect negative turned off Never
74. ch 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 53 Figure 8 55 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 56 Figure 8 53 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 54 Figure 8 56 Installing Frame with Brush Plate Assembly Figure 8 54 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 57 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 55 8 28 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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 59 Figure 8 57 Installing End Cap
75. cing procedures for the starter motor and check out the brushes and armature Repair or replace as required The resistance of the energizing coil should be at least 3 4 ohms If the meter reading is less than 3 4 ohms or an open circuit is indicated infinity ohms the solenoid is faulty and must be replaced The meter should indicate an open circuit infinity ohms no continuity When the circuit is completed applying 12 volts to the energizing coil an audible click should be heard as the solenoid engages and the ohmmeter should then indicate continuity between the large terminals If the results are other than indicated replace the solenoid www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Post Terminals Red White Lead Figure 8 21 Solenoid Details Inertia Drive Electric Starters This subsection covers the operation troubleshooting and repair of the inertia drive permanent magnet electric starter Figure 8 22 Inertia Drive Starter Operation When power is applied to the starter the armature rotates As the armature rotates the drive pinion moves out on the splined 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 the flywheel rotates faster than the starter armature and drive pinion This moves the drive pinion out of mesh wi
76. d SIE 16 10 mm 0 634 in 58 5 950000 neben 18 10 mm 0 713 in 58 5 925000026 s stt 20 10 mm 0 791 in COTO e e t eem n et eet eve 20 10 mm 0 791 in Connecting Rod Journal End I D New 0801 2 out este ad eret 28 000 28 015 mm 1 1023 1 1029 in CS8 5 spec 95xxxx 32 000 32 015 mm 1 2598 1 2604 in 258 5 p06 9200004 n etude 36 000 36 015 mm 1 4173 1 4179 in 910512 ese 36 000 36 015 mm 1 4173 1 4179 in Max Wear Limit C94 Ora are utum m estat fatus 28 115 mm 1 1069 in C S8 5 950000 nune Reo iet oat e iet eben 32 115 mm 1 2644 in 58 50920 ec ent oe kre eer ee d 36 115 mm 1 4219 in CS1012 tete uie ca e een bid 36 115 mm 1 4219 in Crankcase Closure Plate Fastener Torque erre 22 N m 195 in Ib CS8 9 A2 mI tU 30 N m 265 in Ib Oil Drain Plugs Torque 554 65 ip e 17 N m 150 in Ib neces 20 N m 177 in Ib Crankshaft End Play Free i eti tnt etit Eo a 0 04 mm 0 0015 in End Play Threaded Pump Shaft Models Only 0 0 0 2 mm 0 0 0 007 in 1 11 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 1 Safety and General Information Flywheel End Main Bearing Journal
77. e sf e E LI ee 12 N m 106 in Ib CS8 5 SDp8C eee aee eta 12 N m 106 in Ib CS8 5 spec 92Xxxx 44042 0 ntn nnne 20 N m 177 in Ib CS10 12 sioe ctt e t ERU E tee gor 20 N m 177 in lb Connecting Rod to Crankpin Running Clearance 0 016 0 046 0 0006 0 0018 t e eet tc ete 0 1 mm 0 004 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 1 Safety and General Information Connecting Rod to Crankpin Side Clearance o Herz M EE 0 2 0 6 mm 0 008 0 024 in 58 5 SPEC QOXXKK iei ien em een BT e e n uds 0 2 0 6 mm 0 008 0 024 in CS8 5 spec 92Xxxx Mina endine i aea E AAEE aE AEI 0 2 0 65 mm 0 0079 0 0256 in aei eo tete hs toan tes 0 2 0 65 mm 0 0079 0 0256 in Connecting Rod to Piston Pin Running Clearance 0 006 0 025 mm 0 0002 0 0001 in Piston Pin End I D New CS4 CSG 16 006 16 020 mm 0 6301 0 6307 in CS8 5 spec 95 anpra easan 18 006 18 020 mm 0 7089 0 7094 in C S8 5 SPEC 920004 ied n eie edad 20 006 20 020 mm 0 7876 0 7882 in 91051204 A ed A AA 20 006 20 020 mm 0 7876 0 7882 in Max Wear Limit 254056 ute Ont ntis telaio ei
78. e Cylinder Head Mounting valves by compressing the valve springs and Screws removing the keepers See Figure 9 43 9 10 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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 Stem 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 Section 9 Disassembly Figure 9 45 Removing Carburetor Mounting Studs 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 Special Tools page 2 2 and 2 3 may also be used to hold the flywheel when loosening or tightening the flywheel retaining nut NOTE 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 1 Remove the flywheel retaining nut washer and drive cup See Figures 9 46 and 9 47 Figure 9 46 Removing Flywheel Nut using an Impact Wrench 9 11 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 9 Disassembly Remove Ignition Module 1 Remove the two
79. e low idle speed screw in or out see Figures 5 15 and 5 16 1 With the engine warm move the throttle lever clockwise until it stops 2 Checkthe 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 Adjusting Screw Figure 5 15 CS4 CS6 Low Idle Speed Adjusting Screw 5 10 Figure 5 16 CS8 5 12 Low Idle Speed Adjusting Screw www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Go Back CS4 12 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 Figure 6 1 Oil Container Logo Check Oil Level Use high quality detergent oil of API American The importance of checking and maintaining the Petroleum Institute service class SG SH SJ or proper oil level in the crankcase cannot be Higher Select lic viscosity onthe al overemphasized Check oil BEFORE EACH USE as temperature at the time of operation as shown in the follows fol
80. e proper operation of the commutator 8 22 Depth 2 mm 0 079 in Figure 8 35 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 36 Test all the segments Continuity must exist between all or the armature is defective 2 Check for continuity between the armature coil segments and the commutator segments See Figure 8 36 There should be no continuity If continuity exists between any two the armature is defective 3 Check armature windings insulation for shorting See Figure 8 36 Armature Coil Figure 8 36 Armature Checking www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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 37 Installing Thrust Washer and Gasket 2 Carefully apply one or two drops of oil to the bronze bushing in the drive end cap and wipe away any excess Insert the armature shaft through the end cap Figure 8 38 Installing Armature 3 Install the starter frame magnet end first over the armature aligning the scribed marks made earlier See Figure 8 39 Figure 8 39 Installing Frame 4 With the brushes and brush springs in place on brush pl
81. e 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 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 8 Electrical System and 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 Model No Spec No Figure No Page No 901501 Wiring Diagram Selection Tables The following selection tables and individual wiring diagrams Figures 8 4 through 8 15 provide a reference for troubleshooting and servicing Locate the appropriate diagram based on
82. ection Replacement 1 Remove the lower jam nut metal washer 4 Remove the two thru bolts with sealing O Rings insulating washer and O Ring from the positive from the starter See Figure 8 30 4 stud Carefully push the stud inward to separate the brush plate assembly from the end cap See Figure 8 32 Figure 8 30 Removing Starter Thru Bolt 5 Remove the commutator end cap and brush plate Figure 8 32 Removing Brush Plate assembly See Figure 8 31 8 21 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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 33 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 33 Brush Checking Figure 8 34 Brush Plate Details Armature Commutator 1 Clean and inspect commutator outer surface Use 600 grit sandpaper to clean if necessary 2 Measure the mica insulation depth between the commutator segments The depth should be 2 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 35 NOTE The mica insulation of the commutator must be undercut to ensur
83. eee ate ete Bie 50 0 mm 1 97 in CS8 5 spec 95 57 0 mm 2 44 in 58 5 SD66 920000 i itia He m ete e videte sida ex 63 0 mm 2 48 in OS10 12 3 63 0 mm 2 48 in Displacement CS4 123 cc 7 50 cu in es ca e PG He RE EC RATER 171 cc 10 43 cu in C S8 5 Spec 9bXOX 251 cc 15 30 cu in CS8 5 spec 92xxxx v n aeea ai a e a e aoaaa ianao aa ia 301 cc 18 37 cu in SO O E det 301 cc 18 37 cu in 357 21 79 in Compression Ratio CSF 8 31 8 5 1 658 5 Spec 9bXXXX in Eee in etude ates 8 311 CS8 5 spec 92xxxx iiaa aiina ea anaien aaeain ai nenne 8 1 1 SA O EA A A AA EA 8 1 1 Weight 542 MEE 15 4 kg 35 Ib C 58 5 SPEC QOXXKK iicet ide eeu tile ra eee eund 26 kg 57 2 Ib CS8 5 spec 92 Mina miira aaee En nennen AE nnne 31 9 kg 70 5 Ib CST0 12 och x aui ie eei ete HR teta s 31 9 kg 70 5 Ib 1 9 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 1 Safety and General Information Oil Capacity Approx 994 0596 xcd t astitit be fou 0 6 L 0 64 U S qt CS8 5 Spec 95X ii edd o t Fas ae RE nes 1 0L 1 1 0 6 qt CS8 5 spec 92XXXX eee a ie eee RR ERI Re 1 1L 1 2 U S
