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TWO CYLINDER SERVICE MANUAL

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1. OUTER HUB ZZ Ws BALL BEARING P ESSE BELT TENSION SHIMS TSENG NL 2 s NSA 222 IGNITION COIL INTERNAL JA ANSA RETAINING NUT CRANKCASE FAN BELT rper PP TUTTI STARTER CUP OIL SEAL RETRACTABLE STARTER STATOR ASSEMBLY gt A 4 vA 2 CRANKSHAFT NUT 5 3 ALTERNATOR 525 DRIVE SHEAVE AIS 222 772 QA 11 2 MAGNET RING SPARK ADVANCE FIGURE 10 2 CROSS SECTIONAL VIEW OF A TYPICAL AXIAL FLOW MODEL 1 SPARK PLUGS Remove spark plug boots then as the first step remove both spark plugs to prevent unintentional starting 2 STARTER The engine may have retractable starter electric starting motor or both With retractable starter mark position of handle so that it will be installed in same position during reassembly then remove the starter On blower type models remove the electric starting motor or if manual start the starter pad cover 10 2 4 5 BLOWER OR VENTILATOR HOUSING 6 FLYWHEEL BLOWER TYPE ENGINES FAN AXIAL FLOW After removing the air intake guard use spanner wrench to hold fan sheave upper then remove sheave retaining nuts outer sheave and belt tension shims count shims and save Remove belt from lower drive sheave AXIAL FLOW MODELS On these models the crankshaft nut hub and magnet ring sp
2. TWO CYCLE ENGINES TWO CYLINDER SERVICE MANUAL MODELS K295 2 K295 2AX K340 2 K340 2AX SK340 2AS K399 2 K399 2AX K440 2 K440 2AS K440 2AX K618 2 ENS 632 Class I CONTENTS X SECTION SECTION PAGE SECTION SECTION PAGE e NL XE OPERATION 520895 re Sw eee e ONE ENGINE GENERAL SERVICES EIGHT Safety Precautions 1 2 Carbon Removal 8 1 Prestart Instructions 3 Draining Crankcase 8 1 Starting Procedure 1 3 Engine Mounts i e E err eee ace 8 1 Stopping Procedure 1 3 Cooling Systems 2 gt 2 22 8 1 Operational Recommendations 1 3 Belt Tension Axial Flow Models 8 1 Trouble Shooting 1 4 3 Replacement Parts 8 2 Service Schedule 1 5 Power 1 510 8 2 OVERHAUL amp REPAIR NINE FUEL FUEL SYSTEM TWO Tool Requirements 9 1 Fuel Specifications Qul san Inspection Damage Analysis 9 1 Tanks Lines Carburetors 2 2 Model Variations 9 1 DISASSEMBLY d e RR ree ER TEN IGNITION SYSTEMS THREE General Recommendations
3. 10 2 Ignition Circuits 3 1 Sequence of Disassembly 10 2 10 5 Spark Plug Recommendations 3 2 Breaker Points ue Dreh enda 3 3 RECONDITIONING carom een hm meter Rr ELEVEN Condenser lee Lr er er ta aU ede 3 3 Crankshaft Connecting Rods 11 1 Ignition Coils 3 3 5 te reso RR ET e 11 2 Timing Advance Mechanism 3 4 Cylinder HeadS isomer 1 err nnn 11 3 Ignition Timing Procedure 3 4 Cylinders Reboring amp Replacement 11 3 Piston Piston Rings 11 4 Spark Advance Mechanism 11 5 ELECTRICAL SYSTEMS FOUR Ignition Electric System 11 6 Flywheel Alternator Systems ap ui Retractable Starters 11 7 Generator System K618 2 4 5 Carburetors 11 10 ELECTRIC STARTERS i v RR FIVE we vt TWELVE c Bendix Drive Starting Motors 5 1 Beneral tee mE ace 12 1 s Motor Generator K618 2 5 2 Sequence of Reassembly 12 1 12 5 Run In Recommendations 12 5 RETRACTABLE STARTERS SIX Rope Replacement Blower Type Starters 6 1 SPECIAL TOOLS THIRTEEN Alignment Procedure Blower T
4. P ZN 1 ff RETRACTABLE BEARING SUPPORT STARTER PLATE BALL BEARING CENTER MAIN Jj ALTERNATOR COIL SY 55 MAGNET RING NEEDLE BEARING BIG END SUPPORT FLYWHEEL PLATE FRONT DISASSEMBLY Before removing the engine from the vehicle color code wiring leads and make note of hose con This will prevent wrong connections and possible damage later when the reconditioned Disconnect spark plugs first as a safety precaution this eliminates chances of unintentional starting Disconnect muffler or exhaust tubes lines and drive pulley or whatever else is necessary to separate the engine from the vehicle Remove drain plugs from crankcase if provided to allow fuel oil to drain out Before moving engine to bench for disassembly thoroughly clean all exterior surfaces Items such as the engine stand which are listed in the tool section can be very helpful and time saving in repairing 2 cycle engines some of the tools listed are absolutely essential Metric wrenches are required for all model K618 2 and some K399 2 engines if the suffix or last two digits of the K399 2 specification number is 05 or lower it has the metric size All other K399 2 models have U S Standard sizes The following is offered as a suggested sequence of disassembly it may have to be changed to accommodate special equipment and accessories nections etc engine is reinstalled DRIVEN PULLEY FAN
5. 00 ROPE GUIDE ROPE 2 RETAINER CAST STARTER HOUSING SEE NOTE BELOW FELT WASHERS BEND ROPE IN HANDLE ROPE SHAPE AROUND PIN 7 7 RETAINER STEEL WASHERS INSERT IN SHEAVE E RING AS INDICATED RETAINING WASHER FIGURE 6 2 RETRACTABLE STARTER AXIAL FLOW MODELS NOTE Recent axial flow models use a retractable starter which has a cast housing rather than the 2 pressed or formed steel housing as shown above When replacing the rope or aligning the starters with 5 the cast housing follow the procedure stated on page 6 1 the cast housing type starters are similar to those used on the blower engines For starters with the pressed steel housing use the procedure below ROPE REPLACEMENT AXIAL FLOW MODELS This starter must be partially disassembled to replace the rope Use the tollowing procedure tor rope replacement STEP 1 After removing starter from engine remove the E ring retaining washer steel and felt washers and the friction shoe assembly carefully note sequence of these parts when removing STEP 2 Carefully lift the sheave out of the housing Remove any pieces of the old rope remaining in this sheave save the pin that the sheave end of the rope is wrapped around STEP 3 Fuse both ends of the new rope with a match then bend one end into U shape around the pin see illustration then insert this into hole in sheave hub Run the rope in t
6. 1bs 130 150 in lbs 145 155 in lbs 110 130 i 18 ft lbs Engine K295 2 is equipped with a L ring on the top Piston inches BTDC advance 14 1 215 225 1 150 160 i 240 260 i 1150 160 i 170 180 i 150 160 i 130 150 i 145 155 i n lbs 110 130 in 18 ft lbs 010 016 0028 004 0024 003 008 016 006 012 003 018 022 014 018 0 6 090 005 90 100 18 ft 1b lbs lbs lbs lbs lbs lbs lbs lbs 165 Tbs 5 012 018 0035 0048 0028 0040 008 016 006 012 003 018 022 014 018 090 005 4 x 17 ft Ibs 8 x 32 ft Ibs 190 200 in lbs 32 ft 90 100 ft 1b 190 200 in 170 180 in 150 160 in 130 150 in 145 155 in 110 130 in 18 ft lbs gn AO AA FLOW oe SPECIFICATION T Breaker Point Gap K340 2AX 5 340 2 5 K399 2AX K440 2AX K440 2A5 2AS 2 2641 2 4412 2 2 5599 2 6775 2s 677 006 006 006 006 New Standard 2 2604 EMEN 4376 2 358 um ume 2 6740 2 673 STROKE 22 205 232 362 2 3620 362 2 2 352 PISTON RING CYLINDER BORE New Standard Wear Limit PISTON SIZE 010 016 0022 0037 0012 0024 008 014 0022 0037 0012 0024 Ring Gap Side Clearance Top Side Clearance Bottom CONNECTING ROD 008 016 016 008 016 Lateral P
7. to determine if the leads or stator are open or grounded The resistance of the stator assembly should e be 0 2 to 0 6 ohm when checked between the green yellow lead and white lead The ohmmeter should read infinity when checking between either lead and the engine housing No reading across the two leads would indicate an open circuit and a reading from either lead to ground would indicate a grounded circuit If a problem is indicated check the lead wires for worn or broken insulation or a broken lead TESTING OUTPUT AC VOLTMETER Connect the AC voltmeter to the green yellow lead and white lead See Fig 3 12 Start the engine and run the speed up to approximately 4000 RPM The AC volt meter should indicate 40 to 70 volts TESTING OUTPUT TEST BULB Connect the test bulb to the green yellow lead and white lead See Fig 3 12 Start the engine and hold the speed at approximately 2000 RPM The test bulb should have a soft orange glow The bulb should get brighter as the engine speed is increased At approximately 7000 RPM the bulb should be about normal brightness 6 At INDICATOR jj TIMING TOOL 38 455 03 FIGURE 3 13 TIMING KOHLER TRON SYSTEM WITH TIMING TOOL TIMING ENGINES WITH KOHLER TRON IGNITION TIMING Use the following procedure to time the ignition on engines with the capacitor discharge system STEP 1 Remove recoil starter cap sheaves flywheel assembly stator assembly and spark plugs STEP 2 Install dial indicator
8. A carefully rebuilt HR model carburetor should perform well The two most likely causes of t Mu failure are dirt and a careless repair job clean carefully assembled unit should be arly as good as new 11 12 M M ee M M ame Sts Ma ee i eerie es ARA LA m Po maa ilis i MAIN FUEL HIGH NEEDLE METERING DIAPHRAGM LEAF SPRING METERING _ PLATE METERING LEVER CIRCUIT PLATE LEVER PIN SPRING RETAINING PUMP 7 DIAPHRAGM 2 25 gt Sn PUMP PLATE CHECK a DIAPHRAGM GASKET a D FILTER CIRCUIT PLATE 555 SCREEN SS CHECK VALVE DIAPHRAGM PRESSURE SPRING gt gt CHECK VALVE gt SCREEN N serem 4 Ou T GASKET s SPRINGS COVER 47 puMp SECTION ud BOTTOM SCREWS PUMP GASKET TIGHTEN TO 20 25 IN LBS TORQUE FIGURE 11 20 DISASSEMBLED VIEW TYPICAL MODEL WR CARBURETOR 11 13 WRI CARBURETORS Before deciding to recondition a carburetor make sure that the problem is not caused by some Other item in the fuel system If for example the problem cannot be corrected by readjustment check he impulse line and the complete fuel system if these are loose restricted or kinked the carburetor cannot deliver sufficient fuel even when it is in excellent condition After removing the carburetor flean the external surfaces using a petroleu
9. Small locating pins in the piston grooves SPARK ADVANCE MECHANISM Check surface of cam Replace cam if worn or damaged in any way To replace the cam detach screws and cam retaining clip When installing new cam engage tongue on centrifugal flyweight lever in slot on cam Check spring to make sure that it moves freely but without excessive play on the pivot pin Use small amount of Kohler cam grease on wick on breaker points to insure adequate lubrication of cam and breaker point lifter an amount about the size of a match head is usually adequate 11 5 Log gece rere PRIMARY IGNITION COILS fon TIMING TIMING ADVANCE ADVANCE LEVER EXTERNAL 55 PERMANENT A MAGNETS FIGURE 11 10 STATOR EXPLODED VIEW FIGURE 11 11 SPARK ADVANCE MECHANISM IGNITION ELECTRICAL SYSTEM The ignition service centering tool is required whenever the breaker points ignition or alternator Use of this tool establishes the proper air gap and also allows precision setting of Use the following procedure when servicing or replacing components coils are replaced the breaker point gap BREAKER POINTS If points are badly worn or pitted they must be replaced To remove loosen nut and remove leads from ignition coil and condenser Remove circlip and setscrew then lift point pivot arm off pin Remove point gap setscrew then detach bracket portion of breaker point assembly Reverse procedure to install new breaker poi
10. pin retainers piston pins is usually quite easy to diagnose needle bearing is hard enough to cut right thru piston rings without leaving jagged edges a loose retainer will not cut clean but will break the ring If retainer falls out or is not installed in the first place the pin may rub regular groove in the cylinder wall Often damage such as this goes by unnoticed until power becomes extremely poor due to lack of compression RING BREAKAGE Ifa ring breaks the engine may continue running however it will probably back fire badly and it cannot be restarted after it is shut down Ring breakage occurs from overheating due to lack of proper lubrication A poor quality or wrong type of oil may have been used the oil may have been poorly mixed or mixed in incorrect proportion with the gasoline ring that has been sub jected to overheating often becomes soft and is easily bent RINGS STICKING If there have been repeated complaints of spark plug fouling and dark exhaust smoke ED gt gt trom the same engine the rings might be stuck in the grooves due to carbon fouling This usually occurs from an overrich fuel mixture If the build up is shellac rather than carbon this probably indicates use of a poor quality oil BROKEN DAMAGED RODS Pounding on the end of the crankshaft to remove the flywheel can play havoc with connecting rods and rod bearings This practice can push the counterweights together squeezing the
11. the engine will remain vapor locked and will not run until the temperature drops low enough for the vapor to return to liquid state again The best way to avoid vapor lock is to use a carburetor having vapor return with this feature any vapor forming is directed back thru a separate return line into the tank where the pressure can be relieved CARBURETORS Diaphragm type carburetors are used on some Kohler 2 Cycle Engines while float type carburetors are used on other models the float type carburetors are furnished by the equipment manufacturer The main job of any carburetor is to meter a correct amount of fuel for all load or speed conditions and in so doing to change fuel from liquid to vapor and mix this with air in correct proportions to form the volatile gas needed for combustion These diaphragm type carburetors provide an additional function of pumping fuel from the storage tank CARBURETOR Don t change carburetor settings as this affects the amount of lubrication your engine receives Since the optimum setting varies with each application due to differences in carburetors mufflers power requirements etc the settings are not published in this manual 2 2 VENTILATOR HOUSING STATOR ASSEMBLY TUBING MOLDED INSULATOR CONNECTORS HIGH TENSION CABLE TO FAN SIDE SPARK PLUG gt o 2 lt Fr c Ld HIGH TENSION CABLE TO PTO SIDE SPARK PLUG TRIGGER ASS Y FIG
12. after the brush ring is over the commu tator Insert brushes then hook springs and position on brushes CAUTION Brushes can be damaged if the springs are allowed to snap against the top of the brushes Align thru bolts and pull the end down tight then install clip after making sure end play washers are in place Reinstall and secure the bushing cap to complete brush service BENDIX DRIVE SERVICE The starter must be removed from the engine to inspect Bendix drive assembly the splined shaft or pinion are dirty clean with solvent which does not leave a film the drive works best with only small amount of lubricant use dry spray type If damaged replace the complete Bendix drive assembly To remove drive the ring stop back toward the pinion then remove snap ring Spring bushing and pinion assembly can now be removed Reverse this procedure to reinstall new Bendix MOTOR GENERATOR K618 2 If unit fails to crank properly inspect entire cranking circuit for loose or badly corroded con nections and damaged wiring Check battery to determine condition When battery is satisfactory and wiring and connections are in good condition close starting switch If unit fails to crank wire around motor switch with a heavy jumper lead If motor generator operates the switch is defective and should be replaced If unit fails to operate the trouble can be attributed to the engine or to the motor generator Excessive friction in the eng
