Home

Courage Sv710-740

1. Figure 10 5 Installing Governor Shaft a Figure 10 3 Installing Breather Filter and Cover 3 Install the nylon washer onto the governor cross shaft then start the push on retaining ring 3 Secure the breather cover with the M6 hex flange Hold the cross shaft up in position place a 0 50 screw Torque the screw to 10 7 N m 95 in 1b mm 0 020 in feeler gauge on top of the nylon into a new cored hole or 7 3 N m 65 in 1b into washer and push the retaining ring down the a used hole See Figures 10 3 and 10 4 shaft to secure Remove the feeler gauge which will have established the proper endplay See NOTE Make sure the drainback hole in the gasket Figure 10 6 and cover is aligned and open after the cover is secured Check using a piece of wire or similar tool 10 2 H Le Figure 10 6 Setting Governor Shaft Endplay Install Crankshaft 1 Lubricate the flywheel side main bearing surface and the lips of the oil seal in the crankcase with clean engine oil 2 Carefully slide the flywheel end of the crankshaft through the main bearing in the crankcase See Figure 10 7 Figure 10 7 Installing Crankshaft in Crankcase Install Connecting Rods with Pistons and Rings NOTE The cylinders are numbered on the crankcase Make sure to install the piston connecting rod and end cap into its appropriate cylinder bore as previously marked during disassembly Do not mix the end caps and connecting rods
2. 6 Clean the carburetor body jets vent ports seats etc using a good commercially available carburetor solvent Use clean dry compressed air to blow out the internal channels and ports Inspect and thoroughly check the carburetor for cracks wear or damage Inspect the fuel inlet seat for wear or damage Check the spring loaded choke plate to make sure it moves freely on the Figure 5 16 Removing Float and Inlet Needle 3 Remove and discard the round plug from the bottom of the slow jet tower of the carburetor body Use an appropriate size flat screwdriver Jait and carefully remove the slow and main jets from the carburetor After the main jet has been 7 Clean the carburetor float bowl as required removed the main nozzle can be taken out through the bottom of the main tower Save the parts for cleaning and reuse See Figure 5 17 If it has an accelerator pump that is not being serviced at this time prevent the cleaning solvent from contacting the check valve and accelerator pump components 8 Install the main nozzle and the main jet into the tower of the carburetor body See Figure 5 18 5 11 Section 5 Fuel System and Governor Figure 5 18 Installing Main Nozzle and Main Jet 9 Install the slow jet and new plug into end of slow jet tube See Figures 5 19 and 5 20 Figure 5 19 Installing Slow Jet Figure 5 20 Installing Plug into Slow Jet Tube 10 Attach the inlet needle to the metal tan
3. RFI compliant engines use a Champion XC12YC Kohler 25 132 14 S spark plug A high performance spark plug Champion Platinum 3071 Kohler Part No 25 132 12 S is also available Equivalent alternate brand spark plugs can also be used Gap 0 76 mm 0 030 in Thread Size 14mm Reach 19 1 mm 3 4 in Hex Size 15 9 mm 5 8 in Type Spark Plug Service Remove the spark plugs after every 100 hours of operation Check their condition and either reset the gap or replace with new plugs as necessary To service the plugs perform the following steps 1 Before removing a spark plug clean the area around the base of the plug to keep dirt and debris out of the engine 2 Remove the spark plug and check its condition See Inspection following this procedure Replace the spark plug if necessary NOTE Do not clean spark plugs in a machine using abrasive grit Some grit could remain in the spark plug and enter the engine causing extensive wear and damage 3 Check the gap using a wire feeler gauge Adjust the gap to 0 76 mm 0 030 in by carefully bending the ground electrode See Figure 7 1 Wire Gauge Spark Plug Ground Electrode 0 76 mm 0 030 in Gap Figure 7 1 Servicing Spark Plug 4 Reinstall the spark plug into the cylinder head and torque to 24 4 29 8 N m 18 22 ft 1b Inspection Inspect each spark plug as it is removed from the cylinder head The deposits on the tip are an in
4. Dip the ends of the push rods in engine oil and install in their original positions making sure that each push rod ball seats in its tappet socket See Figure 10 49 NOTE Push rods should always be installed in the same position as before disassembly Figure 10 50 Turning Adjusters In to Retain Push Rods 2 Rotate the crankshaft to establish Top Dead Center TDC on the Compression Stroke for the 1 cylinder Check for a Compression will be felt through the spark plug hole Install Sep seat Tappet g b Keyway of crankshaft will be aligned with 1 ee cylinder Figure 10 49 Installed Push Rods c No rocker arm push rod movement if Adjust Valve Clearance crankshaft is rotated slightly back and forth If 1 Turn the adjusters in the rocker arms or pivots they are moving rotate the crankshaft one full revolution down clockwise only enough to capture the push rods in the recesses See Figures 10 50 3 Insert a 0 127 mm 0 005 in feeler gauge between the end of one valve and the rocker arm Turn the adjuster or adjustment nut based on design until a slight drag is felt Hold in this position and tighten the locking nut or setscrew securely Torque setscrew to 7 9 N m 70 in lb After tightening recheck adjustment Proper valve clearance is 0 101 0 152 mm 0 004 0 006 in 10 14 Section 10 Reassembly See Figures 10 51 and 10 52 Check Assembly Important Rotate the crankshaft a minimum
5. misfiring loss of speed and power governor hunting or excessive throttle opening Clogged air cleaner Clean or replace Choke partially closed during operation Check the choke lever linkage to ensure choke is operating properly Low idle fuel mixture is improperly adjusted Adjust low idle fuel needle some models Float level is set too high Separate carburetor air horn from carburetor body adjust float according to steps outlined in Float Replacement procedure Dirt under the fuel inlet needle Remove needle clean needle and seat and blow with compressed air Bowl vent or air bleeds plugged Remove low idle fuel adjusting needle Clean vent ports and air bleeds Blow out all passages with compressed air Leaky cracked or damaged float Submerge float to check for leaks 3 Engine runs lean indicated by misfiring loss of speed and power governor hunting or excessive throttle opening Low idle fuel mixture is improperly adjusted Adjust low idle fuel needle some models Float level is set too low Separate carburetor air horn from carburetor body adjust float according to steps outlined in Float Replacement procedure Idle holes plugged dirt in fuel delivery channels Remove low idle fuel adjusting needle Clean main fuel jet and all passages blow out with compressed air 4 Fuel leaks from carburetor Float level set too high See Remedy 2d Dirt under fuel inlet needle See Reme
6. 0 030 in and retest engine performance If problem persists go to Test 3 b If one cylinder had good spark but the other cylinder had no spark or intermittent spark go to Test 3 c If there was no spark or intermittent spark on both cylinders go to Test 4 Test 3 Check For Timing Advance 1 Make a line near the edge of the flywheel screen with a marking pen or narrow tape See Figure 7 11 Flywheel Screen Mark a e Ze Figure 7 11 Check For Timing Advance 2 Connect an automotive timing light to cylinder that had good spark Run the engine at idle and use the timing light beam to locate the line on the screen Draw a line on the blower housing adjacent to the line on the screen See Figure 7 12 Accelerate to full throttle and watch for movement of the line on the screen relative to the line on the blower housing If both cylinders had good spark repeat the test on the other cylinder Figure 7 12 Check For Timing Advance a If the line on the screen moved away from the line on the blower housing during acceleration the DSAM is working properly If it didn t move away go to Test 5 b If you were able to check timing on both cylinders the lines you made on the blower housing should be 90 apart If they re not go to Test 4 Test 4 Test the Ignition Modules and Connections 1 Remove the blower housing from the engine Inspect the wiring for any damage cuts bad crimps
7. NYYO FONVYHO 137014A OI ALIYW10d SS SLIHM GIy ALITYV 10d Figure 7 17 Wiring Diagram DSAI Ignition System 7 17 Section 7 Electrical System and Components WNOILdO A SSV YSslevls LAIHG QIONS 10S LONISYWHO iFIOIA Y20708 YOLOSNNOD YJONITAJ Ze ee HOLVINGSY K re SCT MINelE q erh SNISHVHD ov amp 3 1HM yi A EE DEE NMOYG 53991184L USR WYSQ YNId vso f z l i dee EE w fob ai k Kach Pe kag k TIM NOILINSI a34 SLIHM wwen 371NGOW o JD HINNE NOTLINOI t IA AW 134 N3349 dhi Gal adns NMOHE gION3710s lt vm tenz ONNOH H 1 Wi EE O Oe i HSn Sea ifi 3 TE a34 1 Wi 3 OTOJINYN 2NNINI SONVYO l AYSLILVe l i HOLOSNNOD HIME 8 Sod Ur e a dm e i ee Z EE e d vm FE e d P De CWNOT LJO N3349 ZEN A SSV HSLHVIS 14IHS GIONS10S HJONITAJ Te 91d wWHvdS FONVYO LATOLA ET i IHW ALIYW10d SLIHM i ONWL OQIONS 105 EAE si d Ons Q1ON3 OS YSLevls Figure 7 18 Wiring Diagram DSAM Ignition System 7 18 Section 7 Electrical System and Components Figure 7 19 15 Amp Stator and Rectifier Regulator Figure 7 21 Rectifier Regulator Location Testing of the rectifier regulator may be performed as follows using the appropriate Rectifier Regulator Tester To Test NOTE Disconnect all electrical connections attached to the rectifier regulator Testing may be performed w
8. Piston Rings and Piston Pin Piston to Piston Pin Running EE 0 006 0 017 mm 0 0002 0 0007 in Piston Pin Bore I D TV AIEE EEEE AIA EE 17 006 17 012 mm 0 6695 0 6698 in ee E E o E A E A A A A E E A 17 025 mm 0 6703 in Piston Pin O D KSE 16 995 17 000 mm 0 6691 0 6693 in Kare VN elite LI E 16 994 mm 0 6691 in Top Compression Ring t0 Groove Side Clearance seserimis 0 025 0 048 mm 0 0010 0 0019 in Middle Compression Ring to Groove Side Clearance ssaiceviinsssitstivssassiiententosseenniass 0 015 0 037 mm 0 0006 0 0015 in Oil Control Ring to Groove Side CIGAR ANC susarsan i 0 026 0 176 mm 0 0010 0 0070 in Top and Center Compression Ring End Gap N w e EE 0 25 0 56 mm 0 0100 0 0224 in Ued Bore EE 0 94 mm 0 037 in Piston Thrust Face O D E 82 947 mm 3 2656 in E E o E 82 802 mm 3 2599 in Piston Thrust Face to Cylinder Bore Running Clearance Eege 0 06 0 100 mm 0 0023 0 0039 in Measure 6 mm 0 236 in above the bottom of the piston skirt at right angles to the piston pin Section 1 Safety and General Information Speed Control Bracket FSC OE en 10 7 N m 95 in Ib into new holes 7 3 N m 65 in lb into used holes Starter Assembly Thru Bolt Torque EE EE 4 5 5 7 N m 40 50 in Ib Delco Remy Solenoid SHUL airs crete ests ean gohs arses vemedoraseoeantsanasdpiesecsensdapesventoane 5 6 9 0 N m 49 79 in Ib Mount ng screw orgue eege 15 3 N m 135 in Ib Brush Holder Mounting Screw Torque
9. Section 10 Reassembly NOTE Proper orientation of the piston connecting rod assemblies inside the engine is extremely important Improper orientation can cause extensive wear or damage Be certain the pistons and connecting rods are assembled exactly as shown in Figure 10 8 Figure 10 8 Proper Piston Connecting Rod Orientation 1 Stagger the piston rings in the grooves until the end gaps are 120 apart The oil ring rails should also be staggered Lubricate the cylinder bore piston and piston rings with engine oil Compress the rings using a piston ring compressor Lubricate the crankshaft journals and connecting rod bearing surfaces with engine oil Make sure the Fly stamping on the piston is facing toward the flywheel side of the engine Use a hammer with a rubber or wood grip and gently tap the piston into the cylinder as shown in Figure 10 9 Be careful that the oil ring rails do not spring free between the bottom of the ring compressor and the top of the cylinder 10 3 Section 10 Reassembly Figure 10 9 Installing Piston Assembly Using Ring Figure 10 11 Torquing Connecting Rod End Cap Compressor Tool 6 Repeat the above procedure for the other 5 Install the inner rod cap to the connecting rod connecting rod and piston assembly using the two hex flange screws Torque the screws in increments to 11 3 N m 100 in Ib Install Valve Tappets and Camshaft Ilustrated instructions are pr
10. burrs can result in leaks Refer to A Guide to Engine Rebuilding TP 2150 A for additional information Measurement Guide TP 2159 B and Engine Inspection Data Record TP 2435 are also available use these to record inspection results Automatic Compression Release ACR Some engines may be equipped with the optional Automatic Compression Release ACR mechanism The ACR lowers compression at cranking speeds to make starting easier Camshaft Inspection and Service Check the lobes of the camshaft for wear or damage See Section 1 Specifications and Tolerances for minimum lift specifications Inspect the cam gear for badly worn chipped or missing teeth Replacement of the camshaft will be necessary if any of these conditions exist Crankshaft Inspection and Service Inspect the gear teeth of the crankshaft If the teeth are badly worn chipped or some are missing replacement of the crankshaft will be necessary Inspect the crankshaft bearing surfaces for scoring grooving etc Measure the running clearance between the crankshaft journals and their respective bearing bores Use an inside micrometer or telescoping gauge to measure the inside diameter of both bearing bores in the vertical and horizontal planes Use an outside micrometer to measure the outside diameter of the crankshaft main bearing journals Subtract the journal diameters from their respective bore diameters to get the running clearances Check the results