84. ents 4 Use a solvent to thoroughly clean any dirt or old Figure 8 27 Installing Retaining Ring lubricant from the splines Starter Disassembly 5 Inspect the splines and drive components for 1 Remove the retaining ring spring holder collar wear or damage If the splines are damaged it spring and drive pinion assembly from the will be necessary to replace the starter The drive armature shaft Refer to Starter Drive Service components are available as individual service parts if any of them are worn or damaged 2 Disconnect the solenoid lead from the starter terminal Hold the lower jam nut from turning with 6 Apply a small amount of molybdenum disulfide a wrench while loosening the top nut to prevent lubricant to the splines damaging internal components See Figure 8 28 The solenoid may be removed or left in place 7 Install the drive pinion spring and spring holder collar onto the armature shaft Figure 8 28 Removing Solenoid Lead Figure 8 26 Installing Drive Components 8 20 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 8 Electrical System and Components 3 Scribe or mark a small line from the starter frame to each end cap to serve as match marks for reassembly later See Figure 8 29 Figure 8 31 Removing End Cap with Brush Plate 6 Pull the armature out of the starter frame Figure 8 29 Match Marks for Reassembly Brush Insp
85. ents could allow unfiltered air into the engine causing premature wear and failure Figure 4 3 Removing Cover Knob Standard 4 1 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 4 Air Cleaner and Air Intake System To service the precleaner perform the following steps 1 Remove the air cleaner cover knob standard air cleaner or unsnap the latches heavy duty air cleaner and remove the cover housing See Figures 4 3 and 4 4 2 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 Figure 4 4 Unsnapping Heavy Duty Latches 3 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 4 Saturate the precleaner with new engine oil Squeeze out all excess oil 5 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 6 Reinstall the air cleaner cover housing assembly Secure with the knob or latches Figure 4 5 Standard Element Precleaner Assembly Figure 4 6 Heavy Duty Element Preclea
86. ever and armature be careful not to lose the thrust washer Figure 8 49 Removing Drive Lever and Armature The stop collar is held in place by being snapped over the retainer from the bottom up The retainer is positioned in a groove in the armature shaft To access the retainer the stop collar must be pushed back or down towards the drive pinion See Figure 8 50 Figure 8 50 Starter Drive and Stop Components 10 11 12 With the stop collar dislodged the retainer can be removed from the armature shaft Do not reuse the retainer Remove the drive pinion assembly from the armature for servicing replacement Clean all parts and the splines on the armature as necessary www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 8 Electrical System and Components 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
87. f 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 69 9 16 Figure 9 69 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 70 Removing Housing Cover 4 Pullthe output shaft gear assembly out of the housing cover or closure plate See Figure 9 71 Figure 9 71 Removing Output Shaft Gear from Cover www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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 72 Figure 9 72 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 73 Figure 9 73 Removing Dowel Pins and Gasket 7 Check the reduction system bearings for wear or excessive play See Figure 9 62 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 other
88. g oil change intervals longer than recommended can cause engine damage Alogo or symbol on oil containers identifies the API service class and SAE viscosity grade See Figure 1 4 Figure 1 4 Oil Container Logo 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 meth
89. gine 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 8 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 Mounting p clarity of illustration Bolt Governor Lever Figure 5 10 CS8 5 spec 92xxxx 10 and CS12 Governor Adjustment 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 8 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 5 Fuel System and Governor Figure 5 11 CS8 5 spec 95xxxx Governor Adjustment High Idle Speed Adjustment The recommended maximum no load high idle speed for the CS engines is 3750 100 RPM for tapered shaft models and 3800 100 RPM for all others T
90. he 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 12 and 5 13 and follow the procedures below 1 Startthe 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 Throttle Stop 1 Screw Figure 5 12 CS4 CS6 Throttle Lever Throttle Stop Screw Details Throttle Stop Screw Figure 5 13 CS8 5 spec 92xxxx CS10 and CS12 Throttle Lever Throttle Stop Screw Details Throttle Lever Throttle Stop Screw Throttle Lever Figure 5 14 CS8 5 spec 95xxxx Throttle Lever Throttle Stop Screw Details 5 9 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 5 Fuel System and Governor Low Idle Speed Adjustment The recommended low idle speed is 2000 100 RPM The low idle speed is set by turning th
91. he closure plate from the engine and remove the float switch for further testing ba 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 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 8 Electrical System and Components 6 Set an ohmmeter to the Rx1K or Rx10K scale 6 Resistance of the ignition module should be and zero Connect one ohmmeter lead to the 13 5 18 0 K ohms Engine Will Not Start Continuity Figure 8 3 kill lead black white terminal and connect 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 remove 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 separat
92. hex flange screws securing the ignition module to the crankcase See Figure 9 50 Figure 9 47 Removing Flywheel Nut Using Holding Tool 2 Remove the flywheel from the crankshaft using a puller See Figure 9 48 and 9 49 Figure 9 50 Removing 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 51 Figure 9 48 Using Puller to Remove Flywheel on CS8 5 CS12 Figure 9 51 Stator and Protective Shield Figure 9 49 Use External Type Puller to Remove Flywheel on CS4 CS6 3 Remove the flywheel key from keyway 9 12 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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 52 Figure 9 54 Removing Reduction Housing Screws on 8 5 12 3 Pull the reduction housing off the closure plate Figure 9 52 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
93. housing to catch any remaining oil See Figures 9 53 and 9 54 Figure 9 56 Removing Reduction Housing on CS8 5 CS12 Figure 9 53 Removing Reduction Housing Screws on CS4 CS6 9 13 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 9 Disassembly 4 Remove the screw and washer securing the crankshaft sprocket gear Figure 9 57 Removing Screw from Crankshaft on CS4 CS6 Figure 9 58 Removing Screw from Crankshaft on CS8 5 CS12 5 Remove the reduction components a On 54 and CS6 leave the chain intact and pull out the two sprockets as an assembly See Figure 9 59 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 60 9 14 Figure 9 59 Removing Sprockets and Chain on CS4 CS6 Figure 9 60 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 61 Figure 9 61 CS8 5 CS12 Disassembled Reduction Assembly www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 9 Disassembly 6 Check the reduction system bearings for wear or excessive play See Figure 9 62 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
94. iginal piston and connecting rod can be reused after new rings are 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 Stuck Broken Rings 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 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 Preignition or ignition of the fuel charge before the timed spa
95. igure 9 28 Removing Control Panel Screws on CS8 5 spec 95xxxx 9 7 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 9 Disassembly 4 Remove the two electric starter mounting bolts See Figures 9 29 and 9 30 Figure 9 29 Removing Starter Mounting Bolts on CS8 5 spec 92xxxx CS10 and CS12 Figure 9 30 CS8 5 spec 95xxxx with 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 9 8 Figure 9 31 CS8 5 spec 92xxxx CS10 CS12 with Electric Starter Assembly Removed Figure 9 32 CS8 5 spec 95xxxx with Electric Starter Assembly Removed Figure 9 33 CS8 5 spec 95xxxx www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 9 Disassembly Remove Left Fuel Tank Bracket if so equipped 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 Head Assembly and Push Rods Remove the four hex flange screws securing the valve cover The air cleaner support bracket CS8 5 12 may