13. checking the stator to see if it has single or double primary coils the only way to tell which system is used is by checking the color of the ignition leads off the primary coil or coils Ifa solid blue lead and a blue white are found the sys tem is the two primary coil type The two ignition leads are color coded solid blue and blue red on the single primary coil system 1 HIGH 2 HIGH Pr PLUG oe 2 PLUG 600 000000 BLUE WHITE 000000 LEAD 0000004 BLUE A 2 POINTS LOW TENSION IGNITION COILS 1 POINTS LI x 00000 connenser sil il Q CONDENSER 2 POINTS LOW TENSION IGNITION COIL CONDENSERS SINGLE LOW TENSION COIL TYPE FIGURE 3 1 SINGLE AND DOUBLE PRIMARY COIL IGNITION CIRCUITS The ignition leads are not connected the same on the two systems after identifying which system is involved connect the ignition leads to the numbered terminals of high tension coils as shown in the accompanying diagrams Reversing the leads may result in damaged coils on the two primary coil sys tem on the single primary coil system a weaker spark will be produced if improperly connected This will usually be evident by immediate and repeated fouling of the spark plug electrodes Engines with model suffix designation AS are equipped with Kohler Tron solid state capacitor dis ignition CDI system Surface gap Champion N19V or equ
14. completely expelled resulting in a dirty mixture during the next combustion or power portion of the cycle Equipment for competitive events often includes expansion chambers for more rapid replacement of the fuel charge which in effect offers a super charging effect but in this case from the exhaust side rather than from the intake side expansion chamber is a popular method of increasing performance by amplifying sound waves for the purpose of speeding up exhaust and fuel transfer portion of 2 cycle operation INSTALLATION When installing a muffler make sure itis the right kind and that the inlet to the muffler is at the specified distance from the exhaust outlet on the engine Use flexible tubing or flexible ball joints these absorb vibration to prevent cracking and breaking which can be a problem especially when travel over rough terrain which is common to many 2 cycle engine applications 14 mean m mM soe Ie MT MA MM n etre mmm qs 22 ENGINE GENERAL SERVICES CARBON REMOVAL If excessive carbon is noted on the spark plug it is a good idea to check the condition of the com bustion chamber and top of the piston as these too may be carbon fouled Remove the cylinder heads and remove the carbon deposits with a wood or plastic scraper to avoid cutting or scratching the alumi num heads and pistons If carbon build up is heavy on top of the piston the rings are often stuck or about ready to stick in t
15. crankshaft ROD SIDE PLAY Mount dial indicator as shown in Figure 11 2 to check lateral movement of connecting Tod Move rod back and forth laterally if movement stays within the 008 016 range end play is within allowable limits SHAFT ALIGNMENT Install crankshaft in the lathe centers and check concentricity with dial indicator riding on shaft as shown in Figure 11 3 If run out exceeds 003 TIR remove shaft and try to bring back into alignment by either pinching weights closer together in a vise or by spreading them further apart with a metal wedge Repeat alignment check after repositioning weights If this fails to bring shafts back into alignment a new assembly must be used USE PROTECTIVE CAPS ON VISE JAWS 11 1 SIDE PLAY 008 016 FIGURE 11 2 CHECK LATERAL MOVEMENT SIDE PLAY OF CONNECTING ROD CLEANING After checking shaft thoroughly clean assembly in a type of cleaning solution which does not leave an oily film use light naptha or similar solution Do not for example use kerosene as this leaves an oily film Alcohol or lacquer thinner also must not be used as these on the other hand leave parts too dry may cause seizure during initial start up after reconditioning RANKCASE Check mating surfaces Carefully inspect upper and lower halves of crankcase assembly replacement of the crankcase assembly may be required if surfaces are badly nicked or grooved sure that all scre
16. discon nected check for wrong connections or if none are found replace the switch CONDENSER Use commercial condenser tester per tester manufacturer s instructions bad condenser will cause premature failure of points COIL Check on coil tester continuity must be indicated COMPRESSION RELATED CAUSES POOR COMPRESSION ABNORMAL COMPRESSION Spark plug loose 1 Build up of carbon Head loose 2 Wrong head Head gasket leaking Piston rings sticking Cylinder badly worn Burned piston Ov P COMPRESSION TEST Most causes of poor compression are readily evident If of the easier tests reveal the cause it will be necessary to disassemble heads and cylinders to find reason Insufficient fuel is often the primary factor leading to damage to pistons and cylinders check out this system too PREVEINHIME SERVICE EE SPARE PLUG Check condition reset gap i SPARK PLUG Replace with new plug p BREAKER POINTS Check regap retime ignition F COMBUSTION CHAMBER Remove carbon p 22 2c2fcl22l2lac EXHAUST PORT Clean out deposits PISTON RINGS Clean carbon free rings 1 5 FUEL FUEL SYSTEM FUEL REQUIREMENTS Since most 2 cycle engines including Kohler receive lubrication only from the oil which must be mixed in with the gasoline it is of utmost importance that the oil be
17. flywheel while the Axial Flow models are cooled by a belt driven blower Never operate your engine with missing or loose air shroud covers or with broken fins on flywheel or blower fan Keep air intake openings on vehicle and engine clean and unobstructed at all times to prevent overheating Proper belt tension must be maintained on Axial Flow models for proper cooling Don t operate Axial Flow engines with broken or badly frayed belts 4 DR DRIVEN BELT TENSION S SHEAVE 1 After removing guard push belt ANN N in at point shown belt should RETAINING NUT deflect about but no more than 35 FT LBS 3 8 USE SPARK To adjust use spanner to hold PLUG WRENCH driven sheave while removing nut then remove outer sheave To increase tension remove shims To decrease tension add shims Save unused shims for future use Reinstall outer sheave tighten nut to 35 ft lbs then recheck 4 tension repeat above until tension wis 3 MAXIMUM is correct Reinstall fan guard DEFLECTION BELT REPLACEMENT Remove guard and Retractable starter Remove outer hub of driven sheave Remove old belt install new use correct replacement Reinstall outer hub of driven Sheave tighten nut to 35 ft 155 Check belt tension and adjust if needed per above SPANNER BELT DRIVE Reinstall Retractable starter and DRIVEN SHEAVE fan guard SHEAVE SHOWN WITH RETRACTABLE STARTER Belt tension should be checked after first 2 3 hours
18. manifolds starter mounts etc Other sources of damage from vibration are unevenly worn drive belts missing cleats misaligned drive components low or flat tire on or sudden shocks and jarring from riding over railroad ties or along rough washboard roads and trails The following chart is presented as a guide to systematic trouble shooting It lists some of the most common causes for example if the engine does not start it may also be due to poor compression which you ll note is not checked however the factors which are checked are perhaps the most likely causes Note too that the problems are grouped under fuel ignition and compression with the more easily detected causes and easiest remedies listed first Use this as check list for faster more accurate trouble shooting TROUBLE SHOOTING GUIDE POSSIBLE CAUSES SEE DETAILS BELOW AND ON NEXT PAGE TO0 MUCH wo IGN is POOR 2 FUEL SPARK IGNITION COMPRESSION WILL NOT START HARD STARTING LACKS POWER POOR ACCELERATION PINGS UNDER LOAD BACKFIRES RUNS UNEVENLY STOPS OR STALLS SUDDENLY FUEL RELATED CAUSES MUCH FUEL NO FUEL INCORRECT FUEL Tank empty Stale fuel won t vaporize Overchoking flooded OS 4 Fuel valve turned off Tank vent closed or plugged Line disconnected Line kinked plugged Filter screens blocked Impulse tube off or plugged Air leaks lo
19. on new belt REMOVED FIGURE 8 1 BELT TENSION BELT REPLACEMENT AXIAL FLOW MODELS 8 1 OBLIQUE FIN HEADS CARBURETOR SIDE OUTLET TOP OR END OUTLET FIGURE 8 2 CYLINDER HEAD FIN DIRECTION DIFFERENCES REPLACEMENT PARTS Always use the Genuine Kohler Service Parts for replacements This insures a quality replace ment and keeps clearances or tolerances within specifications Substitute parts are often designed to fit several engine models with specific categories and may not therefore be perfectly suited for use on any one model in the range Use the Kohler 2 Cycle Engine Parts Manual to obtain the correct part for the engine being repaired Mention Engine SPECIFICATION SERIAL and MODEL number when order ing parts POWER TRANSMISSION While the drive or power transmission units are mainly the responsibility of the vehicle manufac urers service organization anyone repairing engines should know how to disconnect then reconnect the drive properly to retain the correct belt tension and alignment of drive components The engine repair specialist should also know enough about the drive unit to know when the transmission rather than the engine is causing poor performance and lack of power Don t hammer on the crankshaft to bump the pulley loose this may destroy side play of the con necting rods thus squeezing and ruining the needle bearings Use a puller but be careful not to distort the pulleys Pulleys must be ma
20. to the Model Variation para graph below to determine if the engine has Metric or U S Standard size threads INSPECTION Start looking for causes of engine problems before you remove it from the vehicle If cracked or broken parts are evident check for loose engine or torque converter mounts Excessive vibration may also come from an unevenly worn drive belt misaligned pulleys missing cleats flat tire on ATV etc Frequently parts vibrate loose over rough terrain and are simply ignored and not retightened in time to prevent damage Some other types of damage and probable causes follow PISTON BURN THRU Ifa hole is burned right thru the piston look for an improperly adjusted carbu retor or incorrect timing If these items check out OK you may want to question the owner about the use of wrong oil or improperly mixed fuel The wrong type of spark plug for conditions involved may also be the cause of abnormally high combustion temperatures which cause burn thru FOREIGN MATERIAL Operating without an air intake silencer or not cleaning out around spark plug openings berore removing plugs can lead to piston damage from foreign objects dropping into the engine if the damage is on the piston crown something probably fell into the opening when the plug was removed Damage on the sides of piston may indicate that an object was drawn into the intake LOOSE NEEDLE RETAINERS PINS Piston and cylinder damage caused by loose needle bearings
21. 70 in lbs 160 170 in 1585 Spark plug bei tied UT SS ole 18 ft lbs 18 ft lbs 18 ft lbs KOHLER CO of KOHLER WIS 53044 8 2 a ENS 632 11 73 U PRINTED IN U S A
22. AN BLADES FIGURE 10 4 HOLD FLYWHEEL WITH CHAIN CLAMP WHILE REMOVING NUT BLOWER ENGINES 7 STATOR ASSEMBLY Scribe matching marks on stator and bearing plate or crankcase Axial Flow models bearing plate so that stator can be reinstalled in exactly the same position later Disconnect C necessary leads then remove stator mounting capscrews and detach stator DON T BUMP END OF FLYWHEEL TO LOOSEN FIGURE 10 5 USE PULLER TO REMOVE FLYWHEEL MAGNET RING ASSEMBLY BLOWER ENGINES 10 4 9 10 Ti 12 CARBURETOR INTAKE MANIFOLD Disconnect impulse tube from fitting on crankcase remove nuts securing intake manifold to crankcase then remove carburetor and intake manifold as a unit Detach carburetor only if it is to be reconditioned Note Axial Flow models have a two piece intake manifold AIR SHROUDS Remove all screws securing air shrouds blower type models lift air shroud cover over top of cylinder barrels then remove cylinder baffle Axial Flow models have a two section air shroud which is split in center and is removed from the sides FRONT BEARING PLATE BLOWER TYPE ENGINES To remove the front bearing plate not on Axial Flow models remove capscrew then tap plate gently with soft head hammer After plate is detached remove old ring and crankshaft end play adjusting shims note number of shims and use same number here later during reassem bly Shi
23. G CYLINDER WITH HONE CYLINDERS Carefully observe cylinder bore for signs of scuffing check gasket surfaces for nicks or grooves which could prevent proper sealing check for badly chipped or broken fins Also make sure threads are not stripped Use new cylinder barrel if damage is noted If none is evident measure cylinder bore for wear use inside micrometer or bore gauge and check area just below top of bore Wear will be indicated by step worn into the wall Measure at right angles to the piston pin axis at the top where most wear occurs If worn more than 006 the cylinder will have to be replaced or rebored providing oversize piston and rings are available NOTE On AS models pistons and cylinders are color coded make sure both have the same color coding when replacing Oversize cylinders are not available for AS models Chrome plate cylinders are used on the AS models If oversizes are available check parts manual sections rebore cylinder oversize and use corre sponding oversize pistons and rings 010 020 and 040 oversizes are available for some models while only 020 and 040 are available for certain models Check available oversizes before rebor ing After reboring remove any burrs that may have formed at edges of ports Thoroughly wash walls with kerosene and clean rags then after cleaning apply light coating of SAE 10 oil on walls to prevent formation of rust Make sure all trace of gasket material is removed fro