11. if ignited Keep sparks and other sources of ignition away from the engine 1 Install the blower housing with the access door onto the engine Start all the mounting screws The two HI LO thread screws are installed in the front securing the blower housing to the air cleaner base Make sure the wire harness and spark plug leads exit out through the appropriate openings in the shrouding Attach any fuel line clamps used See Figure 10 80 1 Connect the pulse hose to the valve cover The valve cover should be situated between the two formed lips on the pulse hose See Figure 10 81 2 Attach the pulse hose to the fuel pump and secure with a clamp Mount the fuel pump to the blower housing with the two screws Torque the screws to 2 3 N m 20 in 1b 10 23 Section 10 Reassembly Install Muffler 1 Install the muffler and attaching hardware to the muffler bracket Torque screws to 9 9 N m 88 in Ib 2 Install the M8 hex flange nuts or 5 16 18 hex head capscrews based on head design to secure the muffler Torque the hex flange nuts to 24 4 N m 216 in Ib or the capscrews to 16 9 N m 150 in Ib Install Oil Filter and Fill Crankcase with Ou 1 Install the oil drain plug See Figure 10 83 Torque the plug to 13 6 N m 120 in Ib A i TEE Figure 10 81 Installing Pulse Hose NOTE Make sure that the oil drain plug is installed and torqued to the above specification to prevent oil leakage 3 Connec
12. wear present Customer should start planning for overhaul or replacement Gauge reading in high red EE Rings and or cylinder have considerable wear Engine should be reconditioned or D replaced 3 5 Section 3 Troubleshooting 3 6 Section 4 Air Cleaner and Air Intake System Air Cleaners General Air cleaner systems used on these engines will be either the standard size or PRO Series increased capacity slightly taller design Each system uses a replaceable high density paper air cleaner element Some are also equipped with an oiled foam precleaner which surrounds the paper element See Figures 4 1 and 4 2 Standard Element and PRO Series Increased Standard Dolog Figure 4 1 Air Cleaner Element Location Service Check the air cleaner daily or before starting the engine Check for and correct any buildup of dirt and debris along with loose or damaged components NOTE Operating the engine with loose or damaged air cleaner components could allow unfiltered air into the engine causing premature wear and failure Precleaner Service If so equipped wash and reoil the precleaner every 25 hours of operation more often under extremely dusty or dirty conditions Replace the precleaner annually or every 100 hours To service the precleaner see Figures 4 1 and 4 2 and perform the following steps 1 Open the door on the blower housing to access the air cleaner element and precleane
13. 10 26 Figure 10 28 Installing Breather Reed and Retainer 10 8 Section 10 Reassembly 2 Invert the breather housing cover and apply 5 Attach the breather hose to the housing if a 1 5 mm 1 16 in bead of RTV sealant to the disconnected earlier Make sure the cover is perimeter flange of the outer housing cover as between the formed lips of the breather hose shown in Figure 10 29 Use Loctite 5900 or 5910 Position the hose so the opposite end is away Kohler Part No 25 597 07 S from the crankshaft NOTE The RTV sealant should be allowed to cure a minimum of one hour before the engine is started Sealant Bead Figure 10 29 Sealant Applied to Breather Cover 3 Immediately install the housing over the mounting stud and onto crankcase Do not allow the RTV sealant to come in contact with the Figure 10 31 Breather Cover and Breather Hose breather reed or the reed sealing surface Installation 4 Secure with a new sealing washer and the M5 Install Stator and Backing Plate hex nut Torque the hex nut to 1 3 N m 11 5 in 1 Apply pipe sealant with Teflon Loctite No Ib Check that a complete seal has occurred by 59241 or equivalent to the stator mounting holes the RTV sealant being squeezed out around the entire flange perimeter 2 Position the stator aligning the mounting holes so that the leads are at the bottom toward the crankcase 3 Install and torque the two hex flange sc
14. 17 Section 5 Fuel System and Governor Always use new gaskets when servicing or reinstalling carburetors Repair kits are available which include new gaskets and other components Service repair kits available for Nikki carburetors and affiliated components are Carburetor Repair Kit Float Kit High Altitude Kit 1525 3048 m 5 000 10 000 ft High Altitude Kit Over 3048 m 10 000 ft Solenoid Assembly Kit Reassembly Procedure Reassembly is essentially the reverse of the disassembly procedure Use new gaskets springs and adjusting screws as provided in the carburetor repair kit Also use new carburetor and intake manifold gaskets Set the idle speed RPM adjusting screw if equipped 2 1 4 turns open for initial adjustment and make final adjustments as described earlier Governor General The engine is equipped with a centrifugal flyweight mechanical governor It is designed to hold the engine speed constant under changing load conditions The governor gear flyweight mechanism is mounted inside the crankcase on the oil pan and is driven off the gear on the camshaft The governor works as follows e Centrifugal force acting on the rotating governor gear assembly causes the flyweights to move outward as speed increases Governor spring tension moves them inward as speed decreases e As the flyweights move outward they cause the regulating pin to move outward e The regulating pin contacts the tab on the cross shaft c
15. 3 Release the governor lever and allow the engine to return to the governed idle speed Check it with a tachometer against the equipment manufacturers recommended idle speed Governed Idle Speed RPM is typically 300 RPM approximate higher than the low idle speed If adjustment is necessary bend the adjusting tab on the speed control assembly to set See Figure 5 7 La ef Idle Spring Figure 5 9 Fuel Bowl Removed from Carburetor 2 Remove the float pin screw and lift out the old float pin and inlet needle See Figure 5 10 Discard all of the parts The seat for the inlet needle is not serviceable and should not be removed 9 Hold Throttle 8 Lever Aoainst TE Screw e Figure 5 10 Removing Float and Inlet Needle 5 3 Clean the carburetor bowl and inlet seat areas as i required before installation of new parts Figure 5 8 Holding Throttle Lever Against Idle Stop Screw 4 Attach the inlet needle to the metal tang of the float with the wire clip The formed 90 lip of the Carburetor Servicing metal tang should point up with the needle valve hanging down See Figure 5 11 Keihin Carburetors Float Replacement 1 Clean the exterior surfaces of dirt or foreign material before disassembling the carburetor Remove the four fuel bowl screws and carefully separate the fuel bowl from the carburetor Do not damage the O Ring s Transfer any remaining fuel into an approved container S
16. 4 If you get a sign instead of the numerical sequence and or an F at the end of the test cycle recheck all of the connections check the condition of the tester battery and repeat the test If you get the or F sign again in the retest replace the DSAM IMPORTANT Allow 15 20 seconds for the tester to clear and reset itself between tests or if the test is interrupted before completion of the test cycle Otherwise a false reading may be displayed in the form of a or a faint 8 Figure 7 15 Pass Indicator Section 7 Electrical System and Components The tester is powered by a 9 volt battery Most SAM s are designed to operate down to a minimum of 7 25 volts If the tester battery drops below that level incorrect test readings will result The tester battery should be checked periodically by connecting a DC voltmeter between the red and green lead wires with the tester connected to a DSAM Start the appropriate test sequence While the test is running monitor the voltage reading on the voltmeter If the voltage drops below 7 5 at any time during the cycle the 9 volt tester battery must be replaced Use an extended life alkaline battery To replace the battery remove the outer set of screws on the faceplate and carefully lift the panel from the body Unplug the connector and pull battery with mounting tape off the back of the tester Attach the connector to the ne
17. Crank 1 AL E aS PTO drive is engaged Battery is discharged Safety interlock switch is engaged Loose or faulty wires or connections Faulty key switch or ignition switch Faulty electric starter or solenoid Seized internal engine components Engine Runs But Misses 1 oe ay COND Dirt or water in the fuel system Spark plug lead disconnected Poor quality of fuel Faulty spark plug s Loose wires or connections that intermittently ground the ignition kill circuit Engine overheated Faulty ignition module or incorrect air gap Carburetor adjusted incorrectly DSAI or DSAM malfunction applicable models 3 1 Section 3 Troubleshooting Engine Will Not Idle I JE pa N SE Dirt or water in the fuel system Stale fuel and or gum in carburetor Faulty spark plugs Fuel supply inadequate Idle fuel adjusting needle improperly set some models Idle speed adjusting screw improperly set Low compression Restricted fuel tank cap vent Engine overheated cooling system air circulation problem Engine Overheats l Os GL Es St D Air intake grass screen cooling fins or cooling shrouds clogged Excessive engine load Low crankcase oil level High crankcase oil level Faulty carburetor Lean fuel mixture DSAI or DSAM malfunction applicable models Engine Knocks 1 PEL E Excessive engine load Low crankcase oil level Old or improper fuel Internal wear o
18. Cross Shaft 2 Make sure the throttle linkage is connected to the governor lever and the throttle lever on the carburetor Connect the choke linkage to carburetor choke lever See Figure 10 69 10 19 Section 10 Reassembly Figure 10 69 Linkage Details 3 Attach the fuel line to the carburetor and secure with a clamp Install a new air cleaner base gasket and the air cleaner base onto the mounting studs Torque the two hex flange nuts to 6 2 7 3 N m 55 65 in Ib See Figure 10 70 Connect the breather hose to the air cleaner base and secure with the clamp See Figure 10 71 Mounting Locations Figure 10 70 Installing Air Cleaner Base and Gasket 10 20 Ke ih iS Breather Hose and Clamp N s Connection Port gt Figure 10 71 Connecting Breather Hose 6 Move the governor lever toward the carburetor as far as it will go wide open throttle and hold in position 7 Insert a nail or similar tool into the hole on the cross shaft and rotate the shaft counterclockwise as far as will turn then torque the hex nut to 6 8 N m 60 in Ib See Figure 10 72 Figure 10 72 Adjusting Governor Lever Air Cleaner Base Removed for Clarity Section 10 Reassembly Install Air Cleaner Element 1 Install the air cleaner element with precleaner if equipped onto the air cleaner base Secure with the latch See Figure 10 73 Locations Figure 10 75 Throttle Choke Control Bracket
19. Gasoline Alcohol blends Gasohol up to 10 ethyl alcohol 90 unleaded gasoline by volume is approved as a fuel for Kohler engines Other gasoline Alcohol blends are not approved Gasoline Ether blends Methyl Tertiary Butyl Ether MTBE and unleaded gasoline blends up to a maximum of 15 MTBE by volume are approved as a fuel for Kohler engines Other gasoline ether blends are not approved Section 1 Safety and General Information Periodic Maintenance Instructions A WARNING Accidental Starts Disabling engine Accidental starting can cause severe injury or death Before working on the engine or equipment H disable the engine as follows 1 Disconnect the spark plug lead s 2 Disconnect negative battery cable from battery Maintenance Schedule These required maintenance procedures should be performed at the frequency stated in the table They should also be included as part of any seasonal tune up Maintenance Required Fill fuel tank Section 5 Check oil level Section 6 Check air cleaner for dirty loose or damaged parts Section 4 Check air intake and cooling areas clean as necessary Section 4 Every 25 Hours e Service precleaner element Every 50 Hours e Check air cleaner element clean or replace as necessary Replace air cleaner element and precleaner Section 4 Change oil and oil filter More frequently under severe conditions Section 6 Annually or Remove cooling shrouds and clean cooling a