96. illustrated in Figure 8 16 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 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 Charge Pilot Lamp Terminal Stator AC Leads White Figure 8 16 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 17 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 center pilot lamp terminal exists on the 7 10 amp rectifier regulator B Charge Ground Black Floating Isolated Terminal Stator AC Leads amp White Figure 8 17 7 10 amp Rectifier Regulator 8 13 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 8 Electrical System and Components Rectified Only Non Regulated Systems
97. iming 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 will 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 E 1 Proper Oil Level Level Figure 8 2 Cutaway Showing Proper Oil Level Oil Sentry systems typically consist of the following components Anoil warning control unit black box Anoil level float switch An indicator light 8 3 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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 Engine Will Not Start 8 4 Disconnect the cap from the spar
98. 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 After 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 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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 cleara
99. ing the hex flange screws Finger tighten the mounting screws only 2 Pull the rope handle to engage the pawis 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 11 29 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 11 Reassembly Figure 11 116 Engage Pawls and Torque Mounting Screws Install Muffler 1 Install a new exhaust gasket onto the exhaust studs 2 Install the muffler and heat shield assembly Install the hex flange screw with a flat washer through the front support bracket into the crankcase boss Torque hex flange nuts to CS4 CS6 6 8 N m 53 71 in Ib CS8 5 12 18 22 159 195 in Ib Torque hex flange screw to CS4 CS6 7 N m 62 in Ib CS8 5 12 15 N m 133 in Ib Figure 11 117 Torquing Muffler Mounting Screws 11 30 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 4 Reconnectthe rectifier regulator if so equipped Testing the Engine It is recommended that the engine be ope
100. ion Module Oil Sentry Gauge Stator Spark w Starter Ground Plug Ground ibn Solenoid Ground Rectifier Regulator Figure 8 8 Warning Unit Engine w Ground Oil Sentry Gauge pt 1 Stator um Start Ground Spark Ground T id Solenoid omg Ground Rectifier Regulator Charge Lamp Figure 8 9 8 9 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 8 Electrical System and Components Warning Unit Ground 4 Oil Sentry Ei Light Ignition Module Ground Wire Lead y A B Oil Sentry H Gauge Spark Ground Plug Ground Ground Ground Figure 8 10 Oil Warning Unit Ground l oi Sentry 1 Light Ignition Module Wire Lead L Oil Sentry fF Gauge Ground Ground Ground Spark Plug Ground Figure 8 11 8 10 YR YR Rectifier R Starter Solenoid Battery Starter Motor T Ground Rectifier R Ground Starter Solenoid Battery T Ground www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 8 Electrical System and Components Cil Warning Unit Stop Switch q Engine B T Ground Ground Ground Oil Sentry Light L 1 BW a B Y Oil Sentry Gauge Ground Spark Plug Stator Ground Ground Figure 8 12 Main Switch Wire Bw B R
101. ise into the drum of the pulley from larger to smaller diameter www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 7 Retractable Starter 3 Carefully install pulley into recoil housing engaging the spring hook with starter housing tab See Figure 7 10 NOTE Rotating pulley counterclockwise slightly will assist engagement 4 Install the pawl springs CS8 5 12 only and pawls onto pawl studs of pulley 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 Figure 7 10 Assembling Starter Pulley to Housing to the drive cup hold engaged and torque the 7 mounting screws to 5 5 N m 47 7 in Ibs 5 Mount drive plate over pawls onto pulley aligning Figure 7 3 the actuating slots in plate with the raised sections on each drive pawl Torque the screw to 5 6 N m 44 53 in Ibs Rotate the pulley by hand and check operation See Figure 7 11 7 5 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 7 Retractable Starter 7 6 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Go Back CS4 12 Section 8 Electrical System and
102. ive 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 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 11 Reassembly seal installation depth 5 Description 1 2mm 0 08 in Bolt Chain Case Cover Gasket Dowel Pin Cil Seal Bearing Washer Bolt Washer Shaft 2 Idle Sprocket Chain Washer Straight Key B 10 88 in Ib Figure 11 38 CS4 CS6 2 1 Reduction Assembly Components Description Chain Case Cover Gasket Dowel Pins Cil Seal Bearing Bolt Washer Idle Gear Straight Key Shaft C Oil seal installation depth 2mm 0 08 in 65 N m 48 ft Ibs 30 N m 265 in Ibs Figure 11 39 CS8 5 12 2 1 Reduction Assembly Components 11 10 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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 new screws Torque the screws to 20 24 N m bearing s into the housing or cover so the 177 212 in Ib manufacturer s
103. iver to remove the nozzle from the tower If it does not turn easily use some carburetor cleaner to clean the exposed threads in the tower b Soakthe nozzle in carburetor cleaner to remove any deposits and blow it dry with compressed air c Reinstall it in the tower and thread it in until it bottoms 12 Reinstall the main jet and install the bowl gasket in the groove Reassemble the bowl to the carburetor with the screw removed in step 7 Position the bowl so the drain screw will be accessible after the carburetor is mounted to the engine Section 5 Fuel System and Governor 13 Use the reverse of steps 1 5 to reinstall the carburetor on the engine Governor These engines are equipped with a centrifugal flyweight mechanical governor The governor is designed to hold the engine speed constant under 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 7 As the flyweights move outward they cause the regulating pin to extend from the governor gear assembly Speed Increasing Speed Decreasing Figure 5 7 Action of Governor Gear The regulating pin contacts the tab on the cross shaft causing the shaft to rotate when the engine speed changes See Figure 5 8 One end of the cross shaft pro
104. k 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 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
105. l K amp T 606 678 9623 or 606 561 4983 Section 11 Reassembly 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 77 CS4 CS6 Cylinder Air Shroud Mounting Bolt Location 8 Position the spark plug lead within the corresponding cutout in the air shroud 11 20 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 Ib 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 support 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 88 106 in Ib See Figure 11 79 and 11 80 Figure 11 79 CS8 5 12 Torquing Valve Cover Screws www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 11 Reassembly Figure 11 80 CS8 5 12 Torquing Screws Install Fuel Tank Supports If So Equipped Throttle Lever Wiring Harness Ignitio
106. l 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 Figure 10 23 Clean Chain Using Solvent 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 12 345678910 DT TT LLLI LLL LLLA LLLI 89 5 mm 3 5 in Figure 10 24 Chain Strectch Limit 10 14 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 10 Internal Components Figure 10 25 Inspect for Binding Figure 10 27 CS8 5 12 Oil Passage 5 Checkto 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 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 10 Internal Components 10 16 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Go Back CS4 12 Section 11 Reassembly General 20 Install carburetor NOTE Make sure the engine is assembled using all 21 Install air cleaner base and element specified torque values tightening 22 Adjust Set governor sequences and clearances Failure to 23 Install fuel tank and fuel tank supp