24. OK check the ignition switch first If the switch is OK the alternator may be at fault On Kohler Engines an ignition centering tool must be used to establish proper air gap between the alternator coil and magnets IGNITION SWITCH EXTERNAL NES IGN COIL SPARK STARTING STARTING 12 VOLT PLUG T MOTOR SOLENOID BATTERY WATT ELECTRIC START SYSTEM WITH SEPARATE LIGHT SWITCH FIGURE 4 3 75 4 2 Single Primary Ignition Coil Without Starting motor battery With voltage regulator and brake light Capacitor yeilowf green Q Lighting coil Breoker points Primory generating Breaker Spork plug Spark plug points Capacitor 1 blue sr OPTIONAL Secondary ee e 42 Secondary winding E nor Primary rs 2 5 Primory winding ignition coils Light Coil 75 w Light Coil 23 W P Primary Ignition Generating Coil Connect Green Wire of B to Outside Eyelet of L Connect Black Green Wire of B to Top Eyelet of L Circuitry for day and night operation Gouge 12 yellow gr Gouge 12 Switch positions 0 Ignition off I Lights on Il Lights off BRAKE RAKE Starting pa LIGHT SWITCH Front ond tail lights Only one winding lead yellow is connected for this circuit the second winding lead yellow will not be connected and is insulated Day driving Switch position II Night driving Switch position I The connected winding lead i
25. TION FIGURE 11 15 USE CAUTION WITH REWIND SPRINGS FIGURE 11 16 RETAINER KEEPS ROPE ON PULLEY 4 Reinstall dogs pawis in hub of pulley Some starters use individual springs under each dog rather than the small spring which hooks over the post Hook spring when used which is attached to the retainer over post of hub then install washers spacers and retainer Note that the smaller washer is placed next to the retainer Check sequence of washers and make sure holes are centered as the retainer is reassembled Tighten dog retainer capscrew with torque wrench to 120 in lbs When this is done a slight drag will be felt when retainer is turned by hand however when handle is pulled dogs will readily move into engaged position If loose the dogs will not engage or will only partially engage and damage teeth in starting cup Inspect and replace damaged drive cup 5 To pre tension rewind spring thread rope through bushing and pull all the way out to the fully extended position Hold pulley in this position then slack off on rope make loop about diameter of pulley then work pulley around one full turn to increase tension Pull rope out again and make temporary knot to hold while reinstalling handle and retainer Release temporary knot and test pull rope all the way out until the knot is even with bushing in housing then work pulley with thumbs in counterclockwise direction about 1 4 turn more or to the point where it is next to the f
26. URE 3 2 WIRING DIAGRAM CAPACITOR DISCHARGE IGNITION SYSTEM SPARK PLUGS SPARK PLUG SELECTION Observe color of electrodes when removing plug as this often gives a good indication of operaring conditions Take the necessary corrective action if other than normal operation is indicated the indicators are CARBON FOULING NORMAL OVERHEATING Replace plug if carbon fouled or if porcelain is cracked Do not sandblast scrape or otherwise attempt to service a plug that is in poor condition best results are obtained with a new plug Use plugs selected from the accompanying chart only SPARK GAP ALL PLUGS 020 TIGHTENING TORQUE 18 FT LBS SPARK PLUG RECOMMENDATIONS Engine 21 L Kohler Part Number Bosch Number Champion Number Model Normal Duty Normal Duty Heavy Duty Normal Duty Heavy Duty kw wm xe mms w vm me wan amon 7 wm var e Ow 1 1 Heavy duty plugs for all terrain vehicles and summer use Use surface gap spark plugs only 3 2 IGNITION SYSTEMS FLYWHEEL MAGNETO IGNITION o Two types of flywheel magneto ignition systems are used One type has 2 primary low tension coils the stator while the other type uses single primary ignition coil Both systems have 2 external high tension coils one for each spark plug Without actually
27. a fuel gauge with the cap some of these have an open vent hole while others have a screw type valve which can be closed to prevent loss of fuel thru evaporation Vent holes in caps are usually formed with baffled configuration to prevent entrance of foreign material In addition to the screen in the tank there is a filter screen in the carburetor Full flow filters often of the see thru kind are frequently inserted in the fuelline between the tank and carburetor These cannot be overlooked as potential source of fuel starvation If replacing any fuel system components make sure they meet the vehicle manufacturer s specifi cations for any part that restricts flow of fuel not only results in operation with insufficient gasoline but more important insufficient lubrication IMPULSE TUBE This tube transmits pulsating crankcase pressures to the diaphragm of the carburetor for pumping fuel If replacing an impulse tube make sure the replacement is the same length If the tube length is greater than 8 pumping action is lost With WR and WD carburetors the tube is con nected to the 1 cylinder with HR and HD carburetors the tube is connected to 2 Change impulse location if changing from one type of carburetor to another VAPOR RETURN LINES If the area around the carburetor or air into the carburetor becomes hot enough to vaporize gasoline inside the carburetor the pockets of vapor so formed will stop all flow of fuel whenever this occurs
28. a heavy gauge ground wire 4 or 6 should be connected between the engine and the frame of the vehicle Use 6 gauge wire for any connection that must carry heavy battery current ONE ALTERNATOR LEAD ISOLATED YELLOW GREEN ON K295 2AX PRIMARY YELLOW LEADS C540 2AX MODELS IGNITION SWITCH POSITIONS ALTERNATOR COIL A RUN LIGHTS ON B RUN LIGHTS OFF COIL 288 KOHLER TERMINAL TT SWITCH SHOWN NOTE On K295 2AX and K340 2AX Models with yellow green Leads one lead must be grounded for AC output FIGURE 4 1 75 WATT MANUAL START SYSTEM WITH KOHLER SWITCH FLYWHEEL ALTERNATOR SYSTEMS The electrical system functions to provide energy for lighting and or charging a 12 volt storage battery for electric starting An alternator coil attached to the stator plate also uses the magnetic field of the permanent magnets on the flywheel By alternate placement of North South poles in relation to the coil an alternating current is induced in the alternator coil windings battery equipped models the leads from the alternator are brought out to a rectifier to convert the AC to DC which must be done for charging the battery On manual start engines without battery rectification is not required there fore one lead is isolated and the other is brought out to the light switch Some applications use separate voltage regulators which control voltage regardless of load most however have unregulat
29. and move until gap is at 016 On 2 cylinder engines repeat procedure for the second set of points Retime engine with timing tool after adjusting replacing or servicing points TOP BREAKER POINTS FOR CONDENSER E 2 CYLINDER EQ of 524147 c3 f AO n es HIGH ADJUSTING f IAS POINT SCREW gt gt ON BOTTOM BREAKER CONDENSER POINTS FOR 1 CYLINDER FIGURE 3 3 BREAKER POINTS CONDENSER LOCATED UNDER FLYWHEEL OR HUB CONDENSER If the condenser shorts out the system will be unable to produce full output If it decreases in capacitance the output voltage will be greatly reduced and the ignition points will burn excessively If badly burned breaker points occur too frequently the condition of the condenser should be suspected If condenser has too little capacitance metal will transfer from the stationary contact to the movable contact If capacitance is too high metal will build up on the stationary contact The condenser may be tested with an ohmmeter or commercial condenser tester To check with the ohmmeter remove the condenser then connect leads between the condenser lead and a good ground on the engine At first a low resistance should be indicated however this should very quickly rise toa high value If low resistance is indicated continuously the condenser is definitely faulty and must be replaced When using a commercial condenser tester follow instructions g
30. andle Fuse both ends of new rope with match bend end of rope in U shape around retaining pin and insert this end in hole in sheave hub then wrap rope in counterclock wise direction around sheave Insert free end of rope thru notch in outer face of sheave then install pulley in starter housing Reinstall felt washers steel washers friction shoe assembly if installed right side up sharp edge of dogs will be toward outside spring in sequence illustrated and lock in position with washer and E ring Pre tension rewind spring by rotating sheave in counterclockwise direction about 3 1 2 to 4 turns then hold in this position and thread rope end thru rope guide Pull rope out from guide about 1 2 foot tie slip knot in rope to prevent starter from rewinding insert rope thru handle and hole in retainer tie permanent knot in end and reassemble retainer in handle Release the slip knot then reinstall starter on engine no alignment procedure required on this type starter 11 9 CARBURETOR REPAIR There are numerous versions of the HR series carburetors and Model WR carburetors being used _ on these twin cylinder engines The main differences between models is usually found in calibration and or location of throttle and choke lever assemblies Because of these differences several repair kits are needed make sure the correct kit is used for the model being reconditioned Complete dis assembly of the carburetor is not usually necessary ch
31. ark advance assembly must be removed before the ventilator housing can be removed To hold the crankshaft for removing the nut wrap a chain wrench around the drive sheave then loosen the nut Remove the sheave from the hub then use a puller for removing the magnet ring spark advance assembly FIGURE 10 3 USE CHAIN CLAMP TOOL TO HOLD DRIVE CUP FOR REMOVAL BLOWER ENGINES The blower housing or ventilator housing on Axial Flow models is secured at five points on most models but at nine points on the K399 2AX and K440 2AX Remove all retaining screws to remove the housing blower type engines the starting motor or starter pad cover must also be removed before the blower housing can be detached Remove the rope start pulley first use chain wrench to hold pulley while removing the two capscrews The pulley is recessed to be a snug fit over the flywheel retaining nut to free it tap or work it from side to side until loose Remove dust cover then use an impact wrench to remove the flywheel retaining nut or hold flywheel with chain clamp wrench and remove the nut with a breaker bar When using the chain clamp make sure the chain links mesh with the ring gear teeth or if no ring gear make sure chain is on flat surface of flywheel keep chain away from fan blades The flywheel is mounted and keyed to a taper on the crankshaft Use puller to remove do not bump end of crankshaft to loosen 10 3 3 KEEP CHAIN AWAY FROM F
32. ch will ruin an engine In addition to using a poor grade of gasoline and improperly mixed fuel there are numerous other conditions which result in operation with insufficient lubrication The most prevalent cause is perhaps the incorrectly adjusted or malfunctioning carburetor Other causes are partially blocked filters or screens kinked or pinched fuel lines wrong size fuel lines plugged vent hole in gas cap and a cracked or loose impulse tube PRIMER FITTING ENGINE SIDE OF THROTTLE PRIMER BUTTON THROTTLE x PRIMER ave TEE 4 lt SILENCER JF OR AIR FITTING CLEANER IMPULSE TUBE VAPOR RETURN FIGURE 2 1 SCHEMATIC OF A TYPICAL 2 CYCLE ENGINE FUEL SYSTEM 2 1 VAPOR RETURN FITTING Special PRIMER FITTING PRIMER IMPULSE she E FITTING FITTING IMPULSE 2 FITTING VAPOR RETURN FUEL FUEL FITTING Mud SUPPLY SUPPLY FIGURE 2 2 MODEL WR CARBURETOR FIGURE 2 3 MODEL HR CARBURETOR With the possible exception of the carburetor fuel system components are usually furnished by the vehicle manufacturer but since these parts can seriously affect engine operation some of the main points about each are brought out in the following Fuel tank filler caps must be vented Ifa vent is not provided or if it becomes clogged fuel star vation will result Several different types of filler caps are in use One type combines
33. e model involved in the Fuel System Section of this manual before placing the engine in operation 2 Position the two circuit plate gaskets diaphragm and circuit plate on the body and secure with the 3 screws 3 Install inlet needle and seat spring lever and pin then lock pin in place with the screw as shown set the lever 005 010 from the surface as shown in detail 4 Position new metering diaphragm then install the metering plate make sure springs leaf spring pressure spring aud check valves are installed and in good shape 5 Install pump gasket diaphragm and fuel pump plate 6 Position check valve gasket diaphragm and filter plate 7 Install filter screen screen gasket then install and secure the pump section cover with the 4 bottom screws tighten these screws to 20 25 inch lbs to complete reassembly of the carburetor REASSEMBLY bs The following is the suggested sequence for reassembly of a typical two cylinder engine some of the procedure may have to be altered to account for special equipment accessories The procedure ES does not in most cases cover reassembly of the various sub assemblies This has been covered in 2 the Reconditioning Section Make sure work area and all parts are kept clean during final assembly of the engine 1 END PLAY DETERMINATION Install thru bolts in bottom half of crankcase before attaching to engine stand After mount ing the bottom crankcase
34. e rewind spring fits into a slot in the hub of the pulley The pulley must be carefully lifted out of housing to insure that the Spring detaches from the hub 11 7 RECONDITIONING Use extreme caution safety glasses etc when removing handling or installing rewind springs Do not remove spring from recess in starter housing unless replacement is absolutely necessary i 1 SPRING REPLACEMENT Carefully remove rewind spring start on inside loop pull one loop out ata time Place new spring in housing then after blocking spring to prevent lateral move ment carefully remove retaining clip and tape if used tape must be cut and removed in segments do not peel from spring 2 REPLACING BROKEN ROPE When the rope breaks the pulley unwinds violently and may dam age other parts Careiully inspect dogs dog retainers etc and replace if worn or damaged Tie a knot at one end of the new rope slide the washer over rop up next to the knot then guide other end through hole in pulley Pull rope through until washer and knot are tight against the outside surface of pulley Wind rope around groove 3 Position pulley on top of spring in the housing knotted end of rope facing up Note hole in hub of pulley insert piece of stiff wire or nail into this hole then turn pulley The wire will guide the inside end of spring into the hub and allow the pulley to drop into position in the housing mM JN HANDLE SPRING WITH CAU