20. Pan NeW sss scaszncisnveasnaceastcanstecsencuetmescanceemacyaantenceasdaantiens 40 987 40 974 mm 1 6136 1 6131 in Crankshaft Bore In Oil Pan to Crankshaft Ui Clearance NeW eege 0 039 0 074 mm 0 0015 0 0029 in Flywheel End Main Bearing Journal E T E E N EE E E E A N E A 40 913 40 935 mm 1 6107 1 6116 in OD Mis Wear E EE 40 84 mm 1 608 in Mar Ee 0 022 mm 0 0009 in Mak Ouro rK OUN E 0 025 mm 0 0010 in 1 9 Section 1 Safety and General Information Crankshaft Continued Oil Pan End Main Bearing Journal EE ee EE 40 913 40 935 mm 1 6107 1 6116 in De Ia Wear Ue EE 40 84 mm 1 608 in E e KE 0 022 mm 0 0009 in Max Ouro KOON eee a nese ee ses fc cece eta eateceeanaconuce 0 025 mm 0 0010 in Connecting Rod Journal E eege 35 955 35 973 mm 1 4156 1 4163 in OD Max Wear EE eeneg 35 94 mm 1 415 in E e KE 0 018 mm 0 0007 in Max I I EE 0 025 mm 0 0010 in Crankshaft T I R Ia t ch ave Pa C rant E 0 279 mm 0 0110 in Entre Crank 10 V BlOCK lt lt meremennin enter Penner cree tren EN 0 10 mm 0 0039 in Cylinder Bore Cylinder Bore I D KEE 83 031 83 006 mm 3 2689 3 2679 in IVA VGA Mal EE 83 069 mm 3 2704 in Max Ouo ROUT WE 0 12 mm 0 0047 in EN d KE 0 05 mm 0 0020 in Cylinder Head Cylinder Head Fastener Torque Head Bolk Torgue ir KE first to 22 6 N m 200 in Ib finally to 41 8 N m 370 in Ib Mas EE 0 076 mm 0 003 in Rocker Arm e ee UL Senne Onna Tne er mere er emery
21. Part No 25 357 11 S or Fel Pro Lubri Sel dielectric compound The beads should overlap between the terminals to form a solid bridge of compound See Figures 10 58 and 10 60 Do not put any compound inside the terminals E A Ze Leg Figure 10 60 Connect Leads on DSAM Ignition Modules 10 17 Section 10 Reassembly Install Rectifier Regulator Equipped oe Install the B terminal lead into the center position of the rectifier regulator plug so it locks in place and connect the plug to the rectifier regulator See Figure 10 61 Mounting 2 Attach the rectifier regulator to the opening in e E Screw backing plate from the underside and secure de Locations with the two mounting screws See Figure 10 62 B Terminal Figure 10 63 Installing Outer Cylinder Baffles 2 Attach the inner baffles including any lifting straps to the cylinder head flanges and to the two crankcase mounting bosses The lift strap should be outside the outer baffle Secure with the M5 screws See Figure 10 64 The remaining lower inner baffle mounting screws will be installed later Torque the baffle mounting screws M5 screws 6 2 N m 55 in lb into a new cored hole or 4 0 N m 35 in Ib into a used hole M6 screws 10 7 N m 95 in 1b into a new cored hole or 7 3 N m 65 in lb into a used hole Rectifier Regulator Figure 10 62 Installed Rectifier Regulator Install the Inner and Outer Cylinder Baff
22. Starter Motor 4 Figure 8 19 Removing Oil Fill Tube Section 8 Disassembly Remove the carburetor gasket If necessary the carburetor throttle linkage and governor lever can be separated Reattach the bushings to the linkage following separation to avoid losing them Remove Electric Starter Motor 1 Disconnect the leads from the starter Remove the two hex flange screws See Figure 8 18 Remove the starter assembly Pull out the oil fill tube with the lifting strap from the crankcase See Figure 8 19 8 5 Section 8 Disassembly Remove Inner Baffles T n S 1 Remove the mounting screws securing the two Standard Fixed Timing Ignition inner baffles to the crankcase Note the position Module Single Lead shown of any lifting bracket s Remove the inner baffles ve See Figure 8 20 e Leg Strap IDSAM or SMART SPARK Ignition Module Two Leads Inner Baffle s Mounting Screw Figure 8 20 Removing Inner Baffles Remove Ignition Modules 1 Rotate the flywheel so the magnet is away from the modules 2 Disconnect the lead s from each ignition module e Fixed Timing Models and DSAI Models have one Figure 8 21 Removing Ignition Modules lead per module and DSAM or SMART SPARK variable timing ignition modules have two leads per module See Figure 8 21 Remove Intake Manifold and Rectifier Regulator 1 Remove the four hex flange screws securing the intake manifold to
23. amps is generally recommended for starting in all conditions A smaller capacity battery is often sufficient if an application is started only in warmer temperatures Refer to the following table for minimum cold cranking amp cca capacities based on anticipated ambient temperatures The actual cold cranking requirement depends on engine size application and starting temperatures The cranking requirements increase as temperatures decrease and battery capacity shrinks Refer also to the operating instructions for the piece of equipment for specific battery requirements Above 3 09 If the battery charge is not sufficient to turn over the engine recharge the battery 10 F 32 C or below Battery Maintenance Regular maintenance is necessary to prolong battery life A WARNING Explosive Gas Batteries produce explosive hydrogen gas while being charged To prevent a fire or explosion charge batteries only in well ventilated areas Keep sources of ignition away from the battery at all times Keep batteries out of the reach of children Remove all jewelry when servicing batteries Before disconnecting the negative ground cable make sure all switches are OFF If ON a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or gasoline vapors are present 1 Regularly check the level of electrolyte Add distilled water as necessary to maintain the recommended level NOTE Do not o
24. and replace them with burnishing stones Continue with the burnishing stones until the bore is within 0 013 mm 0 0005 in of the desired size and then use finish stones 220 280 grit and polish the bore to its final size A crosshatch should be observed if honing is done correctly The crosshatch should intersect at approximately 23 33 off the horizontal Too flat an angle could cause the rings to skip and wear excessively and too steep an angle will result in high oil consumption See Figure 9 1 Figure 9 1 Cylinder Bore Crosshatch After Honing 4 After resizing check the bore for roundness taper and size Use an inside micrometer telescoping gauge or bore gauge to take measurements The measurements should be taken at three locations in the cylinder at the top middle and bottom Two measurements should be taken perpendicular to each other at each of the three locations Clean Cylinder Bore After Honing Proper cleaning of the cylinder walls following boring and or honing is very critical to a successful overhaul Machining grit left in the cylinder bore can destroy an engine in less than one hour of operation after a rebuild The final cleaning operation should always be a thorough scrubbing with a brush and hot soapy water Use a strong detergent that is capable of breaking down the machining oil while maintaining a good level of suds If the suds break down during cleaning discard the dirty water and
25. be installed in the same positions 1 Remove the spark plug from each cylinder head See Figure 8 25 8 7 Section 8 Disassembly NOTE The exhaust side is located on the output shaft side of the engine while the intake side is located on the fan side of the engine The cylinder head number is embossed on the outside of each cylinder head See Figure 8 30 Figure 8 27 Loosening Pivot Screws End Adjustment Style Shown 4 Remove the four hex flange screws securing each cylinder head Discard the screws once removed Do not reuse See Figure 8 28 Figure 8 30 Match Marks on Cylinder Barrel and Heads Disassemble Cylinder Heads 1 Remove the two hex flange screws rocker arm pivots and rocker arms with adjusters from the cylinder head See Figure 8 31 End Adjustment Style Components Figure 8 28 Removing Cylinder Head Screws Center Pivot Adjustment Style Shown 5 Remove the cylinder head and head gasket See Figure 8 29 Rocker Arm with Adjuster Center Pivot Adjustment Style Components s Arm Figure 8 29 Removing Cylinder Head and Gasket Figure 8 31 Removing Rocker Arm Assemblies 8 8 Section 8 Disassembly 2 Compress the valve springs using a valve spring compressor See Figure 8 32 Figure 8 34 Intake Valve Stem Seal Some Models Figure 8 32 Removing Valves with Valve Spring NOTE On engines with valve stem seals on the Compressor intake valves use a new seal
26. be treated with a stabilizer to prevent deterioration If you choose to 5 Disconnect the battery or use a battery minder to use a stabilizer follow the manufacturer s keep the battery charged during storage recommendations and add the correct amount for the capacity of the fuel system 6 Store the engine in a clean dry place 1 5 Section 1 Safety and General Information Dimensions in millimeters 430 1 16 934 Inch equivalents shown in 10 44 411 Yi SPARK PLUG i l m 10 44 411 SPARK PLUG 427 06 16 814 X e Al 2 103 89 80 CENTER OF GRAVITY 3 536 V W E y 51 72 2 036 OIL FILL m 6 29 amp DIPSTICK MOUNT I NG 248 HOLE A CENTER OF GRAVITY rat Se TOP VIEW ogee d 1 969 ee EXHAUST PORT 1 311 71 12 272 THROTTLE AND CHOKE CABLE MOUNTING SURFACE EE EE 1 969 EXHAUST PORT 2 l 93 06 3 664 ROTATION ne STARTER Tee STUD 248 09 m 111 51 e OIL FILTER 9 767 4 390 EE 4x 8 72 41 00 STARTER 34 l 3 1 614 STUD L MOUNT ING vw A 254 00 B C 10 000 de ENGINE MOUNTING SURF ACE PTO ENE L_ 44 24 1 742 THROTTLE TRAVEL 43 87 34 1 24 5 92 02 3 623 CHOKE TRAVEL 17 8 M
27. disassembled Only clean parts can be accurately inspected and gauged for wear or damage There are many commercially available cleaners that will quickly remove grease oil and grime from engine parts When such a cleaner is used follow the manufacturer s instructions and safety precautions carefully Make sure all traces of the cleaner are removed before the engine is reassembled and placed into operation Even small amounts of these cleaners can quickly break down the lubricating properties of engine oil Basic Engine Tests Crankcase Vacuum Test A partial vacuum should be present in the crankcase when the engine is operating Pressure in the crankcase normally caused by a clogged or improperly assembled breather can cause oil to be forced out at oil seals gaskets or other available spots Crankcase vacuum is best measured with either a water manometer or a vacuum gauge Kohler Part No 25 761 22 S Complete instructions are provided in the kits Section 3 Troubleshooting To test the crankcase vacuum with the manometer 1 Insert the stopper hose into the oil fill hole Leave the other tube of manometer open to atmosphere Make sure the shut off clamp is closed Start the engine and run at no load high speed 3200 to 3750 RPM Open the clamp and note the water level in the tube The level in the engine side should be a minimum of 10 2 cm 4 in above the level in the open side If the
28. firing recheck position of ignition switch and check for shorted kill lead B DSAI Ignition System Explanation A digital spark advance ignition system DSAI is used on some models The DSAI ignition system is an advanced 12 volt version of the fixed timing ignition system used on other models Two inductive style ignition modules control the ignition timing based on engine RPM A typical DSAI application Figure 7 6 consists of the following components e A magnet assembly which is permanently affixed to the flywheel e Two inductive 12 volt ignition modules which mount on the engine crankcase Figure 7 6 e A 12 volt battery which supplies current to the ignition modules e A kill switch or key switch which grounds the spark advance module to stop the engine e Two spark plugs Operation The system provides more consistent energy to the spark plugs at all engine speeds by using the 12 volt battery as its source of power Engine speed and top 7 6 dead center TDC location reference information is provided by the flywheel magnet group as it passes the ignition module System triggering and engine timing is performed by a digitally controlled microprocessor This digital control provides repeatable and consistent engine cylinder spark timing Each DSAI module performs its function independently for each engine cylinder Troubleshooting DSAI Ignition Systems The DSAI ignition system is designed to be trouble free for the
29. for Standard Applications ER Tightening Torque N m in Ib or 10 Property Class Noncritical Fasteners Into Aluminum 18 35 8 60 Size M4 M5 M6 15 9 26 1 36 28 8 51 1 72 H 44 7 7 50 9 88 Ar 0 124 e 5 146 86 11 22 3 38 2 7 O S Z 3 M8 Ps 5 93 6 120 2 4 216 33 9 300 40 7 360 a 0 150 Tightening Torque N m ft Ib or 10 Property Class Noncritical Into Aluminum M10 21 7 16 27 1 20 47 5 35 66 4 49 81 4 60 33 9 25 M12 36 6 27 47 5 35 82 7 61 116 6 86 139 7 103 61 0 45 M14 58 3 43 76 4 55 131 5 97 184 4 136 219 7 162 94 9 70 Section 1 Safety and General Information English Fastener Torque Recommendations for Standard Applications Tightening Torque N m in Ib or 20 Bolts Screws Nuts and Fasteners Assembled Into Cast Iron or Steel Grade 2 Grade 5 2 3 20 2 8 25 3 6 32 4 5 Go 3 6 32 4 5 40 7 9 70 13 0 115 9 6 85 15 8 140 17 0 150 18 7 165 28 3 250 30 5 270 29 4 260 33 9 300 Tightening Torque N m ft Ib or 20 47 5 35 54 2 40 47 5 35 74 6 55 61 0 45 101 7 75 67 8 50 108 5 80 94 9 70 142 4 105 101 7 75 169 5 125 135 6 100 149 2 110 189 8 140 199 3 150 271 2 200 223 7 165 244 1 180 311 9 230 332 2 245 440 7 325 Grade 8 18 7 165 22 6 200 39 6 350 40 7 30 67 8