107. le Ground Stop Switch n Wire Lead B Sentry Light BW Figure 8 5 Section 8 Electrical System and Components Wiring Color Codes Black Blue Red Yellow White Brown Green Gray Black w White Stripe Red w White Stripe White w Blue Stripe Green w Red Stripe Green w Yellow Stripe Blue w White Stripe Blue w Red Stripe Green w Black Stripe Oil Sentry Gauge Lead Black with Gray Shielding Oil Warning Unit Ground Oil Sentry Gauge Ground 8 7 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 8 Electrical System and Components Cil Warning Unit BW Oil Sentry Light Ground Oil Sentry Gauge Ground Spark inii Ground Figure 8 6 Oil Warning Ground B A Oil Sentry Wire Lead Sentry Gauge Light Ignition Module Spark Plug Figure 8 7 8 8 Ignition Module Ground Rectifier Regulator Stop Switch Wire Lead Ground Stator Main Switch Wire Color Bw B R rw off Starter Solenoid Battery Ground www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 8 Electrical System and Components Main Switch Wire Color BW Cil Warning Unit Ground BW Oil Sent E il Sentry Light Wire Lead Y Engine Ground B Ignit
108. ler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 8 Electrical System and Components Troubleshooting Guide Electric Starting System 1 Starter Motor Does Not Operate With Key Switch 8 18 Test battery on unit a Connect a DC voltmeter across the battery terminals and read battery voltage key switch off b Turn key switch to start position and read battery voltage again Turn switch off Remove the electric starter cover panel and check the fuse inside the plastic holder The fuse outside the holder is a spare Disconnect the red white solenoid lead from red white switch lead at the bullet connection Be sure transmission is in neutral and PTO is off Connect one end of a jumper lead to the positive 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 jumper cables to test starter motor Be sure the transmission is in neutral and PTO is off Remove the heavy lead from the post terminal on the starter Connect one end of the positive jumper cable to the post terminal and connect the other end to the positve 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 Disconnect the leads from the starter solenoid and remove it from the sta
109. ll 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 CS8 5 spec 95xxxx only install or make sure the rubber seal for the air cleaner is clean installed and in good condition See Figure 11 106 Figure 11 106 CS8 5 spec 95xxxx Air Cleaner Torque hex flange nuts to Base and Rubber Seal CS4 CS6 5 8 N m 44 71 in Ib 58 5 12 10 12 N m 88 106 in Ib 2 Make sure the seal is on the air cleaner base stud See Figures 11 104 11 105 and 11 106 Torque hex flange screw s to Install the filter element with precleaner and 5 8 N m 44 71 in Ib secure with the wing nut Do not install the outer air cleaner cover and knob at this time Figure 11 104 CS4 CS6 Installing Air Cleaner Base Figure 11 107 Installing Air Filter Element Precleaner and Wing 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 Figure 11 105 CS8 5 12 Installing Air Cleaner Base 11 27 www mymowerparts com
110. lowing table 1 Make sure the engine is stopped level and is cool so the oil has had time to drain into the Krblhzr Yiri sump RECOMMEHOED SAE ViIZCOZITY GRADEE gen 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 NOTE Using other than service class SG SH SJ or higher oil or extending oil change intervals longer than recommended can cause engine damage Alogo or symbol on oil containers identifies the API service class and SAE viscosity grade See Figure 6 1 6 1 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 6 Lubrication System NOTE If the engine stalls or does not start turn the Bring Level Up To engine switch to the position and Point of Overflow attempt to start the engine If the oil warning light flickers for a few seconds the engine oil Nt x is insufficient Add oil and restart Oil Level NOTE sure the oil level is checked BEFORE 77 Oil EACH USE and is maintained up to the point Level 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 5 Ifthe level is low add oil of the proper type to bring hours of operation the level up to the poi
111. lve Guide Running Clearance 94 690 totes tiet 0 04 0 06 0 0016 0 0024 58 0 037 0 064 0 0015 0 0025 Exhaust Valve Stem to Valve Guide Running Clearance 0 06 0 08 0 002 0 003 0 045 0 072 0 0018 0 0028 Intake Valve Guide 1 0 New CS4 CSG Mme 5 5 mm 0 22 in V 6 0 6 012 0 2362 0 2367 Max Wear Limit CS sud uat tim watt oor 5 60 mm 0 220 in 6 10 mm 0 240 in Exhaust Valve Guide 1 0 New 94 688 titus ittis 5 5 mm 0 22 in 98 512 6 0 6 012 mm 0 2362 0 2367 in Max Wear Limit GST CSDL sto au um tetti t i 5 6 mm 0 220 in 298 5 12 6 e nalibus ea eara a eh 6 0 mm 0 236 in Valve Guide Reamer Size STD CS4 Nec n 5 5 mm 0 216 in 98 551210 6 0 0 236 1 Intake Valve Minimum Lift CSG EOD 2 4 mm 0 094 in 58 5125 stie 2 7 mm 0 106 Exhaust Valve Minimum Lift po CSG ii 2 7 mm 0 106 in So pM 2 9 mm 0 114 in Nominal Valve Seat 0 45 Valve to Tappet Clearance 0 1 mm 0 004 in 1 16 www my
112. ly 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 C810 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 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 9 Disassembly 4 On CS8 5 spec 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
113. mowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 1 NOTES Safety and General Information 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 Cil Drain Plugs Tightening Torque N m in Ib Size M10x1 25 M12x1 50 Into Aluminum 17 150 20 177 Model CS4 CS6 CS8 5 CS10 CS12 www mymowerparts com Torque Conversions N m in Ib x 0 113 N m ft Ib x 1 356 in Ib N m x 8 85 ft lb N m x 0 737 Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 1 Safety and General Information 1 18 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Go Back CS4 12 Section 2 Special Tools These quality tools are designed to help you perform specific diagnostic disassembly repair and reassembly procedures By using tools designed for the job you can service engines easier faster and safer In addition you ll increase your service capabilities and customer satisfaction by decreasing engine down time Tool Flywheel Puller Kit Rocker Arm Spanner Wrench
114. mp T 606 678 9623 or 606 561 4983 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 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 Head Diameter CS4 21 0 mm 0 83 in 19 0 mm 0 75 in Head Diameter CS6 24 0 mm 0 94 in 22 0 mm 0 87 in Stem Diameter 5 5 mm 0 22 in 5 5 mm 0 22 in Length CS4 64 5 mm 2 54 in 64 5 mm 2 54 in Length CS6 65 9 mm 2 59 in 64 5 mm 2 54 in Face Seat Width 0 7 mm 0 0276 in 0 7 mm 0 0276 in Face Seat Limit 1 7 mm 0 067 in 1 7 mm 0 067 in Face Seat Angle Insert Area 90 90 Valve Stem Bend Limit 0 01 mm 0 0004 in 0 01 mm 0 0004 in Valve Guide Guide Inside Diameter Stem to Guide Clearance Valve Clearance 5 5 mm 0 22 in 0 04 0 06 mm 0 0016 0 002 in 0 1 mm 0 004 in 5 5 mm 0 22 in 0 06 0 08 mm 0 002 0 003 in 0 1 mm 0 004 in Valve Seat Contact Width Std Limit 0 7 mm 0 03 in 1 7 mm 0 067 in www mymowerparts com 0 7 mm 0 03 in 1 7 mm 0 067 in
115. n Switch and Oil Sentry Control Module CS4 CS6 CS8 5 spec 92xxxx CS10 CS12 1 Attach the left fuel tank support to the crankcase bosses with the two hex flange screws and flat washers under the heads CS4 and CS6 only Torque screws to CS4 CS6 22 26 N m 195 230 in Ib CS8 5 spec 92xxxx CS10 CS12 27 31 N m 237 274 in Ib Figure 11 81 CS4 CS6 Mounting Left Fuel Tank Support Figure 11 82 CS8 5 spec 92xxxx CS10 CS12 Mounting Left Fuel Tank Support 2 Assemble the right fuel tank support and attached electrical components to the crankcase bosses Mount the throttle control bracket off the flywheel side screw as shown in Figures 11 83 and 11 84 Install a flat washer under the head of screw on PTO side only Torque screws to CS4 CS6 22 26 195 230 in Ib CS8 5 spec 92xxxx CS10 CS12 27 31 238 274 in Ib The fuel tank support may have the ignition Switch wiring harness oil sentry control module starter and warning light attached based on model spec involved Figure 11 83 4 CS6 Mounting Right Fuel Tank Support 11 21 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 11 Reassembly Figure 11 84 CS8 5 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 bracke
116. n air cleaner base with a servicable 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 Servicable 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 oftern 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 Mounting Screw Figure 4 16 Mounting Details 2 Remove the foam element from the air cleaner 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 Lightl
117. nce 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 micrometer Section 10 Internal Components For CS4 CS6 5 mm 0 197 in For CS8 5 12 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 www mymowerparts com Kohler Engine Parts Call K a