35. eck the contents of the repair kit first as this will usually determine the extent of disassembly HR CARBURETORS Select a clean work area because dirt and carelessness are the causes of most carburetor trouble Proceed as follows to recondition the standard model HR carburetor CAUTION Some solvents and cleaners have a damaging effect on the synthetic rubber parts used in carburetors It is best to use a petroleum product for cleaning Do not use alcohol acetone lacquer thinner benzol or any solvent with a blend of these ingredients unless the rubber parts and gaskets are removed If in doubt about a solvent test a used part in it and observe the reaction DISASSEMBLY The entire carburetor should be cleaned by flushing with fuel and blown dry with com pressed air before disassembly The carburetor should be inspected for cracks in the casting bent or broken shafts loose levers or swivels and stripped threads 2515 Inspect the idle speed screw washer and tension spring Inspect the casting for thread damage In the event the casting is stripped of threads repair by drilling and tapping then insert an 8 32 Heli coil 3 16 long 2 The fuel inlet and filter cover are removed by removing the center screw Remove the filter cover the cover gasket and the filter screen The filter screen should be cleaned by flushing with fuel or solvent and blowing with compressed air It is advisable to replace the gasket when ever the filter scre
36. ed systems which are controlled only by amount pf load To avoid an over voltage condition on non regulated systems and resulting rapid burn out of bulbs always recommend using full output of the electrical systems If the vehicle lights seem excessively bright this usually indicates an overvoltage condition on the other hand dim lights could indicate that the load is too great For example if you have manual start engine with a 40 watt system use a 5 watt taillight and 35 watt headlamp to total 40 watts Get as close as possible to capacity but don t exceed it On the 75 ap watt systems allow 15 watts to charge the battery on electric start models On manual start models use a resistor of appropriate value to make up for any load not used for lights 4 1 51 LI Vl cuum SD 90 7 RARUA RECTIFIER EEEN NOT EXCEED 60 WATTS 15 WATTS REQUIRED COIL KOHLER 6 TERMINAL SWITCH SHOWN FOR BATTERY CHARGING SWITCH POSITIONS A RUN LIGHTS ON B RUN LIGHTS OFF C STARTING 12 V BATTERY 32 amp hr min The fuses inside the rectifiers do not protect the lights from burning out from overvoltage or causes but rather protect the solid state electronic devices from damage in the event the battery CN hooked up backwards Battery must be negative ground The lights will continue to operate witha If lights will not turn on and the bulbs o blown fuse but the battery cannot be charged when this occurs are
37. eeler gauge as shown in the accompanying illustration Side clearance must not be more than that specified below If more than this groove is worn beyond limits and piston must be replaced Ee MODEL IN INCHES PISTON RING DETAIL 2 2 2 2T K340 28x 2 K399 AT K440 2T 440 2 K618 2 a 0022 0028 0022 0028 0022 0028 0022 0035 0037 004 0037 004 0037 004 0037 0048 SIDE CLEARANCE 0012 0024 0012 0024 0012 0024 0012 0028 BOTTOM RING 0024 0036 0024 0036 0024 0036 0024 004 END GAP 008 010 008 010 008 010 008 012 TOP amp BOTTOM RING 014 016 014 016 014 016 014 018 K295 2T amp 2AX SK340 2AS also KX440 2AS also PIN AT TOP OR BOTTOM PIN TOWARD OF GROOVE PIN IN CENTER OF GROOVE INTAKE SIDE an LP a cmm TOP VIEW 446 0 BEVELED EDGE RING STRAIGHT EDGE RING TOP L RING FIGURE 11 9 PISTON RING VARIATIONS AND INSTALLATION DETAILS When installing rings for blower type engines except K295 2T install the lighter appearing ring in the bottom groove nearest pin first then install the top ring which is the duller or darker moly coated ring in the top groove The Axial Flow and K295 2T engines use L shaped ring in the top groove Use ring expander to install rings all models turn rings so that the ring gap is over the
38. en is serviced Flush all dirt from the plastic cover before assembly 3 Remove the six body screws the fuel pump cover casting Remove the fuel pump diaphragm and gasket Inspect pump diaphragm it must be flat and free from holes The gasket should be replaced if there are holes or creases on its sealing surface Be certain to reassemble these parts in the correct order The pump gasket should be assembled onto the diaphragm cover first then the fuel pump diaphragm should be assembled next to the gasket and flap valve member next to the fuel pump diaphragm so that the flap valves will seat against the fuel pump cover FUEL PUMP SECTION CHOKE LEVER MAIN FUEL ADJUSTMENT PRIMER CONNECTION OPTIONAL IDLE FUEL ADJUSTMENT INSULATING GASKET FIGURE 11 18 TYPICAL MODEL HR CARBURETOR 11 10 CARBURETOR BODY IDLE FUEL NEEDLE 2x MM MAIN FUEL NEEDLE MAIN METER DIAPHRAGM 7 SET LEVER FLUSH WITH CASTING CENTER F BODY EM 2 jr i CENTER GASKET THROTTLE SHAFT CHOKE PLATE CONTROL 7 RUBBER DIAPHRAGM V SPRING gogga LEVER 7 E DIAPHRAGM 2 f gee FUEL INLET COVER FIGURE 11 19 DISASSEMBLED VIEW TYPICAL MODEL HR CARBURETOR diaphragm for holes tears and imperfections order is assembled next to the gasket 5 Remove the fulcrum pin retaining screw the fulcrum pin inlet control leve
39. er gauge Always recheck gap set ting after tightening the adjusting screw as this sometimes alters the gap Use the following procedure to check ignition timing l Remove spark plugs and install timing tool in 1 cylinder first on twin cylinder models 2 Connect timing light leads between black ignition lead for 1 first and good ground engine turn light on 3 Adjust point gap as close as possible to 016 do this to both sets of breaker points on twins Recheck gap after retightening adjusting screw as this sometimes changes the gap 4 Turn flywheel clockwise until piston is at TDC dial will suddenly reverse direction then set dial at zero at this point 53 Move timing advance lever into full advance and hold this position while checking timing 6 Turn flywheel counterclockwise untillight change is noted if this occurs when dial indicator is within range repeat procedure on 2 cylinder If light changes when indicator is outside the specified timing range readjust timing per the following instructors TIMING ADJUSTMENT First try to correct timing by making slight changes to point gap setting if the timing light change occurred before the indicator reached the specified timing point increase gap slightly If it goes past the specified range decrease the gap slightly If timing cannot be brought within range by changing the point gap it will be necessary to reset the gap at 016 then shift the stator until timing i
40. es To understand how the exhaust system does all this remember that sound waves are actually waves of air pressure and are a definite source of energy If you have a wash tub full of water and toss a rock into the center you will note that the waves move outward in circular motion from the impact point then when they reach the side the waves bounce off the side or reflect back in toward the center Likewise sound waves move outward ata terrific rate of speed then reflect back toward the source which in this case is where the hot gases escape from the exhaust port By careful calculation the exhaust components are positioned at a specific distance or built so that the energy of the reflected waves reach the port at the precise moment to block off or hold most of the new charge of fuel to prevent it from being carried along with the gases ZEE FLOW EE NOTE Mounting distance must be to exact spectfications for engine model and type of muffler used check specifications before installing ala do 22 FIGURE 7 1 EXHAUST SYSTEM REQUIREMENTS 2 CYCLE OPERATION Some mufflers are made with a megaphone like device which first amplifies sound to speed up scavenging of the gases then silences the sound thru a series of baffles which must be designed to offer maximum silencing but minimum back pressure If back pressure is too great the intake of fuel thru the transfer port will be retarded plus the exhaust gases will not be
41. ethod for locating 3 6 2 LEAD CONNECTOR ELECTRONICS 100 TO 300 MODULE OHMS eo ELECTRONICS JUMPER LEADS 100 to 300 TIMING OHMS RING FIGURE 3 8 ELECTRONICS MODULE TEST FIGURE 3 9 TIMING RING TEST TRIGGER HOUSING ASS Y the faulty component is to use an ohmmeter measure resistances The ohmmeter test dure for resistance values is stated later however if an ohmmeter is not available the following test procedure can be used A Coil Test Disconnect the primary lead from the nonfiring coil red or white lead Dis connect the primary lead from the firing coil and install it on the nonfiring coil Do not hold the primary lead on the coil primary terminal as a severe electrical shock may result Turn the ignition switch on and pull the starter If the nonfiring coil now produces a spark the coil is good Reconnect the primary leads to the proper coils and proceed to timing ring test If the nonfiring coil still does not produce a spark the coil is defective and must be replaced Check high tension lead before replacing coil B Timing Ring and Electronics Module Test Make three short jumper leads terminated with one male and one female bullet type connector to mate with the terminals in the three lead plug in connector at the electronics module Could use jumper leads with small alligator clips Unplug the three lead plug in terminal from the electronics module Connect
42. he groove on inside of pulley then wrap the rope around the sheave in counterclockwise direction when facing outside face of sheave STEP 4 Pull the open end of the rope thru the notch in the sheave then reinstall sheave in the housing and reassemble washers friction shoe assembly in the same position as removed STEP 5 Pre tension sheave by rotating it counterclockwise 3 1 2 to 4 turns then hold in this position and thread the rope end thru the rope guide STEP 6 Pull the rope out about 1 2 foot tie a slip knot in the rope to prevent it from retracting then insert the rope thru the handle and hole in the retainer Tie a permanent knot in the end of the rope then install the retainer in the handle STEP 7 Release the slip knot and guide the rope slowly back into the retracted position then reinstall starter on the blower housing this type starter does not have to be aligned 6 2 EXHAUST SYSTEMS On 2 cycle engines the exhaust system does more than just muffle the sound and direct the exhaust yases away from the vehicle When properly designed it helps scavenge or clean all exhaust gases from the combustion chamber plus helps get each new fuel charge in more rapidly for cleaner more complete combustion When built to specifications it also momentarily holds the fuel charge in the cylinder dur ing the time the exhaust port is opened It thus helps prevent fuel from being drawn out of the cylinder along with the exhaust gas
43. he grooves To clean the rings remove the cylinder barrel apply oil to the rings then work the rings back and forth until they slide free in the grooves The oil usually dissolves the carbon clean off the oil before reinstalling barrels Apply lubrication to cylinder wall then use the Kohler ring compressor for 2 cycle engines and install the barrels over the piston Tighten barrel nuts and cylinder heads to torque value specified Always use a new cylinder head gasket if the particu lar model does use one some models have precision machined surfaces and do not require gaskets between barrel and head DRAINING CRANKCASE Some models have drain plugs at low points on the crankcase On these remove the plugs occa sionally to allow drainage of any fuel or oil that may have accumulated in the crankcase Excessive amounts of fuel in the crankcase may upset the fuel air ratio and cause erratic operation Accumula tion may be especially heavy after starting difficulties have been encountered ENGINE MOUNTS Check engine mounting at frequent intervals to make sure these are tight This is especially important after running over rough terrain If mounting bolts work loose the resulting vibration may loosen and weaken other parts and cause serious damage Check the vehicle drive too vibration caused by loose pulleys unevenly worn belts etc may be transmitted back to the engine COOLING SYSTEM Blower engines are cooled by a fan attached to the
44. in 1 cylinder spark plug hole set dial at 0 with piston at TDC install Kohler timing tool part 38 455 03 on crankshaft as illustrated making sure the tool is all the way on the crankshaft key and taper loosen the two trigger ring screws o 3 Rotate crankshaft counter clockwise until 0 95 0 100 BTDC is indicated on the dial rotate 4 trigger ring until pointer on tool is matched with timing mark timing mark is the long mark in the middle on the trigger ring tighten the two screws on trigger ring 3 9 ELECTRICAL SYSTEMS There are several types of electrical charging systems in use on the two cylinder models Elec C tric start K618 2 engines use belt driven motor generator system while other electric start models with the exception of the SK340 2AS and K440 2AS use 40 75 100 or 123 watt flywheel alternator systems The SK340 2AS and K440 2AS use a 150 watt flywheel alternator system which is combined with a capacitor discharge ignition circuit this is described on pages 3 6 3 9 The other systems are described separately on the following pages i The battery for electric start models must be of 12 volt size with an amp hour rating of at least 32 It should be securely strapped to the vehicle and have spill proof caps The battery must be kept safely away from the fuel tank The negative terminal must be grounded to the vehicle frame If the engine is rubber mounted so that it is isolated electrically from the vehicle