30. is disassembled Only clean parts can be accurately inspected and gauged for wear or damage There are many commercially available cleaners that will quickly remove grease oil and grime from engine parts When such a cleaner is used follow the manufacturer s instructions and safety precautions carefully Make sure all traces of the cleaner are removed before the engine is reassembled and placed into operation Even small amounts of these cleaners can quickly break down the lubricating properties of engine oil Typical Disassembly Sequence The following sequence is suggested for complete engine disassembly The sequence can be varied to accommodate options or special equipment 1 Disconnect spark plug leads 2 Shut off fuel supply 3 Drain oil from crankcase and remove oil filter 4 Remove adapter and oil cooler if equipped 5 Remove muffler 6 Remove fuel pump 7 Remove blower housing and outer baffles 8 Remove throttle controls 9 Remove external governor controls 10 Remove air cleaner and carburetor 11 Remove electric starter 12 Remove inner baffles 13 Remove ignition modules 14 Remove intake manifold and rectifier regulator 15 Remove spark plugs 16 Remove valve covers and cylinder heads 17 Remove grass screen fan and flywheel 18 Remove backing plate and stator 19 Remove outer breather assembly 20 Remove oil pan assembly 21 Remove camshaft and valve tappets 22 Remove governor cross s
31. life of the engine Other than periodically checking replacing the spark plugs no maintenance timing or module adjustments are necessary or possible Mechanical systems do occasionally fail or break down however so the following troubleshooting information is provided to help you get to the root of a problem Reported ignition problems are most often due to poor connections Before beginning the test procedure check all external wiring Be certain all ignition related wires are connected including the spark plug leads Be certain all terminal connections fit snugly Make sure the ignition switch is in the RUN position NOTE Ignition systems are sensitive to excessive load on the kill lead If a customer complains of hard starting low power or misfire under load it may be due to excessive draw on the kill circuit Perform the appropriate test procedure Test Procedure for DSAI Ignition Systems The following procedures are provided for troubleshooting ignition problems on DSAI equipped engines They will allow you to isolate and pinpoint the failed component s Special Tools Required e Hand Tachometer e Ignition Tester Kohler Part No 25 455 01 S e Automotive Timing Light e Multi meter Digital Specifications Required e Spark plug gap 0 76 mm 0 030 in Section 7 Electrical System and Components RED MANIFOLD I INTAKE SCREW CONNECTOR VIOLET ORANGE See ORANGE RED OPTIONAL SOLENOID SHIFT STA
32. or adjust the ignition module air gap s An air gap of 0 28 0 33 mm 0 011 0 013 in must be maintained under all three legs of the ignition module s Checking adjusting should be performed with the parts at room temperature a If the module was not loosened or replaced check that the specified air gap is present under all three legs If the gap is correct reinstall the second mounting screw removed earlier and recheck gap after tightening b If the gap is incorrect or the module was loosened or replaced adjust the gap as follows 1 Turn the flywheel magnet away from the module position 2 Attach the module to the mounting legs pull it away from the flywheel and tighten the screws to hold it temporarily 3 Rotate the flywheel so the magnet is centered under the module 4 Position a 0 30 mm 0 012 in feeler gauge between the magnet and all three legs of the module The ignition module air gap is critical to proper system performance Do not attempt to set it with a business card or folded microfiche card Use the feeler gauge specified Section 7 Electrical System and Components 5 Loosen the mounting screws allow the magnet to pull the module down against the feeler gauge and retighten the mounting Screws 6 Rotate the flywheel to remove the feeler gauge position the magnet back under the module and recheck that the specified gap minimum of 0 28 mm 0 011 in exists under each leg of the modu
33. provide a path for the the connectors and position or insulate the white spark to discharge to ground kill lead terminal so it cannot touch ground Try starting the engine to verify whether the reported Reported ignition problems are most often due to problem is still present poor connections Before beginning the test procedure check all external wiring Be certain all ignition related NOTE Ifthe engine starts or runs during any of wires are connected including the spark plug leads the testing you may need to ground the Be certain all terminal connections fit snugly Make kill lead to shut it down Because you have sure the ignition switch is in the RUN position interrupted the kill circuit it may not stop using the switch NOTE The CD ignition systems are sensitive to excessive load on the kill lead If a customer a If the problem is gone the electrical system complains of hard starting low power on the unit is suspect Check the key switch or misfire under load it may be due to wires connections safety interlocks etc excessive draw on the kill circuit Perform the appropriate test procedure b If the problem persists the condition is associated with the ignition or electrical Test Procedure for DSAM Ignition Systems system of the engine Leave the kill lead The following procedures are provided for isolated until all testing is completed troubleshooting ignition problems on DSAM or Smart Spark equipped engines to
34. rods with pistons and rings Install valve tappets and camshaft Install oil seal in oil pan Install oil transfer tubes and filter adapter 9 Install oil pan assembly 10 Install breather reed and outer cover 11 Install stator and backing plate 12 Install flywheel and cooling fan 13 Install grass screen 14 Assemble and install cylinder heads 15 Adjust valve clearance 16 Install valve covers 17 Install spark plugs Figure 10 1 Seal Bore of Crankcase oS ee Ss S 2 Apply a light coat of engine oil to the outside diameter of the oil seal 3 Install the oil seal into the crankcase using a seal driver Make sure the oil seal is installed straight and true in the bore and the tool bottoms against the crankcase See Figure 10 2 10 1 Section 10 Reassembly Drainback Hole Must Be Open e Figure 10 4 Torquing Breather Cover Screw Install Breather Filter and Inner Cover Install Governor Cross Shaft 1 Install the breather filter between the two ribs 1 Lubricate the governor cross shaft bearing inside the inner breather chamber See Figure surfaces in the crankcase with engine oil 10 3 2 Slide the lower washer onto the governor cross 2 Make sure the sealing surfaces are clean and free shaft and install the cross shaft from the inside of of nicks or damage Install a new breather cover the crankcase See Figure 10 5 gasket and the breather cover onto the chamber See Figure 10 3
35. spark See Figure 10 56 The ground lead for the fuel plug lead from the module always away from the solenoid equipped models should be attached cylinder On 1 cylinder the single kill tab should to the inner screw on the 2 side Using the be up towards you See Figure 10 55 On the 2 sequence shown in Figure 10 57 torque the four cylinder the single kill tab should be down away screws in two stages first to 7 4 N m 66 in Ib from you then to 9 9 N m 88 in Ib 3 Install each ignition module to the crankcase bosses with the two screws Slide the modules up as far away from the flywheel as possible and snug the screws to hold them in that position 4 Rotate the flywheel to position the magnet directly under one ignition module 5 Insert a 0 30 mm 0 012 in flat feeler gauge between the magnet and the ignition module see Figure 10 55 Loosen the screws enough to allow the magnet to pull the module against the feeler gauge 10 16 Section 10 Reassembly Figure 10 58 Sealant Applied to Terminals Harness 2 Connect the kill lead to the tab terminal on standard ignition modules See Figure 10 59 4 N Le Figure 10 57 Intake Manifold Torque Sequence e NOTE If the wires were disconnected from Figure 10 59 Connecting Kill Leads on Fixed the ignition modules on engines with Ignition Modules DSAM reattach the leads and seal the base of the terminal connectors with GE Novaguard G661 Kohler
36. spring from the governor lever Note the hole locations for reassembly See Figure 8 12 Figure 8 13 Removing Governor Lever Remove Air Cleaner and Carburetor A WARNING Explosive Fuel Gasoline may be present in the carburetor and fuel system Gasoline is extremely flammable and its vapors can explode if ignited Keep sparks and other sources of ignition away from the engine 1 Remove the two carburetor air cleaner base mounting nuts and disconnect the breather hose Remove the air cleaner base and gasket See Figures 8 14 and 8 15 Mounting Locations Governor Spring Figure 8 12 Disconnecting Linkage and Governor Springs Remove External Governor Controls 1 Loosen the hex flange nut and remove the governor lever from the cross shaft See Figure 8 13 Leave the lever attached to the throttle linkage z y a 7 d get e Sal KH s e E kb Figure 8 14 Removing Mounting Nuts 8 4 B SP Figure 8 15 Removing Air Cleaner Assembly 2 Unhook the retainer and remove the air cleaner element and precleaner if equipped from the air cleaner base for servicing See Figure 8 16 Figure 8 16 Removing Air Cleaner Element 3 Disconnect the ground lead and the fuel shut off solenoid lead if equipped 4 Remove the carburetor throttle linkage and governor lever as an assembly See Figure 8 17 Figure 8 17 Removing Carburetor Ss Figure 8 18 Removing Electric
37. the cylinder heads Note which screws hold the wiring clamp s 3 Remove the mounting screws and ignition modules Note the position of the ignition modules 2 Remove the intake manifold and O Rings Leave the wiring harness attached to the manifold See Figure 8 22 Intake Manifold Mounting Locations _ Figure 8 22 Intake Manifold Mounting Locations 8 6 Section 8 Disassembly 3 Remove the two screws securing the rectifier regulator to the backing plate and disconnect the plug See Figure 8 23 4 Use the tip of a small screwdriver or similar small flat tool to bend the locking tang then remove the B center lead from the terminal plug as shown in Figure 8 24 This will allow the intake manifold to be removed with the wiring harness intact Figure 8 25 Removing Spark Plug Remove Valve Covers and Cylinder Heads 1 Remove the four hex flange screws securing each valve cover Most valve covers have the screw hole spacers molded in place Remove the valve covers and O Rings See Figure 8 26 Figure 8 23 Removing Rectifier Regulator Figure 8 26 Removing Valve Covers 2 Loosen the rocker arm pivot screws or inner setscrews T25 TORX based on design and back off the rocker arm adjusting nuts See Figure 8 27 Figure 8 24 Removing B Lead from Terminal Plug 3 Mark the location of the push rods as either intake or exhaust and cylinder 1 or 2 Push rods Remove Spark Plugs should always
38. 1 Remove the oil seals from the crankcase and oil pan See Figure 8 53 Crankcase Seal Oil Pan Seal Figure 8 53 Removing Oil Seals 8 14 Section 9 Inspection and Reconditioning This section covers the operation inspection and repair econditioning of major internal engine components The following components are not covered in this section They are covered in sections of their own Section 4 Air Cleaner and Intake System Section 5 Carburetor amp External Governor Section 7 Ignition Charging amp Electric Starter Clean all parts thoroughly Only clean parts can be accurately inspected and gauged for wear or damage There are many commercially available cleaners that will quickly remove grease oil and grime from engine parts When such a cleaner is used follow the manufacturer s instructions and safety precautions carefully Make sure all traces of the cleaner are removed before the engine is reassembled and placed into operation Even small amounts of these cleaners can quickly break down the lubricating properties of engine oil Use an aerosol gasket remover paint stripper or lacquer thinner to remove any old sealant Apply the solvent allow time for it to work and then brush the surface with a brass wire brush After the old sealant is removed clean the surface with isopropyl alcohol lacquer thinner or aerosol electrical contact cleaner Do not scrape the surfaces as any scratches nicks or
39. 28 Remove the two screws attaching the choke plate to the choke shaft Pull the shaft out of the carburetor body and discard the removed parts Figure 5 28 Choke Details 5 Use a screw extractor easy out and remove the original choke shaft bushing with the old choke lever from the carburetor housing Save the bushing to use as a driver for installing the new bushing Discard the old lever 6 Clean the I D of both choke shaft bores as required 7 Insert the new bushing through the new choke lever from the outside and start the bushing in the outer shaft bore Position the choke lever so that the protruding boss on the carburetor housing is between the two stops formed in the choke lever See Figure 5 29 5 14 Figure 5 29 Assembling Choke Lever ei Turn the old bushing upside down and use it as a driver to carefully press or tap the new bushing into the carburetor body until it bottoms Check that the choke lever pivots freely without restriction or binding See Figure 5 30 Figure 5 30 Installing Bushing J Install the new return spring onto the new choke shaft so the upper leg of the spring is between the two formed stops on the end of the choke shaft See Figure 5 31 Note Make sure it stays in this location during the following step Section 5 Fuel System and Governor Nikki Carburetors Float Replacement If symptoms described in the carburetor troubleshooting guide indicate float level