118. ne Parts Call K amp T 606 678 9623 or 606 561 4983 Figure 11 112 CS8 5 spec 95xxxx Installing Fuel Tank Support 2 Figure 11 113 CS8 5 spec 95xxxx Shut Off Valve 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 Ib If the 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 Ib See Figure 11 113 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 Ib See Figure 11 114 Section 11 Reassembly 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 with the knob Figure 11 115 Installing Outer Air Cleaner Cover and Knob Install the Retractable Starter 1 Install the retractable starter us
119. ner Assembly Figure 4 7 Removing Standard Precleaner Precleaner Service If so equipped wash and reoil the precleaner every 25 hours of operation more oftern under extremely dusty or dirty conditions 4 2 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 4 Air Intake and Air Cleaner System Figure 4 11 Installing Heavy Duty Cover Housing a 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 Figure 4 8 Removing Heavy Duty Precleaner 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 Cleaner 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 Figure 4 9 Removing Heavy Duty Lower Chamber 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 s
120. ns Tolerances and Special Torque Values Replace rod if scored or excessively worn www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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
121. nt of overflowing Figure 6 2 Cutaway Showing Proper Oil Level For an overhauled engine use 10 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 NOTE To prevent extensive engine wear or damage always 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 Change the oil while the engine is still warm The oil will flow more freely and carry away more impurities Make sure the engine is level when filling checking and changing the oil Oil Sentry Some engines are equipped with an Oil Sentry oil Change the oil as follows 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 T TO keep Gir debris 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 3 Fill the crankcase wi
122. nut See Figure 11 99 Figure 11 99 CS8 5 spec 92xxxx CS10 CS12 Attaching Electrical Starter Cover Panel Figure 11 97 CS4 CS6 Silver Screw and Ground Lead Location 11 25 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 11 Reassembly Install Carburetor 1 Install a new carburetor spacer gasket onto the carburetor studs followed by the carburetor spacer and another spacer gasket See Figure 11 100 Figure 11 102 CS8 5 12 Assembling Linkage 3 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 Figure 11 100 Carburetor Spacer and Gaskets the choke lever on the carburetor as shown in Figure 11 103 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 11 103 CS8 5 12 Attaching Choke Link and Dampening Spring Figure 11 101 CS4 CS6 Assembling Linkage 4 Pushthe carburetor and linkage all the way onto the studs 11 26 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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 insta
123. o 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 15 CS4 CS6 Aligning Crankshaft and Camshaft Timing Marks 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 Section 11 Reassembly 2 Install the balance shaft aligning the timing mark hole with the timing mark dimple on the larger crankgear See Figure 11 17 Figure 11 17 CS8 5 12 Aligning Balance Shaft and Crankgear Timing Marks Install Governor Assembly The governor gear assembly is located inside the closure plate If servicing was performed or the governor was removed reassemble as per procedures under Governor Assembly in Section 10 Install Oil Sentry Gauge 1 Mount the Oil Sentry gauge into the closure plate using 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 18 Oil Sentry Gauge Mounting and Lead Routing Details www mymowerparts com 2 Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 11 Reassembly Install shield for lead and secure with the M6x1 0 hex flange screw Torque all three screws to 10 N m 88 5 in Ib See Figure 11 19 Figure 11 19 Tightening
124. od 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 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 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 1 Safety and General Information Maintenance Instructions A WARNING Accidental Starts EI 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 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 Fill fuel tank Section 5 Daily or Before e Check oil level Section 6 Starting Engine Check air cleaner for dirty loose or damaged parts
125. old 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 Install the adapter into the spark plug hole but do not attach it to the tester at 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 Air escaping from exhaust system Air escaping from Carburetor Gauge reading in low green zone Gauge reading in moderate yellow zone Gauge reading in high red 2 3 4 eect Defective rings or worn cylinder walls Defective exhaust valve insi Defective intake valve Piston rings and cylinder good condition
126. on module will be installed Install the ignition module loosely to the bosses with the two hex flange screws Move the module as far away from the flywheel as possible then tighten the screws just enough to hold it in position 11 15 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 11 Reassembly 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 Ib See Figures 11 61 and 11 62 Figure 11 61 CS4 CS6 Setting Air Gap 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 11 16 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 intake valve Always use a new seal when valves are ins
127. operate the battery cable from battery engine with heat shields or guards removed 1 1 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 1 Safety and General Information A WARNING A WARNING Explosive Fuel can cause fires and Carbon Monoxide can cause Explosive Gas can cause fires and severe burns severe nausea fainting or death severe acid burns Charge battery only in a well Stop engine before filling fuel tank Do not operate engine in closed or ventilated area Keep sources of confined area ignition away Explosive Fuel Lethal Exhaust Gases Explosive Gas Gasoline is extremely flammable Engine exhaust gases contain Batteries produce explosive and its vapors can explode if poisonous carbon monoxide hydrogen gas while being charged ignited Store gasoline only in Carbon monoxide is odorless To prevent a fire or explosion approved containers in well colorless and can cause death if charge batteries only in well ventilated unoccupied buildings inhaled Avoid inhaling exhaust ventilated areas Keep sparks open away from sparks or flames Do not fumes and never run the engine in flames and other sources of fill the fuel tank while the engine is a closed building or confined area ignition away from the battery at all hot or running since spilled fuel times Keep batteries out of the could ignite if it comes in contact reach of children Hemove all with hot parts or sparks f
128. ort observe specifications could cause severe 24 Install outer air cleaner cover engine wear or damage Always use new 25 Install retractable starter 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 engine reassembly This procedure assumes that all in the bores for the bearings The closure plate components are new or have been reconditioned and 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
129. owerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 5 Fuel System and Governor Troubleshooting Carburetor Related Causes Possible Cause Probable Remed 1 Engine starts hard runs Low idle fuel mixture speed improperly adjusted Adjust the low idle roughly or stalls at idle speed RPM then adjust the low idle fuel needle speed Engine runs rich Clogged air cleaner Clean or replace indicated by black sooty Choke partially closed during operation Check the choke lever linkage to exhaust smoke misfiring ensure choke is operating properly loss of speed and power Low idle fuel mixture is improperly adjusted Adjust low idle fuel needle governor hunting or Float level is too high Separate carburetor bowl from carburetor body excessive throttle check float setting against specification Replace float if required opening 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 Engine runs lean Low idle fuel mixture is improperly adjusted Adjust low idle fuel needle indicated by misfiring Float level is too low Separate carburetor bowl from carburetor body loss of speed and power check float se