45. ine from tight bearings or pistons may be causing hard crank ing If unit fails to crank properly when engine is known to be in good operating condition and the rest d the cranking circuit is found to be satisfactory the motor generator should be removed for further checking 5 2 MM M M M a M me RETRACTABLE STARTERS While retractable starters do not require regular service they should be checked occasionally to make sure they are secure and that the rope is in good condition If the rope is frayed replace it immediately before it breaks if it does break the pulley is free to rewind violently which can result in a broken rewind spring or other internal damage Complete disassembly of the starters is covered in Section eleven the following deals with rope replacement and alignment of the retractable starters Note that a different type of starter is used on the Axial Flow models follow the appropriate instruc tions for the engine model and starter involved ROPE REPLACEMENT BLOWER MODELS It is not necessary to disassemble this type starter to replace a broken belt This starter must be aligned when installed on the engine To replace the rope remove starter from the engine and proceed as follows STEP 1 Remove any pieces of the broken rope from the starter pulley and handle STEP 2 Fuse both ends of the new rope by burning with a match then install o
46. intained in perfect alignment to minimize belt drag and resulting wear Always check the converter manufacturer s literature when doing any work that requires removal of the drive pulley On Kohler Engines drive pulleys are secured to a taper of the crankshaft with a capscrew BELT TOO LONG OR LOOSE M rr ee CENTERS TOO CAUTION ALWAYS REMOVE DRIVE PULLEY FROM CRANKSHAFT CLOSE BEFORE MAKING HIGH SPEED NO LOAD TEST OF ENGINE FIGURE 8 3 LOOSE DRIVE BELT MAY INDICATE POOR PERFORMANCE 8 2 OVERHAUL AND REPAIR Before starting to disassemble an engine make sure that the work area is clean and well lighted Observe all rules of safety when working on an engine for instance wear safety glasses and don t smoke or use an open flame around the cleaning solvents or other flammable materials found in many shops The best defense against accidents in all situations is good common sense TOOLS REQUIRED Make sure that adequate tools are on hand to do the job If you re in the business of repairing engines the engine stand developed specifically for Kohler 2 Cycle Engines will be an invaluable tool The Basic Tool Kit is a must for any overhaul job the same applies to the Ignition Timing Tool and the Ignition Tool Part numbers for these and other useful tools are listed at the back of this manual Some earlier 2 cycle models require metric size wrenches refer
47. ion shown below note that this varies according to type of starter bracket used Use dial indi cator to check ring gear alignment as shown below run out must be within 004 T I R to avoid vibration LOCKING FLANGE STARTER BRACKET 38 126 01 FLANGE TYPE RING GEAR ASSEMBLY 1 300 WITH STARTER 1 310 BRACKET 38 126 04 1 210 WITH STARTER 1 220 BRACKET 38 126 01 CHECKING RING GEAR RUNOUT i FLANGELESS MAXIMUM ALLOWABLE RUNOUT 004 T I R 12 8 SPECIAL TOOLS Completely equipped shops will have most if not all of the tools shown below and on the next SO page are designed specifically for repair of Kohler 2 Cycle Engines and accessories Some of the tools such as the ignition timing gauge kit are absolutely essential even if only tune up work is Kohler 2 Cycle Engines These special tools will not only save time but will insure accurate replace available 2 cycle engine tools FLYWHEEL PULLER NO 33 455 04 AM rr ree No 33 455 01 E NO 37 455 RING COMPRESSOR NO 33 455 02 DuMMY BEARINGS 1 l L JU PISTON PIN EXTRACTOR NO 33 455 03 NOTE Above tools part of Kit 33 761 04 but may also be ordered separately ath FIGURE 13 1 Contents of Basic Tool Kit No 33 761 04 gt 13 1 being performed The basic tool kit listed below is
48. irst few minutes after starting DO NOT attempt to race or place engine under heavy load immediately performance is best after engine is thoroughly warmed IDLING Avoid idling or slow speed operation for prolonged periods as this can result in crankcase flooding carbon accumulation in head and spark plug fouling 1 3 TROUBLE SHOOTING Always take a systematic approach to trouble shooting First of all determine what is actually causing the problem Is it due to poor quality or insufficient fuel or is it caused by a weak or improp erly timed ignition spark or is it poor compression If the complaint is poor performance don t just assume that it is the engine without first checking out the vehicle drive the drive belt could be loose or worn or the track could be binding If these items check out OK then go back to the engine Do the easiest things first make a visual check for loose connections broken wires etc If you find that the problem is poor compression due to internal damage don t just replace the damaged parts look for and correct the causing factors which are usually fuel related Although parts may work loose crack or break simply because they were not tightened properly in the first place the rough terrain so common to vehicles powered by 2 cycle engines is very conducive to vibration and the resulting loosening of nuts bolts etc Periodically check for and retighten engine mounts air cooling shrouds intake
49. irst post If properly pretensioned pulley cannot be turned further than this Make sure starter is properly centered when reinstalled on engine Reinstall starter loosely on engine then pull handle out about 8 until dogs are firmly engaged in starter cup hold rope in this position while securing starter mounting capscrews 11 8 RETRACTABLE STARTER AXIAL FLOW ENGINES Use the following procedure to retractable starters used on Axial Flow engines STEP 1 STEP 2 STEP 3 STEP 4 DISASSEMBLY Remove starter from ventilator housing on engine Push E ring out with screwdriver blade then remove retaining washer spring steel and felt washers and the friction shoe assembly Carefully lift sheave out of starter housing If rewind spring is broken remove the spring case assembly as a unit don t attempt to separate case covers HANDLE ROPE STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 ROPE PULLEY SHEAVE HOUSING a lt i SEL STEEL WASHER RETAINER RETAINING eese SPRING CASE N INCLUDES SPRING 9 OVAL FOR p ad ROPE amp PIN E RING SPRING WASHE RS FIGURE 11 17 DISASSEMBLED VIEW RETRACTABLE STARTER USED ON AXIAL FLOW MODELS REPAIR REASSEMBLY Replace rewind spring and case assembly with a new unit If rope is frayed replace as follows Remove old rope from hole in hub and disconnect other end from h
50. ith compressed air and carefully blowing out each channel and orifice in the castings REASSEMBLY Make certain that all parts are kept clean before they are assembled to the body cast Ing Few measurements are required to complete the assembly of this simple unit 1 Tighten the inlet seat to 25 30 lbs of torque 2 Adjust the inlet control lever so that the center of the lever that contacts the metering diaphragm is flush to the metering chamber wall as shown in the drawings 3 Install new welch plugs at the nozzle well and bypass chamber if the original parts were damaged or removed Place the new welch plug into the casting counter bore convex side up and flatten it to a tight fit using a 5 16 flat end punch If the installed welch plug is concave it may be loose and cause uncontrolled fuel leak The correctly installed welch plug is flat 4 Assemble the gaskets diaphragms and castings in the correct order 5 Assemble the throttle shaft into the carburetor body and attach the throttle shaft clip before assembling the throttle shutter With the shaft secured in place assemble the shutter into the shaft Make certain that the shutter fits accurately into the throttle bore in the closed position 6 Assemble the spring and ball into the choke shaft hole and assemble the shaft into position Assemble the shutter into the choke shaft Make certain that the choke shutter fits lightly to the carburetor bore in the closed position
51. ivalent spark plugs are used with amp his type ignition This system which is shown schematically in Figure 3 2 is described in detail 4 starting on page 3 6 3 1 BREAKER POINTS After about every 100 150 hours remove the retractable starter pulley drive cup and breaker sover to check condition of gap setting of the breaker points You may have to rotate the crankshaft Antil the points become visible through the openings in the flywheel magnet ring assembly Turn crank shaft until points are wide open If the points are dirty clean them off with small brush if oily dip the brush in gasoline first then blow out the gasoline with compressed air If points are pitted or built up it is best to replace the set To replace points remove blower housing first then flywheel to gain access to points After this is done remove terminal nut and disconnect lead running to the condenser remove circlip and adjust ing screw then lift point assembly off the retaining pin Reverse procedure to install new set Remem ber to adjust point gap and retime the ignition after installing new points To adjust point gap turn the engine until the points are wide open the rubbing block will then be at the highest point on the cam Insert feeler gauge between points to measure gap if correctly gapped it will be 016 014 to 018 If adjustment is needed loosen adjusting screw insert screwdriver blade in adjusting notches
52. iven by the tester manufacturer To replace condensers it is necessary to remove the blower housing flywheel and detach the stator plate from the bearing plate Use Kohler condenser removal tool to avoid damaging stator follow instructions included with the tool 2NITION COILS Ignition coils internal or external do not require regular service however keep them clean and check terminals frequently to see that connections are tight Rubber nipples must be in good condition to prevent leakage across exposed surfaces 3 3 i E TIMING PROCEDURE REFER TO PAGE 3 9 FOR TIMING ENGINES WITH CDI IGNITION The only accurate way to check timing is with a flashlight type continuity tester and dial indicator installed in place of the spark plug as shown in the accompanying illustration With these tools it is pos sible to determine the exact location of the piston at the precise instant when ignition occurs Timing e specifications are given in inches of piston travel before top dead center with timing in the full advance position Timing can be changed by resetting breaker point gap and also by shifting position of the stator plate Since no two people set point gap exactly alike range of 014 018 is stated to account for this variation however keep the gap setting as close as possible to 016 When points are wide open and adjusted properly only a slight drag should be felt on the 016 feel
53. l flow engines One type includes a ting gear which is secured to a locking flange with four socket head capscrews The other type is Jlangeless in that it is a one piece ring gear assembly Different procedures are involved in removing i and reinstalling the two types of ring gears follow the procedure which applies to the engine involved DISASSEMBLY On flange type remove the four capscrews securing the ring gear hub to the flange then separate the hub from the flange Use standard flywheel puller to remove locking flange or ring gear assembly on flangeless type from the crankshaft REASSEMBLY FLANGE TYPE Heat locking flange in oven or hot oil to about 500 to 550 F When thoroughly heated flange will fit easily on PTO end of crankshaft Make sure heated flange does not touch the oil seal make sure flange is 1 210 to 1 220 from end of shaft as shown below Allow flange to cool to room temperature position ring gear hub on the flange then secure with the four socket head capscrews and washers apply general purpose Loktite to screws before installing Tighten capscrews to 55 65 in lbs torque Use dial indicator to check ring gear hub alignment as shown below run out must be within 004 T I R to avoid vibration FLANGELESS Position ring gear assembly with boss facing crankcase then using a pipe of appropriate length and diameter and a long 1 2 NF stud press the ring gear on the crankshaft until it is at the dimens
54. lay CRANKSHAFT 006 012 003 006 012 003 006 012 003 End Play 006 012 Shaft Alignment 003 IGNITION 018 022 014 018 090 005 018 022 014 018 018 022 spark 014 018 Timing J Advance Piston BTDC 090 005 090 005 090 005 090 005 TORQUE SPECS K295 2AX K340 2AX K399 2AX K440 2AX SK340 2AS K440 2AS Crankcase halves cylinder block 180 190 in Ibs 180 190 in lbs 180 190 in lbs Crankcase halves only 90 100 in lbs 150 160 in lbs 150 160 in lbs Ventilator housing 150 160 in lbs 150 160 15 150 160 lbs Cylinder head 220 240 in 155 220 240 in lbs 220 240 in lbs Flywheel nut 90 95 ft lbs 90 95 ft lbs 90 95 ft lbs Nut Ss ae pe 30 35 ft Ibs 30 35 ft lbs 30 35 ft lbs Screws to air shroud and coil cover 90 100 in 155 90 100 in lbs 90 100 in lbs Retractable starter 80 90 Ibs 80 90 lbs 80 90 in lbs Drain plug 90 100 in Ibs 90 100 in lbs 90 100 in lbs Manifold halves 150 160 in lbs 90 100 in lbs 90 100 in 155 Carburetor 5 16 nut MPO 110 130 in Ibs 110 130 185 110 130 in lbs Carburetor 3 8 nut 160 170 in 155 160 1
55. le Lj CRANKSHAFT END PLAY 006 FRONT B EARING PLATE S 2 SHAFT gt FORWARD PTO END BEARING PLATE ENGINE STAND THRU BOLTS 6 FIGURE 12 1 ESTABLISH CRANKSHAFT END PLAY BEFORE FINAL ASSEMBLY 12 1 IGNITION COIL 7 CONDENSER 1477 CYLINDER HEAD fh y 1 t t i Sd i wv 2 HEAD i GASKET NS S 5 PR CYLINDER lt a 1 BASE 5 GASKET i 9 STATOR LIGHTING CL PLATE CUL 1 een we we owe a a 4 mae AIR SHROUD J d PISTON lt Os PIN PISTON gt Scu S2 22 OIL BALL g SEAL g gt w BEARING P NEEDLE 2 S E j BEARING 9 e CRANKSHAFT P d M ASSEMBLY CYLINDER CRANKCASE ROPE STARTING PULLEY BAFFLE 27 A NO UNS O SNL LNINRUST CRANKCASE 7 2 ASSEMBLY gt a O RING SEAL COIL FOR CRANKCASE HIGH VOLTAGE ADVANCE COIL SPRING FLYWEI GHT 7 FIGURE 12 2 DISASSEMBLED VIEW TYPICAL BLOWER TYPE ENGINE 12 2 LUBRICATE BEARINGS BEFORE INSTALLING TOP HALF OF CRANKCASE FIGURE 12 3 APPLY SEALER TO MATING SURFACES OF CRANKCASE HALVES CRANKCASE CRANKSHAFT Remove bearing plates or snap rings and crank