40. 50 81 4 60 108 5 80 142 4 105 155 9 115 223 7 165 237 3 175 311 9 230 352 6 260 447 5 330 474 6 350 637 3 470 Grade 2 or 5 Fasteners Into Aluminum OG 2 3 20 Torque Conversions N m in lb x 0 113 N m ft Ib x 1 356 in lb N m x 8 85 ft lb N m x 0 737 Section 2 Tools amp Aids Certain quality tools are designed to help you perform specific disassembly repair and reassembly procedures By using tools designed for the job you can properly service engines easier faster and safer In addition you ll increase your service capabilities and customer satisfaction by decreasing engine downtime Here is the list of tools and their source Separate Tool Suppliers Kohler Tools SE Tools Design Technology Inc Contact your source 415 Howard St 768 Burr Oak Drive of supply Lapeer MI 48446 Westmont IL 60559 Phone 810 664 2981 Phone 630 920 1300 Toll Free 800 664 2981 Fax 810 664 8181 Tools OO Source Part No Camshaft Endplay Plate For checking camshaft endplay SE Oe eeu Camshaft Seal Protector Aegis To protect seal during camshaft installation Ee Cylinder Leakdown Tester For checking combustion retention and if cylinder piston rings or valves are worn dee Electronic Fuel Injection EFI Diagnostic Software Use with Laptop or Desktop PC EE EFI Service Kit Kohler 24 761 01 5 For troubleshooting and setting up an EFI engine Indiv
41. 7 pV OU arate stnnc se eas neces se esos soascsemesaaoeoaestGaescaaeseace veneaseaceusecsneneaeaacsoaeeasoenieaeies 18 6 kW 25 HP e E 19 4 kW 26 HP AVAA ON EE 20 1 kW 27 HP DOTO eege 83 mm 3 27 in SEENEN 67 mm 2 64 in RE E 725 cc 44 cu in EE EE SCHER Baa ys A E pee atin een eats Aree earn estos E EO ease 41 2 kg 91 1b Oil Capacity w filter approximate determined by oil filter and if oil cooler equipped wasacsssonsssssresstsnsevecraciassevacasoianes 1 6 1 8 L 1 7 1 9 qt Angle of Operation Maximum At Full Oil Level All Directions 00 000 25 Blower Housing and Sheet Metal MEHELO Screws ee 2 8 N m 25 in Ib IV Tast ner Eegen 4 0 N m 35 in Ib Mo e Uo mU epee errr meer er ee eter rT mone rrr ert ta errr ert ener ey 6 8 N m 60 in lb Rec fier Regulator Fastener Por re acccscasgconsrecsrensaensuacssanatseeaun amen oneness 4 0 N m 35 in Ib Camshaft Ee ENEE Eegen 0 076 0 127 mm 0 0030 0 0050 in EE EE 0 025 0 063 mm 0 0010 0 0025 in Bore I D KT 20 000 20 025 mm 0 7874 0 7884 in Maxs Wear CUNIT E 20 038 mm 0 7889 in Camshaft Bearing Surface O D KT 19 962 19 975 mm 0 7859 0 7864 in Mas Ve EE eege 19 959 mm 0 7858 in Carburetor and Intake Manifold Intake Manifold Mounting Fastener Torque MOR CT Ee first to 7 4 N m 66 in Ib finally to 9 9 N m 88 in Ib Carburetor Mounting Ee EE 6 2 7 3 N m 55 65 in lb Values are in Metric units Values in parentheses are English equ
42. IN OR Cia AE EE 2 5 3 3 N m 22 29 in lb Solenoid Starter Mounting Hardware Torque ING OC KE aerie EE E EEEE EER 4 0 6 0 N m 35 53 in Ib Nut Positive Brush Lead Torque SCO Dari I ego easpaeregeso aren inp EEEE A 8 0 11 0 N m 71 97 in lb Stator le Ee Lee EE 6 2 N m 55 in lb Valve Cover Valve Cover Fastener e E 6 2 N m 55 in lb Valves and Valve Tappets VK CCA e 0 101 0 152 mm 0 004 0 006 in Valve Tappet to Crankcase Running Clearance eeeseseeseseeseeseeseeeeeeeeeees 0 013 0 073 mm 0 0005 0 0029 in Intake Valve Stem to Valve Guide Running Clearance eeceeeeeeeeeeens 0 038 0 076 mm 0 0015 0 0030 in Exhaust Valve Stem to Valve Guide Running Clearance ees eeeeeeeeeees 0 050 0 088 mm 0 0020 0 0035 in Intake Valve Guide I D KI 7 038 7 058 mm 0 2771 0 2779 in Max Wear Toth EE 7 134 mm 0 2809 in Exhaust Valve Guide I D TS 7 038 7 058 mm 0 2771 0 2779 in Max Wear E te EE 7 159 mm 0 2819 in Valve Guide Reamer Size SES de E 7 048 mm 0 2775 in RE 7 298 mm 0 2873 in Intake Valve Minimum Lift sessiccsnccnseveinasertecidenciccvesendevenscedpdeveusdenasstoeaiinnaesGeurentaenesdeas 8 07 mm 0 3177 in Exhaust Valve Minimum Lift oscssceccacenvasenenecondonsevexnedenneovenstenaeaveawennteeanvenevonceadenatsazt 8 07 mm 0 3177 in Nopumnal Valve Deal AND Esseri rp ir raa n iEn EEE EE EEEE 45 Section 1 Safety and General Information General Torque Values Metric Fastener Torque Recommendations
43. LS i li Avay i iat d D ONT NN i i in OR i GION3710S E n ler CHE lok been wf al i 39 NVY0 iil Ji l Hh i WE TH E i gt BR 8 L SLIHM HIH ALIYV 10d N3349 TYNOI Leit l 4VNOILdO A SSV YSLYVLS 3ONVHO z N3349 LAIHS OIONZOS 0384 39NVYY0 Sewer SONVHO LSIOIA SONVHO LSTIOIA O38 OI ALIYV 10d I i JLIHM U Electrical System and Components Figure 7 16 Wiring Diagram Fixed Timing Ignition System 7 16 Section 7 Electrical System and Components GO ONTOUWH7 OV 2IIHN J INAON NOILINOI YAQN I IAD 1 9N ld WYVdS IWNOI LaO HOLIMS SYNSSAud 110 AATYO VI LYAN 9N I SYVHO LAIOIA M00 1d YO1OANNO3D HO IV VO YJAN IAD 2 9N Id MYVdS asl sl Lose YOLV INDSY O O SSS ee eee eee ege eee 2 INGOW NOT LINO 32720 a SEI A a SSY YOLVLS TASHMA 14 QNLS AV laH Lu A SSY YALYVLS IWNMOT LdO Aa SSY YSALYVLS L4IITHS QION3TOS 9NY L dI ON3 10S H YHALYVLS A atest eer ee eee reine e Beet QION3 10S Yalavis NIJY9 l H ONT MNVYD AW Tae SL THM a10ONJ70S O31 danS HOI SAYNEYVO HAWOLSND ONnOYS 5 oN d M e Ss SE SONVHO gay QosINvN HOLISNNOD II EE bp TVNO I Lat 5 A SSY_HJLHY1S L4IHS QION310S TYNOI Leit N3349 ASNVYO SASNVYO LA IOLA TVNOI Leit N3349 3Nn78 03 4 da34 3
44. Mounting Detail 3 Connect the governed idle spring to governor lever and main control bracket Connect the governor spring from the throttle control bracket to the appropriate hole in the governor lever as indicated in the applicable chart Note that hole Install Throttle and Choke Controls positions are counted from the pivot point of the 1 Connect the choke linkage to the choke actuator governor lever See Figure 10 76 lever on the main control bracket assembly See Figure 10 74 Figure 10 73 Installing Air Cleaner Element Choke Linkage Choke Actuating Lever Figure 10 76 Governor and Dampening Spring Installation Typical Figure 10 74 Connecting Choke Linkage 2 Install the main control bracket to the cylinder heads using the four hex flange screws The two lower screws should also secure the inner baffles Torque the screws to 10 7 N m 95 in 1b into new holes or 7 3 N m 65 in 1b into used holes See Figure 10 75 10 21 Section 10 Reassembly Governor Lever Figure 10 77 Governor Lever and Hole Position RPM Chart Figure 10 78 Throttle Choke Control Bracket and Governor Lever Detail 10 22 Governor Lever and Hole Position RPM Chart High Idle Governor Lever Governor Spring RPM Hole No Color Code Description Bracket speed control Clamp cable Lever choke Lever throttle Linkage choke Lever throttle actuator bottom Washer wave Screw Washer
45. Nuts 2 Figure 4 3 Air Cleaner System Components Air Cleaner Components Whenever the air cleaner cover door is opened and Gr the paper element or precleaner is serviced check the following Air Cleaner Element Make sure the element is not bent or damaged Check that the element is properly secured and the latch is not damaged or missing Air Cleaner Base Make sure the base is secured tightly to the carburetor and not cracked or damaged 4 2 4 Gently tap the air cleaner element to dislodge dirt Do not wash the paper element or use pressurized air as this will damage the element Replace a dirty bent or damaged element with a genuine Kohler element Handle new elements carefully do not use if the sealing surface is bent or damaged 5 Clean the air cleaner base as required and check condition 6 Reinstall the precleaner if equipped over the paper air cleaner element and install on the base Secure with the latch 7 Close and latch the door Carburetor Gasket Breather Hose Air Cleaner Base Gasket Breather Hose Make sure the hose is attached to the air cleaner base and the breather reed cover NOTE Damaged worn or loose air cleaner components can allow unfiltered air into the engine causing premature wear and failure Tighten or replace all loose or damaged components Section 4 Air Cleaner and Air Intake System Air Cleaner Base Air Intake Cooling System To ensure proper cooling m
46. OTE The DSAM must be at room temperature when tested Disconnect all of the DSAM leads isolating it from the main wiring harness and the ignition module s Testing may be performed with the module mounted or loose The figures show the part removed from the engine for clarity Figure 7 13 1 Connect the tester to the DSAM as follows Attach Yellow tester lead to the long yellow module lead Brown tester lead to the long brown module lead Red tester lead to the red module lead Black tester lead to the green or black module ground lead with the eyelet terminal Pink tester lead to the short yellow or pink module lead Brown tester lead with black band or terminal to the short brown module lead Caution Do not allow the alligator clip leads to touch each other IMPORTANT 2 Check the DSAM part number stamped on the end of the tester housing noting the last two digits Using those numbers refer to the table below or tester faceplate to determine the test number to be used DSAM Part No 24 584 31 DSAM Part No 3 Depress the tester button repeatedly until the correct test number appears on the display After a few seconds the test number will flash three times and the test will begin A reverse numerical sequence will be displayed starting with a 6 and progressing down to 1 followed by a P pass or F fail indicating the condition of the part See Figures 7 14 and 7 15
47. OUNT I NG HOLE A ENG I NE Ee MOUNT ING pants SURFACE 6 037 LARDURE TOR al Figure 1 4 Typical Engine Dimensions 1 6 Section 1 Safety and General Information Dimensions in millimeters Inch equivalents shown in PRO 342 40 357 74 13 480 14 084 340 34 13 399 Up S 154 00 Se eee I 6 063 i SPARK PLUG 1 liso 92 00 2 196 512 40 80 3 622 72 00 EXHAUST STARTER 1 606 MOUNT ING STUD SURFACE 2 835 PORT 1 EXHAUST MOUNT ING PORT 2 HOLE A OIL DRAIN PLUG 3 8 NPT INCH Sr ees GLIE 134 00 KS 5 276 420 81 413 08 SPARK 16 567 16 263 PLUG 159 00 6 260 CENTER OF GRAVITY Y OIL FILTER SIDE Dseil W in Ee E i 4 301 2 018 SE SURF ACE L A FILTER 1 4 INCH SQUARE KEYWAY MOUNT ING Se 86 30 GE ee 3 397 Tenet AATA 7 OIL FILTER 18 357 17 618 J PRO enen 460 46 2 18 934 L18 128 rr 28 56 1 125 7 16 20 UNF INCH l 50 INCH DEEP Figure 1 5 Typical Engine Dimensions 1 7 Section 1 Safety and General Information General Specifications Power 3600 RPM Horsepower ratings exceed Society of Automotive Engineers Small Engine Test Code J1940 EE E 14 9 kW 20 HP See 16 4 kW 22 HP NT IV 2 ETEA A SE TE T TE EAA ATT 17 2 kW 23 HP ee 17 9 kW 24 HP
48. RTER ASS Y OPTIONAL i SOL ENO TG ORANGE i ARBURE TOR POLARITY RIB WHITE VIOLET ORANGE GREEN E ORANGE OPTIONAL TO STARTER SOLENOID OIL PRESSURE 8 SWITCH OPTIONAL Figure 7 6 Digital Spark Advance Ignition DSAI System REGULATOR RECTIFIER SPARK PLUG 1 CYLINDER IGNITION MODULE FLYWHEEL STATOR ASS Y IGNITION MODULE SPARK PLUG 2 CYLINDER WHITE AC CHARG ING LEADS CONNECTOR BLOCK NOTE Ignition tester Kohler Part No a Ifthe problem goes away the electrical system on 25 455 01 S must be used to test ignition the equipment is suspect Check the key switch on these engines Use of any other tester can wires connections safety interlocks etc result in inaccurate findings The battery on the unit must be fully charged and properly b Ifthe problem persists the condition is associated connected before making any of these tests with the ignition or electrical system of the a battery that is hooked up or charged engine Leave the kill lead isolated until all backward will crank the engine but it won t testing is completed have spark Be certain the drive is in neutral and all external loads are disconnected c Identify the white kill lead of the engine wiring Test 1 Isolate and Verify the Trouble is Within the Engine Ignition System 1 Locate the connectors where the wiring harness connector Establish a connection to a known good ground loca
49. SERVICE MANUAL KOHLERCOURAGE 8v710 740 KOHLERCOURAGE PRO Svs10 840 VERTICAL CRANKSHAFT KOHLER ENGINES Section 1 Section 2 Section 3 Section 4 Section 5 Section 6 Section 7 Section 8 Section 9 Section 10 Reassembly Section 11 Emission Compliance Systems Contents Safety and General Information cccccsseseeeeesseeceeseeseenseeseenseesessessenseessonseesees TOOS Ge te TEE Trou bleshooling E Air Cleaner and Air Intake System Fuel System and Governor Lubrication System Electrical System and Components Disassembly Inspection and Reconditioning Section 1 Safety and General Information Safety Precautions To ensure safe operation please read the following statements and understand their meaning Also refer to your equipment manufacturer s manual for other important safety information This manual contains safety precautions which are explained below Please read carefully A WARNING Warning is used to indicate the presence of a hazard that can cause severe personal injury death or substantial property damage if the warning is ignored A CAUTION Caution is used to indicate the presence of a hazard that will or can cause minor personal injury or property damage if the caution is ignored NOTE Note is used to notify people of installation operation or maintenance information that is important but not hazard relate