130. r Arms and Pivot Shaft www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 11 Reassembly Figure 11 72 CS8 5 spec 92xxxx CS10 CS12 4 Adjustthe valve tappet clearance as follows a Make sure the piston is still at the top of the compression stroke b Insert a flat feeler gauge between the rocker arm and the valve stem The recommended valve to rocker arm clearance for both intake and exhaust is 0 1 mm 0 004 in 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 Turn counterclockwise to increase clearance CS8 5 spec 92xxxx CS10 CS12 Hold the adjuster up when making adjustment Figure 11 74 CS8 5 spec 92xxxx CS10 CS12 Adjusting Valve to Rocker Arm Clearance d Hold the adjuster from turning and tighten the locknut Torque locknut to CS4 CS6 CS8 5 spec 95xxxx 10 88 5 in Ib CS8 5 spec 92xxxx CS10 CS12 7 N m 62 in Ib 5 Use anew 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 Ib Figure 11 75 Installing and Torquing New Spark Plug 11 19 www mymowerparts com Kohler Engine Parts Cal
131. rated on a test stand or bench prior to installation on a piece of equipment 1 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 midrange Adjust the carburetor settings as required Low idle speed should be set to 2000 RPM 150 or application specifications 2 Make sure the maximum engine speed does not exceed Maxmum Taper Shaft Models 3750 100 RPM Others 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 31 Refer also to Fuel System and Governor section www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 11 Reassembly Figure 11 118 CS4 CS6 High Speed Stop Screw Figure 11 120 CS8 5 spec 95xxxx High Speed Stop Screw Figure 11 119 CS8 5 spec 92xxxx CS10 CS12 High Speed Stop Screw 11 31 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 KOHLER 81761185 ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 www mymowerparts com FORMNO TP 2503 A ISSUED 12 99 REVISED 8 00 MAILED 9 00 LITHO IN U S A
132. re 11 93 CS8 5 spec 92xxxx CS10 CS12 Reconnect Electrical Leads 11 24 Figure 11 94 CS8 5 spec 92xxxx CS10 CS12 Reconnect Solenoid Wiring Harness Lead CS8 5 spec 92xxxx CS10 CS12 1 Align and mount the electric starter motor to the crankcase Install and torque the two hex flange screws to 30 265 in Ib See Figure 11 95 Figure 11 95 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 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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 flange 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 98 CS8 5 spec 92xxxx CS10 CS12 Blower Housing Installed 3 Attach the electric starter cover panel if so equipped to the right tank support with the three phillips head screws and one flange
133. re secure and in good condition 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 Prevent the stator AC leads from touching or shorting while the engine is running 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 Wheninstalling 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 the 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 Section 8 Electrical System and Components 18 amp Rectifier Regulator The 18 amp rectifier regulators contain a 6 terminal plug in configuration
134. retor outward and off the mounting studs 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 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 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 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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 21 Cover Panel Mounting Screws Figure 9 19 CS8 5 spec 92xxxx CS10 and CS12 Blower Housing Screws Figure 9 22 CS8 5 spec 9
135. retor throat for dirt Dirt in the throat is further indication that the air cleaner was not functioning properly e Check 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 Itis 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 in
136. rk 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 See Figure 10 13 for common types of piston and ring Scored Piston and Rings damage Figure 10 13 Common Types of Piston and Ring Damage 10 10 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 10 Internal Components Replacement pistons are available in STD bore size 4 After installing the new rings on the piston check and in 0 25 mm 0 010 in and 0 50 mm 0 20 in piston to ring side clearance Maximum oversizes Replacement pistons include new piston recommended side clearance is ring sets and new piston pins Top ring 0 04 0 08 mm 0 0016 0 0033 in Service replacment pistion ring sets are also available 2nd ring separately for STD pistons and for 0 25 mm 0 010 CS4 CS6 0 02 0 06 mm 0 0008 0 0024 in in and 0 50 mm 0 020 in oversized pistons Always CS8 5 12 0 03 0 07 mm 0 0012 0 0028 in use new piston rings when installing pistons Never Piston Ring Side Clearance Limit 0 1 mm reuse old rings 0 004 in The cylinder bore must be deglazed before service If side clearance is greater than specified a new piston ring sets are used must be used Refer to Figure 10 15 Some important
137. rom WA R NI N G jewelry when servicing batteries ignition Do not start the engine near spilled fuel Never use Before disconnecting the negative gasoline as a cleaning agent ground cable make sure all switches are OFF If ON a spark Uncoiling Spring can cause severe Will occur at the ground cable injury terminal which could cause an Wear safety goggles or face explosion if hydrogen gas or protection when servicing retractable gasoline vapors are present amp WARNING starter Spring Under Tension A CAUTION Cleaning Solvents can cause Retractable starters contain a powerful recoil spring that is under 3 tension Always wear safety severe injury or death Use only in well ventilated areas away from ignition sources goggles when servicing retractable starters and carefully follow instructions in the Retractable Starter Section 7 for relieving Electrical Shock can cause injury Flammable Solvents Carburetor cleaners and solvents Do not touch wires while engine is are extremely flammable Keep spring tension running sparks flames and other sources of ignition away from the area Follow the cleaner manufacturer s Electrical Shock warnings and instructions on its Never touch electrical wires or proper and safe use Never use components while the engine is gasoline as a cleaning agent running They can be sources of electrical shock 1 2 www mymowerparts com Kohler Engine
138. rted 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 camshatt 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 dB f 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 54 56 26 9 0 05 mm 26 68 0 05 mm 1 06 0 002 in 1 05 0 002 in CS8 5 10 32 55 0 05 mm 32 55 0 05 CS12 1 28 40 002 in 1 28 0 002 in www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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 grooving etc Do not replace the main bearings unless they shown signs of damage or are out of running clear
139. rter for testing See Figure 8 21 on page 8 19 a Set an ohmmeter on the Rx1 scale and zero the meter Connect one ohmmeter lead to the terminal of the red white lead from the solenoid Connect the other ohmmeter lead to the solenoid mounting bracket With the ohmmeter still on the Rx1 scale connect the leads to the two large post terminals Leave the ohmmeter leads connected to the large terminals Connect a jumper lead from 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 a Battery voltage should be at least 12 volts If low charge battery Battery voltage should not fall below 9 volts during cranking If it does battery may be faulty or there may be a short in the starting circuit Have battery load tested If battery passes load test check circuitry If fuse is blown check for a wiring problem bare wire short circuit Correct problem and replace fuse Try to start engine If it still won t start go to step 3 If solenoid engages and starter begins to crank the key switch is faulty or there is a wiring problem to from the key switch Check wiring and test key switch circuits with an ohmmeter When negative jumper cable is touched to crankcase or starter housing starter motor should operate If it does continue with step 5 If starter does not operate refer to the servi
140. rw om OF Oil Warning Unit Engine BW OilSentry Ground Light Ground Ignition Stator Oil Sentry I 1 Spark T Ground p Ground Ground Battery Starting Motor Ground Figure 8 13 8 11 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 8 Electrical System and Components Cil Warning Unit Engine R Ground B B L Ground BW Y Ground Oil Sentry Gauge Ignition Modul w w B odule Oil Sentry Gauge ij w Stator Ww R xw Bj Spark Ground Ground Ground Rectifier Figure 8 14 Rectifier Assembly Oil Warning OilSenry S il Sentry Rectifier Regulator Y B Light Main Switch E B B Y 1 d _ m gt sanf C E GR JGR Fuse 15 amp Ignition B Fuel Shut Off 1 Module oil Sentry 4 uel Shut 4 Gauge 7 rot w Heater Solenoid R E M d wy i Starter 1 oo i 1 5 Spark end Starter Battery plug Motor i ts i Rectifier Regulator Ground Ground Ground Ground Ground Figure 8 15 8 12 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 NOTE Observe the following guidelines to avoid damage to the electrical system and components Make sure the battery polarity is correct A negative ground system is used Make sure all ground connections a