56. ll punch Inspect the idle bypass holes to insure they are not plugged Do not push drills or wires into the metering holes This may alter carburetor performance Blow plugged holes clean with compressed air Remove the main nozzle ball check assembly with a screwdriver of correct blade width If this ball check is defective the engine will not idle unless the high speed mixture screw is shut off or there will be poor high speed performance with the high speed mixture screw adjusted at 1 1 4 turns open Replace the defective part 10 The choke and throttle shafts may be removed if there is evidence of wear on these parts The shafts do not have to be removed before cleaning the body casting if the parts are not worn Mark the throttle and choke shutters before removing them so that they can be reassembled correctly The edges are tapered for exact fit into the carburetor bores Remove two screws and pull the shaft out of the casting Examine the shaft and the body bearings for wear If the shaft shows excessive wear replace it If the body bearing areas are worn replace the body casting Remove the choke shaft from the body carefully so that the friction ball and spring will not fly out of the casting Inspect the shaft and bushings Cy Clean all parts before reassembling the carburetor The metal parts can be cleaned in a good grade of commercial carburetor solvent If the carburetor is not very dirty it can be cleaned by blowing the parts w
57. m base type solution Always use the carburetor repair kit jor reconditioning Recondition the WRI carburetor as follows DISASSEMBLY Refer to the exploded view for parts identification and disassemble the carburetor in the following sequence l Pump section cover 4 screws 2 Filter screen and gasket 3 Filter plate 4 Check valve diaphragm and gasket LE Fuel pump plate 6 Pump diaphragm and gasket 7 Metering plate and diaphragm 8 Inlet needle and seat from carburetor body 9 Circuit plate diaphragm and gaskets from body 10 Remove idle and main fuel needles and packing etc RECONDITIONING PROCEDURE Wash all metal parts such as the carburetor body cover and plates in the carburetor cleaning solution Blow out passages with compressed air Discard all parts which can be replaced by items from the repair kit Carefully inspect the carburetor body particularly in the around the throttle and choke shafts if the bearing area of the shafts worn enough to admit e r replace the shafts or carburetor if the body is worn After all trace of cleaning solution is removed reassemble and adjust carburetor as _4ollows 1 Place new packing rings in the carburetor body then install washers springs and the idle and main fuel needles turn the needles all the way in until they bottom lightly then back out 1 1 4 turns both for preliminary adjustment reset the needles as specified for the particular engin
58. m surfaces 11 3 MEASURE PISTON SKIRT JUST BELOW BOTTOM RING PERPENDICULAR TO PIN WEAR LIMIT 002 FIGURE 11 6 CHECK PISTON SKIRT FOR WEAR WITH MICROMETER PISTON PISTON RINGS To check wear measure piston at the top level of the piston skirt just below bottom ring and at right angle to the piston pin if wear exceeds 002 the piston must be replaced Also replace if there is any evidence of pitting on top of the piston If cylinder has been rebored oversize use appropriate oversize piston and rings Check parts manual for available oversizes oversizes are not available for certain models NOTE On AS models pistons and cylinders are color coded make sure the piston has the same color coding as the cylinder when replacing Oversizes are not available for AS models If piston is undamaged and can be reused remove used rings and fit new rings never reuse rings After removing old rings break one of the old rings in half and use this to clean carbon deposits from the ring grooves be careful not to scratch or enlarge grooves when doing this Before installing new rings insert each ring into the bottom of the cylinder bore square with piston then check ring end gap with feeler gauge FIGURE 11 7 CHECK RING END GAP FIGURE 11 8 CHECK RING SIDE CLEARANCE 11 4 Ring side clearance must also be checked before installation Todo this place ring in its proper groove and check side clearance with f
59. meter during the tests STEP 1 STEP 2 STEP 3 STEP 4 Unplug the three lead connector from the electronics module and make the following checks at the connector on the wiring harness Connect the ohmmeter leads between the red lead terminal and the white lead terminal The ohmmeter should indicate between 100 and 300 ohms Connect the ohmmeter leads between the white lead terminal and the black lead termi nal The ohmmeter should indicate between 100 and 300 ohms Connect one ohmmeter lead to the engine block Then check the three terminals with the other ohmmeter lead The ohm meter must indicate an open circuit infinity at all three terminals See Fig 3 9 If these readings are not obtained the timing ring assembly is defective and must be replaced ALTERNATOR STATOR 40 TO 70 VOLTS AC a FIGURE 3 12 ALTERNATOR STATOR OUTPUT TEST Unplug the two lead connector from the electronics module and make the following checks at the connector on the wiring harness See Fig 3 10 Connect ohmmeter lead to a good ground connection on the engine block Connect the other ohmmeter lead to the black lead terminal The ohmmeter should indicate between 30 and 100 ohms Remove the ohmmeter lead from the black lead terminal and connect it to the white lead terminal The ohmmeter should indicate between 2000 and 3000 ohms Change scales and reset ohmmeter to zero if necessary If these readings n
60. ms are also used at PTO end bearing plate which is removed later CYLINDER HEADS CYLINDERS Before disassembly put matching marks on intake side cylinder heads cylinder and crank case On engines with removable flange type exhaust tubes remove the brass nuts and detach both tubes On engines with threaded exhaust tubes do not attempt to remove the tubes unless replacement is necessary a special sealer compound is used during installation which hardens with use making removal difficult Remove cylinder head capscrews note position of support spacers for air shrouds then detach heads Remove cylinder barrel nuts then remove barrels over top of pistons Keep 1 and 2 cylinder parts separate Discard head and base gaskets PISTONS Remove circlips from ends of pin pry out with pick like instrument then use a piston pin extractor tool to push pin out and separate pistons from rods 13 CRANKCASE CRANKSHAFT On all models except K399 2AX and K440 2AX remove PTO end bearing plate O ring and shims note number of shims On all models remove nuts and capscrews used to secure crankcase halves sealant is used between the halves to break the seal lift the top assembly and tap gently on the crankshaft with soft head hammer until the halves separate Lift the top half off over the studs On K399 2AX and K440 2AX remove the oil seals snap ring and shims at both ends Lift the crankshaft out of the bottom half if it sticks tap b
61. nd about ready to break replace do this pull handle all the way out block and hold starter pulley in position then untie or cut knotted end of rope and remove and discard old rope Insert end of new rope in pulley hole install washer then tie knot in rope With nylon rope the knot can be permanently fused by burning with a match use proper precautions when doing this DISASSEMBLY If starter must be disassembled use the following procedure STEP 1 Remove capscrews and detach retractable starter from the engine STEP 2 If rope is not broken pull handle out about 8 and tie temporary knot at this point Pry rope retainer out of handle then untie knot and remove handle and retainer Hold pulley untie temporary knot then allow pulley to unwind slowly brake with thumb on pulley surface until all tension on spring is released ONE PIECE TYPE HOUSING AIR INLET INCLUDES SCREEN mw HOUSING MES USED WITH SEPARATE AIR INLET SCREEN ROPE WASHER NN PULLEY DOG SPRING BRAKE X DOG RETAINER X a N LARGE WASHER amp SPRING 0 RETAINER SPRING go hen MODELS ONLY DOG TENSION SPRING CAPSCREW TIGHTEN TO 120 IN LBS LATER MODELS FIGUR STEP 3 Remove capscrew on dog retainer then detach retainer and associated parts from pulley Note sequence of removal STEP 4 Use extreme caution when removing pulley the inside of th
62. ne end in the starter handle STEP 3 Pre tension rewind spring by rotating pulley counterclockwise until it cannot rotate further about 1 2 to 3 4 turns then back off until notch in pulley lines up with rope guide in housing hold pulley in this position then insert rope thru guide and notch slip washer over the rope then tie permanent knot in rope STEP 4 Gradually release pulley allowing rope to rewind slowly don t release all at once as this could damage starter internally Use following instructions to align starter STARTER ALIGNMENT BLOWER TYPE Reinstall starter to blower housing but do not tighten mounting capscrews pull handle out about 8 until dogs engage in drive cup then hold in this engaged position while tightening the mounting screws A LN EMERGENCY START If the retractable starter fails the Blower type engines may be rope started using starting rope in 001 kit Remove the starter insert in notch in drive cup and loop rope around then turn ignition ON and pull rope to start Axial Flow models may also be rope started even though there is no notch in the drive cup on these wrap the first turn of rope around the hub at angle then loop succeeding turns over the first loop to provide a firm grip the hub BLOWER HOUSING FIGURE 6 1 RETRACTABLE STARTER REMOVED BLOWER TYPE ENGINE 6 1 PRESSED STEEL STARTER HOUSING SPRING CASE
63. nstalled as illustrated on page 8 2 Make sure the special air shroud support nuts are installed in correct position Tighten head nuts in criss cross pattern to torque value called for in the Specifications section AIR SHROUDS BAFFLES On Axial Flow models remove the intake manifold installed in Step 5 for cylinder alignment then install air shroud sections On blower type engines the intake manifold does not have to be removed to install baffles and air shrouds VENTILATOR HOUSING AXIAL FLOW MODELS On Axial Flow models assemble ventilator housing to crankcase and to air shrouds STATOR ASSEMBLY Align matching marks on stator to mark on bearing plate or crankcase on Axial Flow models then secure stator assembly Thread ignition and alternator leads thru grommet on bearing plate or ventilator housing then connect ignition leads to ignition coils refer to accompanying diagram for connections i PET MAGNET RING FLYWHEEL Check the magnets to make sure they are clean and free of metallic particles On blower models reinstall flywheel with magnet ring and fan attached on the crankshaft and tighten retain ing nut to specified torque value Axial Flow models install magnet ring to the hub then install this assembly on the crankshaft tighten nut to torque value specified Time engine per instructions found in Section 3 BLOWER HOUSING BLOWER MODELS Reinstall blower housing on engine and secure with capsc
64. nts Use of the cam sleeve allows precision adjustment of the breaker point gap Set gap at 016 Apply a small amount of Kohler cam grease about size of match head to the wicks IN ONDENSER To remove unsolder two leads then break locking burrs if present before pressing or driving condenser out of stator plate When reinstalling condenser apply pressure slowly and gently to avoid damaging condenser To prevent distortion or cracking of the stator plate use the condenser replacement tool per instructions in the kit IGNITION amp LIGHTING COILS To replace ignition coil unsolder wire running to condenser at the condenser then remove the two screws which secure the coil to the stator The lighting or alternator coil is removed in the same manner except that the leads do not have to be unsoldered After reinstalling coil loosen capscrew slightly then slide coil outward until both ends of coil contact metal centering ring Tighten screws while holding coil firmly against the ring This correctly establishes air gap at 012 CENTERING RING FROM BLACK LEAD FROM AIR GAP IGNITION BREAKER POINTS FIGURE 11 12 CONDENSER DETAILS FIGURE 11 13 IGNITION SERVICE TOOL 11 6 RETRACTABLE STARTERS Retractable starters do not need regular service and should not require complete disassembly unless rope breaks or starter will not engage due to worn or broken parts If starter works properly but rope looks frayed a
65. of proper quality and thoroughly mixed plus mixed in the correct proportions On Kohler Engines the correct ratio of gasoline to oil is 40 to 1 If there is proportionately too little oil overheating scuffing and scoring and eventual seizure are certainties Too much oil on the other hand causes incomplete combustion and rapid build up of carbon which badly fouls spark plugs and often becomes especially heavy on top of the piston GASOLINE A good quality REGULAR grade gasoline with an octane rating of at least 92 is required Premium grades may also be used The use of Premium may in fact be beneficial especially in warmer weather in preventing detonation or after run conditions Heavier build up in the combustion chamber may however be expected when using Premium because these fuels contain greater amounts of lead additives which leave deposits The new non leaded gasoline fuels have not yet been approved for 2 cycle operation Promote using name brand gasolines purchased from popular service stations to avoid stale gasoline or leftover gasoline not adjusted to seasonal changes OIL REQUIREMENTS Air cooled operation encompasses more widely varying speeds and much higher combustion chamber temperatures than experienced with water cooled engines For this reason out board type motor oils are definitely not suitable for use in 2 cycle air cooled engines Automotive type multi viscosity oils are also not suitable because they contain many additi
66. on the stand the first step is to establish proper end play of the crank shaft use the following procedure END PLAY ADJUSTMENT Carefully lower crankshaft into position in the bottom crankcase then on engines using front and rear bearing plates install these plates on the bottom half of the crank case On K399 2AX and K440 2AX models which do not have end plates install the snap rings in grooves at both ends of the bottom crankcase To check end play push on the PTO end of the crankshaft until the front ball bearing touches the crankcase With a feeler gauge measure clearance between the rear bearing and the PTO end bearing plate or snap ring on engines so equipped The correct clearance is attained by installing 006 shims between the bearings and bear ing plate or snap ring If for example a clearance 033 is measured subtract 009 nomi nal end play 006 012 from 033 to determine the uncorrected end play which in this case is 024 033 009 2 024 Next divide 006 thickness of shims into 024 to determine number of shims required in this case 4 shims are required 024 006 4 As final proof subtract the total thickness of the 4 shims 024 from the actual measurement 033 to arrive at the adjusted end play which is 009 033 024 009 this is within acceptable end play limits of 006 to 012 When installing put an equal number of shims at each end of the shaft when ever possib