50. a metered amount of air is drawn through the slow air bleed jet fuel is drawn through the main jet and further metered through the slow jet Air and fuel are mixed in the body of the slow jet and exit to the transfer port From the transfer port this air fuel mixture is delivered to the idle progression chamber From the idle progression chamber the air fuel mixture is metered through the idle port passage At low idle when the vacuum signal is weak the air fuel mixture is controlled by the preset idle mixture setting This mixture is then mixed with the main body of air and delivered to the engine As the throttle plate opening increases greater amounts of air fuel mixture are drawn in through the fixed and metered idle progression holes As the throttle plate opens further the vacuum signal becomes great enough so the main circuit begins to work ee niin Nikki Carburetors Only lt Idle Speed RPM Se Adjustment Screw Fuel Inlet A i uel Inle Float Valve ra Capped Preset See Di Float l Low Idle ge Mixture Setting ain Float Valve A Emulsi n e Hole ini i i Idle fe a Il Progression MAIN Chamber l h Hl lt Low Idle Mixture Screw ie Transfer TH Slow Jet II Port Ei lt Spring Fe Limiter Jet N Slow Air Bleed Jet so lt a Idle Port Main Air Bleed Jet Choke S ST S ah Idle Progression Holes EN Bowl Vent E gt Valve Main Nozzle S Slow Passage Pipe M
51. advance module O Power B 12 VDC Source Pulse To Ban O Semi Conductor Generator i Switch Circuit onditioning 7 Delay Circuit Comparator Reset Circuit Figure 7 10 Block Diagram Spark Advance Module DSAM 7 10 Section 7 Electrical System and Components Troubleshooting CD Ignition Systems Battery on unit must be fully charged and The CD ignition systems are designed to be trouble properly connected before making any of free for the life of the engine Other than periodically these tests a battery that is hooked up or checking replacing the spark plugs no maintenance charged backward will crank the engine or timing adjustments are necessary or possible but it won t have spark Be sure drive Mechanical systems do occasionally fail or break is in neutral and all external loads are down however so the following troubleshooting disconnected information is provided to help you get to the root of a reported problem Test 1 Isolate and Verify the Trouble is Within the A Engine Ignition System CAUTION High Energy Electric Spark 1 Locate the plug connectors where the wiring The CD ignition systems produce a high energy electric harnesses from the engine and equipment are spark but the spark must be discharged or damage to the joined Separate the connectors and remove the system can result Do not crank or run an engine with a white kill lead from the engine connector Rejoin spark plug lead disconnected Always
52. ady for thorough inspection and cleaning Section 5 Fuel System and Governor Carburetor Body Idle Fuel Adjusting Screw Idle Fuel Adjusting Spring Passage Cover Cover Gasket Cover Retaining Screw Main Jet Ground Lead Solenoid only Fuel Bowl Gasket Float Kit Fuel Bowl Bowl Retaining Screw Gasket Bowl Retaining Screw Shut off Solenoid Assembly Throttle Shaft Lever Throttle Plate Choke Shaft Choke Plate Air Filter Collar Spring Ring Choke Lever Idle Speed Screw Idle Speed Spring Setscrews Plates 4 ee te ey E Included in Carburetor Repair Kit Figure 5 33 Typical Carburetor Exploded View Inspection Repair e Inspect the fuel inlet needle and seat for wear or To clean vent ports seats etc use a good damage commercially available carburetor solvent such as a Gumout and clean dry compressed air to blow out e Inspect the tip of the low idle fuel adjusting internal channels and ports Use a suitable shop rag to needle if equipped for wear or grooves prevent debris from hitting someone e The choke plate is spring loaded Check to make Carefully inspect all components and replace those sure it moves freely that are worn or damaged e Inspect the carburetor body for cracks holes and other wear or damage e Inspect the float for cracks holes and missing or damaged float tabs Check the float hinge and shaft for wear or damage 5
53. against the values in Section 1 Specifications and Tolerances If the running clearances are within specification and there is no evidence of scoring grooving etc no further reconditioning is necessary If the bearing surfaces are worn or damaged the crankcase and Dr oil pan will need to be replaced Inspect the crankshaft keyways If worn or chipped replacement of the crankshaft will be necessary 9 1 Section 9 Inspection and Reconditioning Inspect the crankpin for score marks or metallic pickup Slight score marks can be cleaned with crocus cloth soaked in oil If wear limits as stated in Section 1 Specifications and Tolerances are exceeded it will be necessary to replace the crankshaft Crankcase Inspection and Service Check all gasket surfaces to make sure they are free of gasket fragments Gasket surfaces must also be free of deep scratches or nicks Check the cylinder bore for scoring In severe cases unburned fuel can cause scuffing and scoring of the cylinder wall It washes the necessary lubricating oils off the piston and cylinder wall As raw fuel seeps down the cylinder wall the piston rings make metal to metal contact with the wall Scoring of the cylinder wall can also be caused by localized hot spots resulting from blocked cooling fins or from inadequate or contaminated lubrication If the cylinder bore is badly scored excessively worn tapered or out of round resizing is necessary Use an
54. ain Jet Fuel Shut Off Solenoid with Main Jet Figure 5 2 Slow Circuit Typical 5 4 Section 5 Fuel System and Governor Main Circuit See Figure 5 3 At high speeds loads the engine operates on the main circuit As a metered amount of air is drawn through the main air bleed jet fuel is drawn through the main jet The air and fuel are mixed in the main nozzle and then enter the main body of airflow where further mixing of the fuel and air takes place This mixture is then delivered to the combustion chamber The carburetor has a fixed main circuit no adjustment is possible an a i _ _ Air J el H Idle Speed CO RPM Fuel GH Adjustment SS Screw Mixture Fuel Inlet SCH Float Valve L LI Float Il ER Main Emulsion D Float Valve Fe Keihin Carburetors I Ba only Main Air Bleed Jet Choke Valve te Bowl Vent HN Throttle Valve Main Nozzle Main Jet Fuel Shut Off Solenoid with Main Jet mm mm mmm mm mm mm mm Figure 5 3 Main Circuit Typical 5 5 Section 5 Fuel System and Governor Troubleshooting Carburetor Related Causes Possible Cause Probable Remedy 1 Engine starts hard runs roughly Low idle fuel mixture some models speed improperly adjusted or Stalls at idle speed Adjust the low idle speed tab then adjust the low idle fuel needle 2 Engine runs rich indicated by black sooty exhaust smoke
55. ake sure the grass screen Disassembly Reassembly cooling fan fins and other external surfaces of the If the air cleaner base requires removal proceed as engine are kept clean at all times follows Annually or every 100 hours of operation more often 1 Remove the mounting screws for the fuel pump under extremely dusty or dirty conditions remove if equipped and the blower housing the blower housing and other cooling shrouds Clean the cooling fins and external surfaces as necessary 2 Raise or remove the blower housing for access to Make sure the cooling shrouds are reinstalled the air cleaner base NOTE Operating the engine with a blocked grass 3 Remove the air cleaner components from the screen dirty or plugged cooling fins and or base See Figure 4 3 cooling shrouds removed will cause engine damage due to overheating 4 Remove the two hex flange nuts securing the air cleaner base onto the mounting studs 5 Disconnect the breather hose from the air cleaner base then remove the base and gasket 6 Reverse procedure to reassemble components Torque the two hex flange nuts to 6 2 7 3 N m 55 65 in lb Torque the blower housing screws to 4 0 N m 35 in lb and the two front HI LO screws to 2 8 N m 25 in Ib 4 3 Section 4 Air Cleaner and Air Intake System 4 4 Section 5 Fuel System and Governor This section covers the carbureted fuel systems used on these engines The governor system is covered
56. allow Test 2 Test for Spark you to isolate and pinpoint the failed component s 1 With the engine stopped disconnect one spark plug lead Connect the spark plug lead to post Special Tools Required terminal of spark tester Kohler Part No e Hand Tachometer 24 455 02 S and attach tester clip to a good e Tester Kohler Part No 24 455 02 S engine ground e Automotive Timing Light e Multi Meter Digital NOTE If two testers are available testing can be performed simultaneously for both cylinders Specifications Required However if only one tester is available two e Spark Plug Gap 0 76 mm 0 030 in individual tests must be performed The side e Ignition Module Air Gap 0 28 0 33 mm not being tested must have the spark plug 0 011 0 013 in 0 30 mm 0 012 in nominal lead connected or grounded Do not crank the engine or perform tests with one spark NOTE Ignition tester Kohler Part No plug lead disconnected and not grounded or 24 455 02 S must be used to test ignition permanent system damage may occur on these engines Use of any other tester can result in inaccurate findings 2 Crank the engine over establishing a minimum of 550 600 RPM and observe tester s for spark 7 11 Section 7 Electrical System and Components Ds Repeat the spark test on the opposite cylinder if cylinders are being tested individually a If both cylinders have good spark but the engine runs poorly install new spark plugs gapped at 0 76 mm
57. and 7 41 NOTE Test procedure for checking starter solenoid on page 7 35 7 27 Section 7 Electrical System and Components Figure 7 41 Removing Plunger 4 Remove the two thru larger bolts See Figure 7 42 Figure 7 42 Removing Thru Bolts 5 Remove the commutator end plate assembly containing the brush holder brushes springs and locking caps Remove the thrust washer from inside the commutator end See Figure 7 43 7 28 Figure 7 43 Removing Commutator End Plate Assembly 6 Remove the frame from the armature and drive end cap See Figure 7 44 Figure 7 44 Starter Frame Removed 7 Remove the drive lever pivot bushing and backing plate from the end cap See Figure 7 45 Figure 7 45 Removing Pivot Bushing and Backing Plate 8 Take out the drive lever and pull the armature out of the drive end cap See Figure 7 46 9 Remove the thrust washer from the armature shaft See Figure 7 46 Figure 7 46 Armature and Lever Removed 10 Push the stop collar down to expose the retaining ring See Figure 7 47 Figure 7 47 Retaining Ring Detail Section 7 Electrical System and Components 11 Remove the retainer from the armature shaft Save the stop collar NOTE Do not reuse the old retainer Figure 7 48 Removing Retaining Ring 12 Remove the drive pinion assembly from the armature 13 Clean the parts as required NOTE Do not soak the armature or us
58. ankcase plus a spring steel reed retainer breather cover and breather hose mounted on the outside of the crankcase See Figure 9 20 When the pistons move downward crankcase gasses pass through a passage into the inner chamber in turn air is pushed past the reed into intake system The upward travel of the pistons closes the reed and creates a low vacuum in the lower crankcase in the process separating the oil from the airflow in the mesh filter Any oil separated out through the filter drains back into the crankcase through a small hole in the cover of the inner filter chamber Section 9 Inspection and Reconditioning Breather Stud Reed Retainer Breather Figure 9 20 Breather Assembly Details Governor Cross Shaft Oil Seal If the governor cross shaft seal is damaged and or leaks replace it using the following procedure Remove the oil seal from the crankcase and replace it with a new one Install the new seal to the depth shown in Figure 9 21 Governor Cross Shaft Seal 9 13 Section 9 Inspection and Reconditioning 9 14 Section 10 Reassembly General 18 Install ignition modules NOTE Make sure the engine is assembled using 19 Install intake manifold all specified torque values tightening 20 Install rectifier regulator sequences and clearances Failure to observe 21 Install inner and outer cylinder baffles specifications could cause severe engine wear 22 Install carburetor and air cleane