141. s 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 74 and 9 75 Pry Tap Pads Figure 9 74 CS4 CS6 Closure Plate Mounting Screws Figure 9 75 CS8 5 CS12 Closure Plate Mounting Screws 2 Locate the pry tap pads on the closure plate See Figures 9 74 and 9 75 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 crankcase or closure plate as this can cause damage and leakage 9 17 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 9 Disassembly Figure 9 76 Separating Closure Plate From Crankcase 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 77 Grommet Figure 9 77 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
142. 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 main body and remove the bowl gasket from the 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 4 Measure the float height from the casting surface as illustrated in Figure 5 5 Float height for the CS4 and CS6 is 16 mm 0 63 in Float height for the CS8 5 C810 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 Figure 5 4 Float Height Position Figure 5 5 Measuring Float Height CAUTION Do not bend the float in an attempt to reset the height
143. sion 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 1 Release spring tension and remove the handle and starter rope Refer to Rope Replacement 2 Unscrew the center screw and lift off the drive plate The screw will be captured within plate by the clip on backside 3 Carefully note the positions of the pawls and pawl springs CS8 5 12 only before removing them Remove the parts from the starter pulley 4 Rotate the pulley clockwise 1 2 to 1 full turn this will ensure the spring is disengaged from the starter housing 5 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 6 Wearing adequate eye face protection carefully remove the spring from the pulley cavity 7 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 9 Disassembled Retractable Starter Reassembly 1 Generously lubricate the recoil spring with a commercially available bearing grease 2 Engage the outer spring hook into the pulley slit opening then carefully wind the spring counterclockw
144. st RE Washer Retainer Starter c Stop Collar Brushes Assembl y m Bush fur Spring zx Holder ME ia Z Insulator Nut UJ 2 M Commutator B End Cap ome Thru Bolt Figure 8 46 Nippendenso Solenoid Shift Starter 8 25 www mymowerparts com Ele Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 8 ctrical System and Components Starter Disassembly 1 Remove flange nut and disconnect the braided wire from lower main solenoid terminal Remove the two hex flange nuts securing the solenoid and carefully separate the solenoid from the starter assembly the front end of solenoid must be lifted slightly to permit disengagement from drive lever in starter See Figure 8 47 Figure 8 47 Starter with Solenoid Removed 3 4 Remove the two thru bolts Remove the commutator end cap from the starter frame and the rubber insulating grommet Carefully remove the insulator and brush springs from the brush holder Lift the four brushes out of their corresponding slots and remove the brush holder Remove the frame from around the armature and drive end cap See Figure 8 48 Figure 8 48 Disassembled Starter 8 26 8 9 Pull outward on the pivot portion of the drive lever and remove the drive lever and armature from the drive end cap See Figure 8 49 NOTE When removing the l
145. t 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 Ib On retractable start engines mount the Oil Sentry control module to the crankcase and attach the ground lead to the same mounting screw Torque the screw to 10 12 N m 88 106 in Ib 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 Ib 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 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 2 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 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 11 Reassembly Hole Position CS8 5 spec 92xxxx all CS1
146. talled in the cylinder head Replace the seal if it is deteriorated or damaged in any way Never reuse an old seal 2 Install the valves valve springs and retainers into their respective locations in the cylinder head 3 Compress each valve spring retainer assembly with a valve spring compressor and lock in place with lock clip Install the lock clip with its rounded edges down Figure 11 64 Installing Valves Using Valve Spring Compressor www mymowerparts com Inst 1 4 Figu 5 Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 11 Reassembly 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 all Cylinder Head 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 re 11 65 Installing Dowel Pins and New Head Gasket 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 1
147. th 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 4 Reinstall the oil fill check plug and tighten securely Figure 6 3 Oil Sentry Operation 6 2 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 6 Lubrication System 6 4 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Go Back CS4 12 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 Starter s A UK Handle 2 Drive Cup S M E Center Screw Starter sje M Drive Plate Friction
148. th the ring gear and into the retracted position When power is removed from the starter the armature stops rotating and the drive pinion is held in the retracted position by the anti drift spring Section 8 Electrical System and Components Starter Drive Service Every 300 hours of operation or annually whichever occurs first clean and lubricate the splines on the starter drive shaft If the drive pinion is worn or has 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 Retaining Spring 2 9 Holder Collar Figure 8 23 Drive Components 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 24 Removing Retaining Ring 8 19 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 8 Electrical System and Components 3 Remove the spring holder collar spring and 8 Install a new retaining ring into the groove of the drive pinion assembly from the armature shaft armature shaft Squeeze it with a pliers to 4 3 compress it into the groove It must fit into the recess in the end of the spring holder Figure 8 25 Disassembled Drive Compon
149. 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 1096 ethyl alcohol 9096 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 1596 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 5 1 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 5 Fuel System and Governor 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 Troubleshooting Fuel System Related Causes Test Conclusion Checkthe following
150. the model and specification number involved Model No Paga Nos 931501 901502 931502 901503 931503 901504 931504 901505 931505 901506 911501 911502 911503 911504 911505 911506 911510 931506 931507 931508 931509 931510 931511 931512 CS12T 941501 911507 CS12T 941502 911508 CS12TG 941503 911509 CS8 BT 921501 CS8 5T 921502 CS8 5TP 921503 CS8 5TR 921504 CS8 5TR 921505 CS8 5TG 921506 CS8 5TG 921509 CS8 5ST 921507 CS8 5ST 921508 CS8 5TG 921510 Model No Spec No Figure Page No 951500 951501 951502 951503 951504 951505 951506 951507 951508 951509 951510 OO O0 Cd O0 CO Cd 00 CO Cd CO Co za nnm ete oie ne bared aie Pre eae DO RID PD D D D 951511 8 6 CS12TG 941511 CS12TP 941504 CS12TR 941505 CS12TR 941506 CS12STG 941507 CS12STG 941512 5125 941508 5125 941509 CS12ST 941510 CS12GT 941513 CS12STG 941515 CS12STG 941516 CS12STG 941517 CS12STG 941518 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Ignition Module Stop Switch Wire Lead B Figure 8 4 Ignition Modu
151. ting of lightweight lithium grease to the lip of the seal 2mm 0 08 in Figure 11 45 Torquing Cover Mounting Screws 8 Addoil 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 Figure 11 47 Oil Seal Installation Depth Capacity 0 15 liter 5 02 fl oz 9 Install the 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 19 133 168 in Ib 11 12 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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 24 177 212 in Ib 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
152. to operation Even small amounts of these cleaners can quickly break down the lubricating properties of engine oil www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 3 Troubleshooting Basic 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 Kohler Part No 25 761 02 S or vacuum pressure tester Kohler Part No 25 761 22 S Complete instructions are provided in the kits Test the crankcase vacuum following the instructions with the engine running at high idle speed gt 3500 rpm a The engine should have a minimum of 4 of vacuum A vacuum less than 4 is usually due 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 b Referto the following chart for possible causes and solutions Low No Crankcase Vacuum or Pressure in Crankcase Possible Cause OOO y 1 Crankcase breather clogged or inoperative Disassemble breather clean parts thoroughly reassemble and recheck pressure 2 Seals and or gaskets leaking Loose or Replace all worn or damaged seals and gaskets improperly torqued fasteners