67. ose components Improper fuel and or mixture Carburetor set wrong Fuel lines restricted Exhaust port blocked Vapor lock 1 4 Restricted air intake Carburetor set wrong Carburetor malfunctioning Wrong carburetor 6 Choke left on NAUN FUEL SYSTEM TESTS FUEL IN COMBUSTION CHAMBER If engine won t start remove spark plug if electrodes are wet this prob ably indicates fuel is getting to engine If dry check out system from carburetor back to tank FUEL TO CARBURETOR If fuel flows out of carburetor and from inlet line when disconnected from carburetor this indicates fuel is getting this far IGNITION RELATED CAUSES NO IGNITION SPARK POOR IGNITION 1 Switch turned off l Plug wet 2 Leads disconnected or broken 2 Plug gap incorrect 3 Bad plug 3 Plug carbon fouled 4 Ignition switch faulty 4 Wrong plug 5 Breaker points oxidized 5 Breaker points dirty or bad 6 Breaker points stuck 6 Point gap wrong 7 Condenser faulty 7 Timing wrong 8 Ignition coil faulty 8 Condenser weak IGNITION TESTS SPARK PLUG Remove plug set gap at 020 place plug with side electrode against cylinder head then crank engine at speed sufficient to produce a good spark if a sharp snappy spark is noted between the electrodes this eliminates the ignition components as the fault wrong timing could however be causing problems SWITCH Unplug the switch disconnect all terminals if the engine can be started with switch
68. ot obtained the stator assembly is defective and must be replaced Remove the coil cover to expose the ignition coils Check each coil separately Remove the primary lead from the coil red or white lead Connect one ohmmeter lead to the primary terminal stud on the coil Connect the other ohmmeter lead to the ground connection at the coil See Fig 3 11 ohmmeter should indicate 1 to 5 ohms Because of the low pri mary resistance make certain the ohmmeter has been set to zero Remove the ohmmeter lead from the ground connection and connect it to the spark plug wire terminal The ohm meter should indicate 100 to 300 ohms If the above readings are not obtained the coil is defective and must be replaced Use the same procedure to test the other coil Check high tension lead before replacing coil If all tests to this point have been within the listed specifications the trouble presumably lies in the electronic package Because of the many variables involved when testing solid state componentry with an ohmmeter we suggest checking the electronic package by replacement only 3 8 TROUBLE SHOOTING THE ALTERNATOR SECTION The alternator can be tested for output using either an AC voltmeter or a 60 watt 125 volt light bulb with test leads To test the alternator it will be necessary to disconnect the green yellow lead and white lead from the system wiring A preliminary check of the alternator can be made with an ohmmeter
69. ottom half gently until shaft is free then remove 10 5 RECONDITIONING CRANKSHAFT CONNECTING ROD If a visual check fails to uncover any damage install crankshaft rod assembly in vise use pro tective caps on jaws Make the following tests to determine if the crankshaft rod assembly can be reused Do not attempt to dissassemble crankshaft for reconditioning special tools and equipment required for this If center main or rod bearings or crankshaft are damaged or worn beyond limits replace assembly as a unit Do not reinstall outer main bearings until after end play is established ROD BEARING CHECK First check connecting rod small end bearing for evidence of binding or rough ness Turn rod back and forth as shown if bearings are in good condition rotation will be smooth The small end bearing may be removed and replaced if necessary MAIN BEARINGS The center main bearings cannot be removed if these are damaged replace crank Shaft assembly The outer main bearings can be removed and replaced Use one of the special bearing removal tools see toollisting at back of this manual Place expansion ring within 1 2 of bearing for best results in removing bearing Do not install new outer main bearings until after the crankshaft end play has been checked use dummy bearings for this during reassembly of the engine Before fitting new bearings heat them in clean oil to about 100 150 F then press them onto the
70. ouble shooting guide if the corrective action stated fails to remedy a problem the starter should be disassembled and serviced per the instructions on the following page It is not necessary to realign the starter when it is reinstalled perfect alignment is provided by the precision machined surface of the mounting pad and position of the mounting studs TROUBLE ANALYSIS Although a problem may appear to be caused faulty starter check other items first as inciated in the following chart Ree PROBABLE CAUSE SUGGESTED REMEDY 875 1 Starter does not turn or turns too slowly Battery low or dead recharge or replace as needed e Electrical connections poor or broken Clean terminals tighten connections Faulty starter switch replace Brushes commutator dirty or excessively worn or replace as needed 2 Starter stops when pinion engages 2a Battery charge low recharge Battery cables too long or connections causing excessive voltage drop Starter solenoid defective replace solenoid Brush tension too low due to excessive wear or weak Springs Replace Engine siezed or locked up 3 Starter spins but will not engage Pinion sticking in retracted position due to dirt or grease on splined shaft clean Chipped teeth on pinion and or ring gear Replace Burrs forming on gear teeth to block engagement file edges 4 Starter does not disengage properly after Pinion dirty or ret
71. r and the inlet tension Use caution in removing these parts because the spring pressure may cause the inlet spring lever to fly out of the casting Inspect the parts must rotate freely on the fulcrum pin Handle the inlet spring carefully characteristics If in doubt about its condition 7 Remove the inlet needle Remove the inlet seat wrench Remove the inlet seat gasket 4 Remove the diaphragm cover casting the metering diaphragm and diaphragm gasket Inspect the These parts must be reassembled in the correct The diaphragm gasket is assembled onto the body casting first and the metering diaphragm for wear or damage The inlet control lever Do not stretch this spring or in any way change its compression replace it assembly using a 5 16 inch thin wall socket The inlet seat assembly consists of a brass cage and a rubber insert for the inlet needle seat The insert goes into the cage only one correct way flat and smooth the other side has a ridge or rim molded around the outside edge Looking at the insert one side is This ridge is to be assembled away from the inlet needle point seat and a copper gasket inlet seats 11 11 Some models of the HR carburetor are equipped with a rubber tipped needle a brass inlet The installation instructions below are applicable to both types of The inlet needles and seats are matched and tested for leaks at the factory and the parts should not be in
72. recommended for any shop engaged in the repair of ment without damage when properly used Refer to the Kohler Tool Catalog for an up to date listing of FIGURE 13 3 IGNITION TOOL 33 455 08 LONG amp SHORT INCLUDED FIGURE 13 4 IGNITION TIMING GUAGE KIT 33 755 03 FIGURE 13 5 FLYWHEEL HOLDER LIGHT 33 455 10 38 455 02 T FIGURE 13 6 BEARING PULLER SET 33 761 06 FIGURE 13 7 CONDENSER REPLACEMENT KIT 33 455 09 13 2 CYLINDER BORE New Standard Ist 0 5 010 2nd O S um 3rd 0 5 040 Wear Limit PISTON SIZE New Standard Ist 0 5 010 2nd 0 5 020 3rd 0 5 040 STROKE xcu 2 205 2 362 2 362 2 756 PISTON RING Ring Gap Side Clearance Top Side Clearance Bottom CONNECTING ROD Lateral Play CRANKSHAFT End Play Shaft Alignment IGNITION Spark Gap Breaker Point Gap Timing TORQUE SPEC Crankcase Halves Bearing Plates Cylinder Head Flywheel Nut Blower Housing Pulley Rope Start Retractable Starter Exhaust Tubes Intake Manifold Carburetor Spark Plug 008 014 0022 0037 0012 0022 008 016 006 012 003 018 022 014 018 090 005 NOTE 11 dimensions are in inches 006 012 006 012 003 003 018 022 014 018 090 005 018 022 014 018 090 005 1 6 215 225 in Tbs 150 160 185 240 260 lbs 90 100 ft 1bs 150 160 1bs 170 180 in lbs 150 160 in
73. rews Reinstall starting motor or Starter pad cover on manual start models ni FAN BELT AXIAL FLOW MODELS Install belt on drive sheave first then place shims 5 or 6 usually needed on the fan shaft next to the inner sheave section place belt on sheave then assemble outer sheave assembly use Spanner wrench to hold sheave while tightening the retaining nut Check belt tension remove or add shims as necessary to obtain 3 8 deflection refer to Section 8 for adjustment procedure RETRACTABLE STARTERS The retractable starter used on blower type engines must be realigned when installed the type used on the Axial Flow models does not Refer to Section 6 for alignment instructions on blower type engines ENGINE SYSTEMS ACCESSORIES Reinstall carburetor air cleaners exhaust tubes or mufflers etc to complete reassem bly of engine Use new gasket or parts whenever applicable Tighten screws and nuts to torque value as specified RUN IN PROCEDURE After engine has been completely reassembled bench test engine if facilities are available and make necessary adjustments If engine cannot be bench tested reinstall engine in vehicle and make final adjustments under actual load conditions Run in recommendations for a reconditioned engine are the same as for a new engine refer to Section 1 for run in instructions 12 5 RING GEAR INSTALLATION AXIAL FLOW ENGINES Two types of ring gears are used on the electric start axia
74. rod small end bearing indicated by the metal lapped over edges This of course freezes the needle bearing and snaps the connecting rod Always use a puller to remove the flywheel and also to get the drive pulley off the taper of the crankshaft MODEL VARIATION If the engine you are working on has a seven digit ENGINE SPECIFICATION number and the suffix last 2 digits is 05 or lower this indicates that the engine has metric size threads If the suffix is 06 and higher or if a six digit engine specification number is found the engine has U S Standard thread sizes The model variation is described in further detail at front of each parts manual Vol 13004 430NIT42 2 WIIdAL V 40 M3IA 1VNOIL23S SSOWD 1 01 380914 2 REAR OUTLET 1 SPARK PLUG 2 SPARK PLUG BLOWER HOUSING TYPE AIR COVER GROMMET CYLINDER HEAD A aE CYLINDER BARREL EXHAUST PORT PISTON N E e N E E D L E B E A R I N G C227 pA RING GEAR ELECTRIC START i FLYWHEEL zzz F SMALL END m STATOR PLATE v7 4 PISTON PIN 4i i IGNITION COILS fr MN 4 25 Pa MM x TRANSFER PORT 2 Fera SNe 53 DRIVE CONNECTING ROD Kf N PULLEY CRANKCASE CAs 08 by nA UPPER HALF t Er SASSY F 2 H CRANKSHAFT imm PTO END mE Fc LAA a OIL SEAL REAR i 110
75. rst hour run for short periods of time at varying speeds up to 4 throttle void operation at low and continuous speeds as this causes buildup of heat especially during warm weather or heavy load conditions After first hour operate normally up to full throttle no further babying of the engine is necessary BATTERY If battery has been removed or disconnected for any reason make sure that the negative terminal is connected to ground when battery is reinstalled FUEL MIXTURE Mix leaded Regular or Premium grade of gasoline 92 octane minimum with SAE 30 or SAE 40 two cycle air cooled type engine oil in a gasoline to oil ratio of 20 to 1 for the first fill ona new engine and thereafter at a 40 to 1 ratio Low lead or non leaded gasoline is not approved for two cycle operation The use of a Premium grade gasoline may be especially beneficial in warm weather operation to help prevent detonation or after run condition Pre mix the fuel thoroughly in a separate container before filling fuel tank on the vehicle Add about 1 gallon of gasoline to the mixing container first then add the oil and mix thoroughly before pouring in the remaining quantity of gasoline The chart below lists the 40 to 1 ratio for some common size containers GASOLINE 7 1 Gallon 2 Gallons 3 Gallons 4 Gallons 26 GalTons ee STARTING PROCEDURE If engine has been out in snow make sure air intake or baffle is cleared before attempting to star
76. s disconnected by the light switch 2 FIGURE 4 4 RECOMMENDED WIRING MANUAL START 75 100 123 WATT SYSTEM least 32 amp hr In all cases the negative terminal is the ground refer to the accompanying ELECTRIC STARTERS Bendix drive type starting motors are used on all electric start models except the Model K618 2 electric start which uses a belt driven motor generator unit The two types are discussed separately on the following pages BATTERY REQUIREMENTS Energy for cranking is provided by 12 volt battery with a rating of at wiring diagrams Spill proof caps must be used because of the rough terrain and extreme angles so common to vehicles powered by 2 cycle engines With the exception of the motor generator equipped model energy for charging the battery is furnished by an alternator coil which is mounted on the stator plate under the flywheel The alternating current produced in this coil is converted to Direct Current ina rectifier unit Two 5 amp fuses are provided in the rectifier to protect the diodes against damage from overcurrent this condition could occur for example if the battery is hooked up wrong BENDIX TYPE STARTING MOTORS These starters are self lubricated and require therefore very little attention The brushes and commutator should be inspected only when there are indications that these are getting worn or dirty Some of the problems that are possible are listed below in the tr