59. ase See Figure 8 48 Governor 4 so 4 d A Deg ZZ 3 Remove the governor shaft seal from the crankcase Section 8 Disassembly Remove Connecting Rods with Pistons Remove Crankshaft and Rings 1 Carefully pull the crankshaft from the crankcase 1 Remove the two hex flange screws securing the See Figure 8 51 closest connecting rod end cap Remove the end cap See Figure 8 49 Figure 8 51 Removing Crankshaft Figure 8 49 Removing Connecting Rod End Cap Remove Inner Breather Assembly NOTE Ifa carbon ridge is present at the top of 1 Remove the screw securing the inner breather either cylinder bore use a ridge reamer cover and gasket to the crankcase tool to remove it before attempting to remove the piston 2 Carefully remove the cover gasket and the breather filter See Figure 8 52 Make sure the 2 Carefully remove the connecting rod and piston drain back hole is not plugged or restricted assembly from the cylinder bore See Figure 8 50 NOTE The cylinders are numbered on the crankcase Use the numbers to mark Drainback each end cap connecting rod and piston for reassembly Do not mix end caps and connecting rods Ja H r Figure 8 52 Removing Breather Cover and Filter Figure 8 50 Removing Connecting Rod and Piston Assembly 3 Repeat the above procedure for the other connecting rod and piston assembly 8 13 Section 8 Disassembly Remove Flywheel and PTO End Oil Seals
60. at the end of this section A WARNING Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent Fuel System Components The typical carbureted fuel system and related components include the following Fuel Tank Fuel Lines In line Fuel Filter Fuel Pump Carburetor Operation The fuel from the tank is moved through the in line filter and fuel lines by the fuel pump On engines not equipped with a fuel pump the fuel tank outlet is located above the carburetor inlet allowing gravity to feed fuel to the carburetor Fuel then enters the carburetor float bowl and is drawn into the carburetor body There the fuel is mixed with air This fuel air mixture is then burned in the engine combustion chamber Fuel Recommendations General Recommendations Purchase gasoline in small quantities and store in clean approved containers A container with a capacity of 2 gallons or less with a pouring spout is recommended Such a container is easier to handle and helps eliminate spillage during refueling e Do not use gasoline left over from the previous season to
61. ausing the shaft to rotate One end of the cross shaft protrudes through the crankcase The rotating action of the cross shaft is transmitted to the throttle lever of the carburetor through the external linkage See Figure 5 34 5 18 e When the engine is at rest and the throttle is in the fast position the tension of the governor spring holds the throttle plate open When the engine is operating the governor gear assembly is rotating The force applied by the regulating pin against the cross shaft tends to close the throttle plate The governor spring tension and the force applied by the regulating pin balance each other during operation to maintain engine speed e When load is applied and the engine speed and governor gear speed decreases the governor spring tension moves the governor lever to open the throttle plate wider This allows more fuel into the engine increasing engine speed As speed reaches the governed setting the governor spring tension and the force applied by the regulating pin will again offset each other to hold a steady engine speed Adjustments General The governed speed setting is determined by the position of the throttle control It can be variable or constant depending on the engine application y High Speed Adjusting Figure 5 34 Governor Controls and Linkage External Initial Adjustment Make this adjustment whenever the governor arm is loosened or removed from the cross shaft See F
62. ave all parts See Figure 3 9 5 9 Section 5 Fuel System and Governor DU OUUU E EE E E 2 Figure 5 11 Float and Inlet Needle Figure 5 13 Checking Float Height 5 Install the float and inlet needle down into the NOTE Be sure to measure from the casting seat and carburetor body Insert the new pivot surface not the rubber gasket if still pin through the float hinge and secure with the attached new retaining screw See Figure 5 12 8 When the proper float height is obtained carefully reinstall the fuel bowl with the O Ring s in place onto the carburetor Secure with the four original screws Torque the screws to 2 5 0 3 N m 23 2 6 in Ib Reattach the accelerator pump hose if so equipped and secure with the clip See Figure 5 14 Figure 5 12 Installing Float Assembly 6 Hold the carburetor body so the float assembly hangs vertically and rests lightly against the fuel inlet needle The inlet needle should be fully seated but the center pin of the needle on retainer clip end should not be depressed Check the float height adjustment Figure 5 14 Installing Fuel Bowl NOTE The inlet needle center pin is spring loaded Disassembly Overhaul Make sure the float assembly rests against 1 Clean the exterior surfaces of dirt or foreign the fuel inlet needle without depressing the material before disassembling the carburetor center pin Remove the four fuel bowl screws and separate the fuel bowl from th
63. cal System and Components Starter Service Clean the drive lever and armature shaft Apply Kohler electric starter drive lubricant Part No 52 357 02 S Versilube G322L or Mobil Temp SHC 32 to the lever and shaft Clean and check the other starter parts for wear or damage as required Starter Reassembly 1 Apply drive lubricant Kohler Part No 52 357 02 S to the armature shaft splines Install the drive pinion onto the armature shaft 2 Install and assemble the stop collar retainer assembly a Install the stop collar down onto the armature shaft with the counter bore recess up b Install a new retainer in the larger rear eroove of the armature shaft Squeeze with a pliers to compress it in the groove c Slide the stop collar up and lock it into place so the recess surrounds the retainer in the eroove If necessary rotate the pinion outward on the armature splines against the retainer to help seat the collar around the retainer NOTE Figure 7 55 Installing Stop Collar and Retainer NOTE Always use a new retainer Do not reuse old retainers which have been removed 3 Install the offset thrust stop washer so the Figure 7 56 Installing Thrust Washer 4 Apply asmall amount of oil to the bearing in the drive end cap and install the armature with the drive pinion 5 Lubricate the fork end and center pivot of the drive lever with drive lubricant Kohler Part No 52 357 02 S Position the for
64. cap dipstick and thread until tight Oil Fill Cap Dipstick Oil Fill Tube KN Figure 10 85 Oil Fill Cap Dipstick and Oil Fill Tube Section 10 Reassembly Oil Fill Cap Oil Fill Cap Dipstick N Dipstick Oil Fill Tube Reg ei Operating Range Figure 10 87 Oil Level Marks on Dipstick Typical Connect Spark Plug Leads 1 Connect the leads to the spark plugs See Figure 10 88 Figure 10 88 Connect Spark Plug Leads 10 25 Section 10 Reassembly Prepare the Engine for Operation The engine is now completely reassembled Before starting or operating the engine be sure to do the following 1 Make sure all hardware is tightened securely 2 Make sure the oil drain plug oil sentry pressure switch and a new oil filter are installed 3 Fill the crankcase with the correct amount weight and type of oil Refer to oil recommendations and procedures in Section 1 Safety and General Information and Section 6 Lubrication System 4 Adjust the carburetor idle fuel needle or idle speed adjusting screw as necessary Refer to Section 5 Fuel System and Governor Testing the Engine It is recommended that the engine be operated on a test stand or bench prior to installation in the piece of equipment 1 SE Run the engine at idle for 2 3 minutes then 5 6 minutes more between idle and midrange Adjust the carburetor mixture setting as necessary Adjust the idle speed screw and h
65. ck for clearance between the valve spring coils at full lift or bending of push rod s can occur Minimum allowable clearance is 0 25 mm 0 010 in 10 15 Section 10 Reassembly Install Spark Plugs 1 Use new Champion or equivalent spark plugs Kill Tab Fixed Feeler A Timing Module Gauge 2 Set the gap at 0 76 mm 0 030 in 3 Install new plugs and torque to 24 4 29 8 N m 18 22 ft Ib See Figure 10 54 tion Module Gap Figure 10 55 Setting Igni 6 Torque the screws to 4 0 6 2 N m 35 55 in Ib 7 Repeat steps 4 through 6 for the other ignition module Figure 10 54 Ins 8 Rotate the flywheel back and forth checking talling Spark Plugs for clearance between the magnet and ignition modules Make sure the magnet does not strike Install Ignition Modules the modules Check the gap with a feeler gauge 1 Rotate the flywheel to position the magnet away and readjust if necessary Final air gap from the ignition module bosses 0 280 0 330 mm 0 011 0 013 in 2 On engines equipped with a DSAI or DSAM Install Intake Manifold Ignition system both modules are installed the 1 Install the intake manifold using new O Rings same way with the tabs out See Figure 10 60 with the wiring harness attached onto the cylinder heads Slide any wiring harness clips On engines equipped with a Fixed Ignition onto the appropriate bolts before installing System the modules are installed with the
66. d For Your Safety These precautions should be followed at all times Failure to follow these precautions could result in injury to yourself and others Accidental Starts can cause severe injury or death Disconnect and ground spark plug leads before servicing Accidental Starts Disabling engine Accidental starting can cause severe injury or death Before working on the engine or equipment disable the engine as follows 1 Disconnect the spark plug lead s 2 Disconnect negative battery cable from battery Rotating Parts can cause severe injury Stay away while engine is in operation Rotating Parts Keep hands feet hair and clothing away from all moving parts to prevent injury Never operate the engine with covers shrouds or guards removed AA WARNING adi LE Hot Parts can cause severe burns Do not touch engine while operating or just after stopping Hot Parts Engine components can get extremely hot from operation To prevent severe burns do not touch these areas while the engine is running or immediately after it is turned off Never operate the engine with heat shields or guards removed 1 1 Section 1 Safety and General Information AA WARNING Explosive Fuel can cause fires and severe burns Do not fill the fuel tank while the engine is hot or running Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only
67. d properly in the keyway The flywheel can become cracked or damaged if the key is not installed properly Figure 10 35 Clean and Dry Flywheel Hub Section 10 Reassembly 2 Install the flywheel onto the crankshaft being Flywheel Holding careful not to shift the woodruff key See Figure Tool Ban 10 36 3 Una d ep Figure 10 38 Torquing Flywheel Fastener Figure 10 36 Installing Flywheel Install Grass Screen 1 Snap the screen onto the fan See Figure 10 39 3 Install the fan onto the flywheel so the locating pins fit into the corresponding recesses 4 Install the fan mounting plate onto the fan aligning the four cutouts followed by the heavy flat washer and hex flange screw See Figure 10 37 Figure 10 39 Installing Grass Screen Figure 10 37 Installing Fan and Mounting Hardware to Flywheel 5 Use a flywheel strap wrench or holding tool to hold the flywheel Torque the hex flange screw securing the flywheel to the crankshaft to 74 5 N m 55 0 ft Ib See Figure 10 38 10 11 Section 10 Reassembly Assemble and Install Cylinder Heads Valve Stem Seals Some engines use a valve stem seal on the intake valves If the engine being serviced used a valve stem seal use a new seal whenever the valve is removed or if the seal is deteriorated or damaged Never reuse an old seal ATM a ZE ER Inte e Valve Stem Seal Some eg jModels Only 2 Ka e Fi
68. d can be reused after new rings are installed the original pin can also be reused but new piston pin retainers are required The piston pin is included as part of the piston assembly if the pin boss in the piston or the pin are worn or damaged a new piston assembly is required 9 7 Section 9 Inspection and Reconditioning Ring failure is usually indicated by excessive oil consumption and blue exhaust smoke When rings fail oil is allowed to enter the combustion chamber where it is burned along with the fuel High oil consumption can also occur when the piston ring end gap is incorrect because the ring cannot properly conform to the cylinder wall under this condition Oil control is also lost when ring gaps are not staggered during installation When cylinder temperatures get too high lacquer and varnish collect on pistons causing rings to stick which results in rapid wear A worn ring usually takes on a shiny or bright appearance Scratches on rings and pistons are caused by abrasive material such as carbon dirt or pieces of hard metal Detonation damage occurs when a portion of the fuel Overheated or Deteriorated Oil Figure 9 6 Common Types of Piston Damage 9 8 charge ignites spontaneously from heat and pressure shortly after ignition This creates two flame fronts which meet and explode to create extreme hammering pressures on a specific area of the piston Detonation generally occurs from using low octane fue