153. trudes through the side of the closure plate Through external linkage attached to the cross shaft the rotating action is transmitted to the throttle lever of the carburetor When the engine is at rest and the throttle control is in the fast position the tension of the governor spring holds the throttle plate open When the engine is operating the governor gear assembly is rotating the force applied by the regulating pin against the cross shaft tends to close the throttle plate The governor spring tension and the force applied by the regulating pin are in equilibrium during operation holding the engine speed constant 5 7 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 5 Fuel System and Governor When a load is applied and the engine speed and 5 Rotate the governor shaft clockwise until it stops governor gear speed decreases the governor spring tension moves the governor lever to open the throttle 6 Hold both in this position and tighten the governor plate wider This allows more fuel into the engine lever bolt increasing engine speed This action occurs very rapidly so a reduction in speed is hardly noticed As Torque the bolt to the speed reaches the governed setting the governor 8 N m 70 8 in Ib on CS4 CS6 spring tension and the force applied by the regulating 10 N m 88 5 in Ib on CS8 5 CS10 CS12 pin will again be in equilibrium This maintains the en
154. ts 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 lower jam nut from turning with a wrench while tightening the top nut to prevent damaging the internal components See Figure 8 44 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 45 8 24 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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 jel Thru
155. tting against specification Replace float if required governor hunting or Idle holes plugged dirt in fuel delivery channels Remove low idle fuel excessive throttle adjusting needle Clean main fuel jet and all passages blow out with opening compressed air 4 Fuelleaks from carburetor Float level too high See Remedy 2d Dirt under fuel inlet needle See Remedy 2e Bowl vent plugged Blow out with compressed air Carburetor bowl gasket leaks Replace gasket Troubleshooting Checklist Make sure the air cleaner base and carburetor If engine troubles are experienced that appear to be are securely fastened to the engine using gaskets fuel system related check the following areas before in good condition adjusting or disassembling the carburetor Make sure the air cleaner element is clean and all Make sure the fuel tank is filled with clean fresh air cleaner components are fastened securely gasoline Make sure the ignition system governor system Make sure the fuel cap vent and inlet filter are not exhaust system and throttle and choke controls blocked and operating properly are operating properly Make sure fuel is reaching the carburetor This If after checking all items listed above the engine is includes checking the fuel shut off valve screen hard to start runs roughly or stalls at low idle speed it filters and fuel lines for restrictions may be necessary to adjust or service the carburetor 5 8
156. ty e Hue aw RS P Cus uet es Battery Figure 8 20 Battery Voltage Test www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 8 Electrical System and Components Electric Starting Motors NOTE If the engine develops sufficient speed to Electric start engines in this series will use either an disengage the starter but does not keep inertia drive or a solenoid shift starter Each style has running a false start the engine rotation its own respective starter solenoid incorporated into must be allowed to come to a complete stop the mounting configuration The inertia drive starters before attempting to restart the engine If the are covered first beginning on page 8 19 and the starter is engages while the flywheel is solenoid shift style covered starting on page 8 25 rotating the starter pinion and flywheel ring gear may clash resulting in damage of the Starting Motor Precautions starter NOTE Do not crank the engine continuously for more than 10 seconds at a time If the engine NOTE If the starter does not crank the engine shut does not start allow a 60 second cool down off the starter immediately Check the period between starting attempts Release the condition of the inline fuse and do not make switch as soon as the engine starts Failure to further attempts to start the engine until the follow these guidelines can burn out the condition is corrected starter motor NOTE Do not
157. ure 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 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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 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 Section 11 Reassembly Figure 11 25 CS8 5 12 Installing Bearing 2 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 08 in Figure 11 26 Oil Seal Installation Depth 3 Pre lube all bearing surfaces with engine oil 4 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 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 11 Reassembly Figure 11 27 CS4 CS6
158. ure 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 Air Cleaner Element Cover and Seal 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 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 Air Cleaner Housing Swirl Dirt Chamber Latch Clips 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 preventing 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 13 Cutaway View www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 CS8 5 spec 95xxxx engines use a
159. urfaces are bent or damaged Figure 4 10 4 3 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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 Install 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 Sec
160. wn in Figure 10 10 Valve details illustration Section 10 Internal Components Valve Seat Cover Typical 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 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 10 Internal Components Pistons and Rings Inspection Scuffing and scoring of pistons and cylinder walls occurs when internal temperatures approach the melting 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 or
161. ww mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 1 Safety and General Information Description CS4 12 General Specifications Power 3600 RPM corrected to J1349 2 9 kW 4 HP wt tue emn ee reete 4 47 kW 6 HP 698 5 5 QOXXXX 1x ron e ete pl e prb br t 5 40 kW 8 5 HP CS8 5 spec 92 00000040 00 nennen nnne 6 33 kW 8 5 HP GS910 a eer tet dete ue eta ne det 7 45 kW 10 HP COV 2 astute ide deo Et e vae ei Shee a ah 8 95 kW 12 HP Peak Torque CS4 2000 RPM nnne 7 6 N m 5 6 ft Ib CS6 2000 4 04 04 0 10000000 10 8 8 ft Ib CS8 5 spec 95 2400 16 5 N m 12 1 ft Ib CS8 5 spec 92xxxx 9 2000 19 66 N m 14 5 ft Ib CGST0 Q 2000 RPM a iier eee teinte ces 19 66 N m 14 5 ft Ib 512 2000 22 6 N m 16 7 ft Ib Bore I 56 0 mm 2 20 in 66 0 mm 2 60 in 658 5 SPEC QOXXKX 12 cina e Hem e e v o eet tapas 75 0 mm 2 95 in CS8 5 spec 92 2 78 0 mm 3 07 in CS 10 em e teet n ted al dee ness 78 0 mm 3 07 in 85 0 3 35 in Stroke CSA CSB
162. y key switch or 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 2 3 Dirt or water 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 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 Air intake grass screen cooling fins or cooling shrouds clogged Excessive engine load Low crankcase oil level High crankcase oil level Faulty carburetor 3 1 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Section 3 Troubleshooting Engine Knocks 1 Excessive engine load 2 Low crankcase oil level 3 Old improper fuel 4 Internal wear or damage Engine Loses Power 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
163. y oil the element with new engine oil Squeeze element to evenly distribute the oil and remove any excess 4 5 www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 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 screen dirty or plugged cooling fins and or cooling shrouds removed will cause engine damage due to overheating www mymowerparts com Kohler Engine Parts Call K amp T 606 678 9623 or 606 561 4983 Go Back CS4 12 Section 5 Fuel System

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