77. s within specifications After timing is corrected for 1 check timing on 2 cylinder don t readjust 2 by shifting the stator plate as this would throw timing off for f1 adjust 2 by changing point gap only IGNITION SET DIAL TOO TIMING AT ZERO EARLY RANGE SPECS WHEN CLOSE GAP PISTON TDC IGNITION TOO LATE OPEN GAP TURN FLYWHEEL TURN FLYWHEEL CLOCKWISE COUNTERCLOCKWISE UNTIL PISTON UNTIL TIMING IS AT TDC LIGHT CHANGES SET DIAL INDICATING PISTON ZERO AT THIS IGNITION IF BTDC POINT INDICATOR IS NOT IN RANGE SPECIFIED RETIME IGNITION FIGURE 3 5 IGNITION TIMING PROCEDURE WITH TIMING GAUGE 3 5 CAPACITOR DISCHARGE IGNITION coe ROTOR MAGNETIC FLYWHEEL ROTOR IGNITION TIMING STATOR ALTERNATOR IGNITION COILS RING IGNITION TIMING MODULE ELECTRONICS FIGURE 3 7 MAIN COMPONENTS OF KOHLER TRON IGNITION SYSTEM The KOHLER TRON Ignition System is a combination permanent magnet flywheel alternator and solid state capacitor discharge ignition system The magnet supplies the high voltage for ignition and generates the current required for battery charging and or for lighting systems OPERATION The flywheel rotor which incorporates a special flexible magnet and is mounted on the engine crankshaft revolves around the alternator stator which is fixed to the engine Current is gen erated in the windings on the twelve poles of the stator plate nine of which supply po
78. shaft from bottom half of crankcase after end play adjustment is determined then apply Kohler crankcase sealer or similar sealant to mating Next lubricate all bearings with SAE 10 weight oil install shims number determined in Step 1 at both ends of shaft then install crankshaft in bottom half of crank case On models using snap rings install rings in groove at both ends of crankcase lower the top half of the crankcase into position on the lower half tighten nuts just enough to hold the halves together the thru bolts and end studs cannot be tightened surfaces of crankcase sections until cylinder barrels are installed BEARING PLATES OIL SEALS On engines with bearing plates new oil seals should have been installed in the plates during On these models carefully guide bearing plates over ends On K399 2AX and Make sure seals are reconditioning don t reuse old seals of crankshaft and into position on crankcase then secure with capscrews K440 2AX models press new seals in with seal driver of appropriate size installed the right way with lip toward inside S WY LOCATING PINS FACE TOWARD CARBURETOR INTAKE SIDE G Ss FIGURE 12 4 USE EXTRACTOR TOOL TO INSTALL PISTON PIN 12 3 MATING SURFACES On models with studs in center 4 PISTON RING ASSEMBLY Pistons new rings installed during reconditioning must be installed so that locating pins will be toward carbure
79. t CAUTION Throttle must move freely to prevent accidental sticking in running position during start up Check for freedom of movement 1 CHOKE Puil choke full on in cold weather Little or no choking required with warm engine Atter engine starts open choke 2 PRIME If vehicle has primer button press button several times before attempting to start when cold Choking not normally required with primer 3 THROTTLE Hold throttle slightly off idle while cranking engine 4 CRANK ENGINE A RETRACTABLE START MODELS Turn ignition switch ON pull starting Tope in quick steady motion Do not allow handle to snap back B ELECTRIC START MODELS Move switch to START position release as soon as engine starts switcn wiil remain in position Do not continue cranking if engine fails to start after 20 seconds Allow starter to cool off before making another attempt Use retractable starter if battery is low or dead STOPPING PROCEDURE 1 THROTTLE Release throttle and allow engine to idle for few moments under no load 2 IGNITION SWITCH Move switch to OFF position EMERGENCY STOPPING After operating under heavy load in warmer weather engine may be hot enough to continue running after ignition is turned off To stop the engine under this condition pull full choke and open throttle to shut off air and stall engine OPERATION WARM UP Allow gradual warm up by operating at moderate speed and load for the f
80. terchanged they must be kept in matched sets When installing the insert cage into the carburetor body use a new gasket Do not force the cage as you may strip the threads or distort the insert Use a torque wrench to apply 25 to 30 in lbs pressure The b needle and seat assembly must be clean to insure correct performance Remove and inspect the points of both the high speed and idle mixture screws Notice the idle mixture screw point has the step design to minimize point and casting damage Through misuse either mixture screw point may be bent extruded from being forced into the casting seat or pos sibly broken off in the casting If either mixture screw is damaged be sure to inspect the con dition of the casting If the adjustment seats are damaged a new body casting is required 9 The idle bypass ports and main nozzle ball check valve are sealed from the metering chamber by welch plugs It is seldom necessary to remove either of these plugs because there is no wear in either section and any dirt that may accumulate can usually be blown out with compressed air through the mixture screw holes If the carburetor is unusually dirty and the welch plugs must be removed it will require careful work Drill through the welch plug using 1 8 inch drill Allow the drill to just break through the welch plug If the drill travels too deep into the cavity the casting may be ruined Pry the welch plug out of its seat using a sma
81. the three jumper leads as shownin Fig 3 8 Make sure of good electrical connections Turn the ignition switch on and pull starter If the nonfiring coil now produces a spark the problem lies in the timing ring and it must be replaced If the nonfiring coil still does not produce a spark the problem lies in the electronics module and it must be replaced NOTE Do not operate the starter with the plug in connectors completely disconnected from the electronics module Internal damage can result to the electronics module If spark discharges are not observed at either cylinder the system will have to be tested with an ohmmeter or checked by replacing components However before testing the system make cer tain the on off switch is not the problem Disconnect the lead from the switch position the lead so the terminal cannot contact ground and again check for spark discharges at the test plug 30 TO 100 STATOR IGNITION OHMS 100 0 300 OHMS 2000 TO 3000 OHMS FIGURE 3 10 ALTERNATOR STATOR IGNITION TEST FIGURE 3 11 IGNITION COIL TEST 3 7 COMPONENT REPLACEMENT METHOD If component replacement is going to be used to locate the faulty component the following sequence is recommended 1 2 3 Ignition Coils 4 Timing Ring Electronics Module 5 Flywheel Alternator Stator OHMMETER TEST PROCEDURE Make certain the ohmmeter being used is accurate and the batteries are fresh Periodically zero the
82. tor side of engine Insert circlip groove at one end of piston heat piston to about 100 F then position piston over connecting rod carefully insert piston pin thru needle d bearing in connecting rod and piston then lock by installing circlip at open end Use the piston pin tool when installing pin HEAD CYLINDER VENTILATOR SHROUD AIR EXHAUST SIDE N la HOUSING N VENTILATOR FAN RING PISTON IN RETAINING PISTON Q 2 BEARING BALL FAN S MANIFOLD INTAKE SHROUD AIR INNER amp OUTER INTAKE SID ED CRANKCASE e ion INCLUDES RODS T BEARING BALL FIGURE 12 5 DISASSEMBLED VIEM TYPICAL AXIAL FLOW MODEL COVER HIGH TENSION COIL 5 CYLINDERS Install new base gaskets on crankcase lubricate piston and rings then using ring compressor tool from tool kit carefully guide cylinders over pistons and into position on crankcase Reinstall washers and nuts but do not tighten completely at this time Install intake manifold to cylinders Ww for alignment purposes then tighten all retaining nuts to 180 190 in lbs or about 16 ft lbs 12 4 O 10 12 13 14 CYLINDER HEADS 24 3 Position new head gaskets on cylinders then install cylinder heads On models with side outlet cooling heads are installed with fins at right angles or perpendicular to the crankshaft Heads with fins running at an oblique angle are i
83. urn spring broken Clean or engine starts replace as needed Gear teeth dirty or damaged File off burrs or o replace 5 1 DRIVE ASSEMBLY PLATE DE BUSHING DE ARMATURE END CAP gt BUSHING Y COIL SET OF 4 99 PRING 65 o BRUSH HOLDER PLATE PROTECTIVE CAP po ad BOLT DE DRIVE END CE COMMUTATOR END FIGURE 5 1 EXPLODED VIEW SHOWING TYPICAL STARTING MOTOR BRUSH SERVICE The starter does not have to be removed from engine to service brushes To gain access to the brushes on these starters remove the bushing protective cap the clip washer at end of the armature then the commutator end C E cap or plate Note that it may be necessary to loosen the lower nut on the terminal post so that the plastic terminal insulator will not crimp and hold the end cap Tap end cap lightly to free it from the starter frame then slip it off over the end of the commuta tor and armature Use a small hook to lift springs then remove each brush from its holder for inspec tion and cleaning If brushes are worn unevenly or worn down to less than 5 16 about half original length unsolder leads and replace all 4 brushes Clean commutator with coarse lint free cloth do not use emery or sand paper for this If grooved scored or extremely dirty the commutator should be turned down on a lathe however this calls for removal of the armature When reinstalling leave brushes out and springs off until
84. ves not intended for 2 cycle type operation Always recommend using an SAE 40 weight diluted 2 cycle air cooled type motor oil A good quality SAE 30 weight 2 cycle air cooled type oil may be used as a temporary substitute however a diluted oil does have some advantages The diluent makes the oil pour more freely even more impor tant at low temperatures common to many 2 cycle applications oil gets colder one of its ingredi ents takes on an interlocking crystalline form which bind together until finally the oil solidifies and becomes too thick to pour a diluent blocks formation of these crystals quart of oil should be mixed with 10 gallons of gasoline to attain the fuel to oil ratio of 40 to 1 for Kohler Engines dye is usually included to give the user visual proof that oil has in fact been mixed in with the gasoline For correct mixing always pour some of the gasoline into the container first then add the oil agitate this partial mixture then add the rest of the gasoline Many filling station Operators will pour the oil into the can first They think that pump pressure is adequate to mix the fuel and oil This method does not mix properly Don t do it this way Agitate thoroughly after final amounts in the can Once mixed the oil will remain in solution indefinitely If however storing fuel for any length of time add a gasoline stabilizer to prevent oxidation and the resulting formation of varnish and corrosive acids whi
85. w threads studs etc are clean and undamaged Remove varnish gum etc deposits from internal surfaces also thoroughly clean external sur aces Make FIGURE 11 3 CHECK ALIGNMENT OF SHAFTS WITH DIAL INDICATOR 11 2 BEARING PLATES OIL SEALS Check bearing recess for signs of wear replace plates if recess is grooved or damaged First check the depth to which the old oil seals are pressed then remove the seals and thoroughly cleanthe bearing plates Remove all trace of gasket and sealer material Lubricate new oil seals liberally then using a driver of size which presses against most of the flat surface of the seal press the new seal squarely into the plate to the same depth as the old seal The spring side of the seal must be toward the inside or facing crankcase of the engine Lubricate the seals again when the plates are slipped over the crankshaft during reassembly CYLINDER HEAD Make certain that cooling fins are unbroken and that threads for spark plug are clean and undam aged Also check gasket surface of head Replace head if internal surface is scratched nicked or distorted Clean out any carbon deposits from inside the combustion dome if badly varnished or if carbon deposits cannot be removed use a new cylinder head BORE WEAR LIMIT 006 MEASURE BORE AT 22 TWO POINTS 90 APART 5 Vy iy CROSS HATCH AFTER HONING FIGURE 11 4 CHECK BORE FOR WEAR FIGURE 11 5 REBORIN
86. wer for the vehicle s lights and or for charging the battery and three of which supply power for ignition The electronic module incorporates the ignition condensers and the necessary solid state circuitry for charging and discharging them The timing rotor revolving within the timing ring triggers the dis charge of these condensers through the electronic box to the ignition transformers which step up the voltage to a level necessary to insure successful firing of the surface gap spark plugs TROUBLE SHOOTING THE IGNITION SYSTEM PRELIMINARY CHECKS Check all plugs in connections to make certain they are clean and tight Check all leads to make certain one is not broken or has rubbed through the insulation and is grounding out Since the ignition system and charging system operate independent of each other the trouble shooting and service procedures are separated into their respective sections Disconnect a plug wire from one cylinder and connect it to a test plug Wico 14281 Turn the switch to the on position then pull the starter and check for a spark at the test plug Test both cylin ders in the same manner If sparks are observed at the test plug for both cylinders the problem lies elsewhere in the engine carburetion timing or mechanical failure i l If a spark discharge is observed at one cylinder but not the other the problem lies in the coil or high tension lead the timing ring or the electronics module The easiest m
87. ype Starters 6 1 Requirementso ob acca oes eee ie reis 13 1 Rope Replacement Axial Flow Models 6 2 Tools TOO KITS 5 eneas 13 1 13 2 EXHAUST SYSTEMS TEE SEVEN SPECIFICATIONS nen yis FOURTEEN General Requirements 7 1 Blower Type Engine Specifications 14 1 Axial Flow Engine Specifications 14 2 Installation Recommendations 7 1 SAFETY PRECAUTIONS Do notadd fuel while engine is running Stop engine and if possible allow cooling period to prevent spilled fuel from igniting on contact with hot engine parts Make sure ignition switch is in OFF position and spark plug disconnected before working on engine j Make sure all safety guards on engine and driven equipment are in proper position and secure i Make sure hands feet and clothing are at a safe distance from any movable parts prior to Starting Do not operate engine in closed building unless exhaust is piped safely outside Fuel may escape from fuel tank vent when operating over rough terrain onan incline or from expansion and ignite from hot engine or electrical spark Stop engine and remove some fuel from tank 1 2 PRE START INSTRUCTIONS COOLING Make sure baffles and cooling shrouds are in place and tight Air intake openings must be Kept clean and unrestricted at all times RUN IN NEW ENGINE During the fi

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