69. d charge rate increases when load is applied the charging system is OK and battery was fully charged If voltage is less than 13 8 or charge rate does not increase when load is applied test stator Tests 2 and 3 If voltage is 28 volts or more stator is OK Rectifier regulator is faulty Replace the rectifier regulator If voltage is less than 28 volts stator is probabl faulty and should be replaced Test stator further using an ohmmeter Test 3 If resistance is 0 064 0 2 ohms the stator is OK If the resistance is infinity ohms stator is open Replace stator If the resistance is infinity ohms no continuity the stator is OK not shorted to ground If resistance or continuity is measured the stator leads are shorted to ground Replace stator If the voltage is 14 7 volts or less the charging system is OK The battery is unable to hold a charge Service battery or replace as necessary If voltage is more than 14 7 volts the rectifier regulator is faulty Replace rectifier regulator If the engine develops sufficient speed to disengage the starter but does not keep running a false start the engine rotation must be allowed to come to a complete stop before attempting to restart the engine If the starter is engaged while the flywheel is rotating the starter pinion and flywheel ring gear may clash resulting in damage to the Starter Section 7 Electrical System and Components NOTE If the starter
70. de Factory Code Year 2005 2006 2007 2008 Figure 1 2 Explanation of Engine Identification Numbers 1 3 Section 1 Safety and General Information Oil Recommendations Using the proper type and weight of oil in the crankcase is extremely important So is checking oil daily and changing oil regularly Failure to use the correct oil or using dirty oil causes premature engine wear and failure Oil Type Use high quality detergent oil of API American Petroleum Institute Service Class SJ or higher Select the viscosity based on the air temperature at the time of operation as shown in the following table RECOMMENDED SAE VISCOSITY GRADES SS ee RSR ee 10W 30 SW 20 SW 30 ae E Kohler 10W 30 TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE Use of synthetic oil having 5W 20 or SW 30 rating is acceptable up to 4 C 40 F Synthetic oils will provide better starting in extreme cold below 23 C 10 F NOTE Using other than service class SJ or higher oil or extending oil change intervals longer than recommended can cause engine damage NOTE Synthetic oils meeting the listed classifications may be used with oil changes performed at the recommended intervals However to allow piston rings to properly seat a new or rebuilt engine should be operated for at least 50 hours using standard petroleum based oil before switching to synthetic oil A logo or symbol on oil containers identifies the API serv
71. dication of the general condition of the piston rings valves and carburetor Normal and fouled plugs are shown in the following photos 7 1 Section 7 Electrical System and Components a Normal A plug taken from an engine operating under Wet Fouled A wet plug is caused by excess fuel or normal conditions will have light tan or gray colored oil in the combustion chamber Excess fuel could deposits If the center electrode is not worn a plug be caused by a restricted air cleaner a carburetor in this condition could be set to the proper gap and problem or operating the engine with too much reused choke Oil in the combustion chamber is usually caused by a restricted air cleaner a breather problem or worn piston rings cylinder walls or valve guides Carbon Fouled Soft sooty black deposits indicate incomplete combustion caused by a restricted air RMR eee ET TTT cleaner over rich fuel mixture weak ignition or poor Overheated Chalky white deposits indicate very high compression combustion temperatures This condition is usually accompanied by excessive gap erosion Lean carburetor settings an intake air leak or incorrect spark timing are normal causes for high combustion temperatures Worn On a worn plug the center electrode will be rounded and the gap will be greater than the specified gap Replace a worn spark plug immediately 7 2 Battery General A 12 volt battery with minimum of 400 cold cranking
72. does not crank the engine shut Starter Removal and Installation off the starter immediately Do not make Refer to the Disassembly and Reassembly Sections for further attempts to start the engine until the starter removal and installation procedures condition is corrected Inertia Drive Electric Starters NOTE Do not drop the starter or strike the starter This subsection covers the operation troubleshooting frame Doing so can damage the starter and repair of the inertia drive permanent magnet electric starters Troubleshooting Guide Starting Difficulties 1 Check the specific gravity of battery If low recharge or replace battery as necessary Starter 1 Clean corroded connections and tighten loose connections Does Not 2 Replace wires in poor condition and with frayed or broken Energize insulation Starter Switch 1 By pass the switch or solenoid with a jumper wire If starter or Solenoid cranks normally replace the faulty components Solenoid Shift Starters Perform individual solenoid test procedure See page 71 Battery 1 Check the specific gravity of battery If low recharge or replace battery as necessary 1 Check for excessively dirty or worn brushes and commutator Starter Clean using a coarse cloth not emery cloth Energizes 2 Replace brushes if excessively or unevenly worn but Turns Slowly Brushes 1 Make sure the clutch or transmission is disengaged or placed in neutral This is especially importan
73. dy 2e Bowl vents plugged Blow out with compressed air Carburetor bowl gasket leaks Replace gasket Troubleshooting Checklist e Make sure the air cleaner base and carburetor are When the engine starts hard runs roughly or stalls securely fastened to the engine using gaskets in at low idle speed check the following areas before good condition adjusting or disassembling the carburetor e Make sure the air cleaner element including e Make sure the fuel tank is filled with clean fresh gasoline Make sure the fuel tank cap vent is not blocked and that it is operating properly Make sure fuel is reaching the carburetor This the precleaner if equipped is clean and all air cleaner components are fastened securely Make sure the ignition system governor system exhaust system and throttle and choke controls are operating properly includes checking the fuel shut off valve fuel tank filter screen in line fuel filter fuel lines and fuel pump for restrictions or faulty components as necessary If the engine is hard starting runs roughly or stalls at low idle speed it may be necessary to service the carburetor 5 6 High Altitude Operation When operating the engine at altitudes of 1500 m 5000 ft and above the fuel mixture tends to get over rich This can cause conditions such as black sooty exhaust smoke misfiring loss of speed and power poor fuel economy and poor or slow governor response To co
74. e ACR mechanism it is difficult to obtain an accurate compression reading As an alternative perform a cylinder leakdown test Cylinder Leakdown Test A cylinder leakdown test can be a valuable alternative to a compression test By pressurizing the combustion chamber from an external air source you can determine if the valves or rings are leaking and how badly Kohler Part No 25 761 05 S is a relatively simple inexpensive leakdown tester for small engines The tester includes a quick disconnect for attaching the adapter hose and a holding tool Leakdown Test Instructions 1 Run the engine for 3 5 minutes to warm it up 2 Remove the spark plug s and the air filter from engine 3 Rotate the crankshaft until the piston of cylinder being tested is at top dead center of the compression stroke Hold the engine in this position while testing The holding tool supplied with the tester can be used if the PTO end of the crankshaft is accessible Lock the holding tool onto the crankshaft Install a 3 8 breaker bar into the hole slot of the holding tool so it is perpendicular to both the holding tool and crankshaft PTO 3 4 Disassemble breather clean parts thoroughly reassemble and recheck pressure Replace all worn or damaged seals and gaskets Make sure all fasteners are tightened securely Use appropriate torque values and sequences when necessary Recondition piston rings cylinder bore valves and valve guid
75. e See Figure 7 24 Momentarily one of the four status lights will illuminate indicating the condition of the part Ko ECT E We KG R i i hire eau Me eS Figure 7 24 a If the OK green light comes on and stays steady the part is good and may be used b If any other light is displayed the rectifier regulator is faulty and should not be used NOTE A flashing LOW light can also occur as a result of an inadequate ground lead connection Make certain connection location is clean and clamp is secure 7 20 25 Amp Rectifier Regulators 1 Connect the single lead adapter in between the B center terminal of the rectifier regulator being tested and the squared single end of the tandem adapter lead See Figure 7 25 Figure 7 25 2 Connect the tester ground lead with spring clamp to the body of the rectifier regulator 3 Connect the red lead and one of the black leads to the pair of terminals on the open end of the tandem adapter lead connections are not location specific 4 Connect the remaining black lead from the tester to one of the outer AC terminals on the rectifier regulator See Figure 7 26 KOHLER Woy thrizr Cheese i ie ee ee p mm r Figure 7 26 5 Plug the tester into a 110 volt AC outlet and turn on the power switch The POWER light should be illuminated and one of the four status lights may be on as well See Fig
76. e carburetor As an initial adjustment set to 1 turn out from lightly seated See Figure 5 26 ech um OU Doo fuuu Bumm p 1 S ET es Figure 5 23 Checking Float Height Je 14 When the proper float height is obtained carefully install the new O Rings for the fuel bowl and transfer passage if so equipped See Figure 5 24 Screw and Spring 18 Place the shorter new spring onto the idle speed adjusting screw and install it into the carburetor Thread in until 3 or 4 threads are exposed as an initial adjustment See Figure 5 27 Figure 5 24 Installing Fuel Bowl O Rings 15 Install the fuel bowl onto the carburetor Secure with the four original screws Torque the screws to 2 5 0 3 N m 23 2 6 in Ib See Figure 5 25 EE i Ir 5 2m p f i L Leg 1 GR EN e M L e i Pi F 6 i d a al y T oa Iw Figure 5 27 Installing Idle Speed Adjusting Screw and Spring Figure 5 25 Installing Fuel Bowl 5 13 Section 5 Fuel System and Governor Choke Repair 1 Remove the carburetor from the engine Discard the old mounting gaskets for the air cleaner and carburetor 2 Clean the areas around the choke shaft and the self relieving choke mechanism thoroughly 3 Remove and discard the plastic cap from the top of the choke lever shaft assembly 4 Note the position of the spring legs and the choke plate for correct reassembly later See Figure 5
77. e carburetor Transfer any 7 The correct float height adjustment is 12 0 mm remaining fuel into an approved container 0 472 in measured from the float bottom to the Remove and discard the old O Ring s body of the carburetor See Figure 5 13 Adjust See Figure 5 15 the float height by carefully bending the metal tang of the float 5 10 Section 5 Fuel System and Governor Figure 5 15 Fuel Bowl Removed from Carburetor Figure 5 17 Main Jet and Slow Jet Removed NOTE Further disassembly of fuel bowl is not 4 Remove the two screws securing the top cover necessary unless a Fuel Solenoid Kit gasket and ground lead fuel solenoid equipped obtained separately is also being installed models Discard the gasket and screws only 2 Remove the float pin screw and lift out the old 5 Remove the idle speed and idle fuel adjusting float pin and inlet needle See Figure 5 16 screws and springs from the carburetor Discard Discard all of the parts The seat for the inlet the parts needle is not serviceable and should not be removed NOTE The carburetor is now disassembled for appropriate cleaning and installation of the parts in the overhaul kit Further disassembly is not necessary The throttle shaft assembly fuel inlet seat and bowl chamber baffle are non serviceable items and should not be removed The choke shaft assembly is serviceable however it should not be removed unless a Choke Repair Kit will be installed
78. e proper type and weight of oil in the crankcase is extremely important so is checking oil daily and changing the oil and filter regularly Use high quality detergent oil of API American Petroleum Institute Service Class SJ or higher Select the viscosity based on the air temperature at the time of operation as shown in the following table RECOMMENDED SAE VISCOSITY GRADES TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE Use of synthetic oil having 5W 20 or 5W 30 rating is acceptable up to 4 C 40 F Synthetic oils will provide better starting in extreme cold below 23 C 10 F NOTE Using other than service class SJ or higher oil or extending oil change intervals longer than recommended can cause engine damage NOTE Synthetic oils meeting the listed classifications may be used with oil changes performed at the recommended intervals However to allow piston rings to properly seat anew or rebuilt engine should be operated for at least 50 hours using standard petroleum based oil before switching to synthetic oil A logo or symbol on oil containers identifies the API service class and SAE viscosity grade See Figure 6 1 Figure 6 1 Oil Container Logo The top position of the symbol shows service class such as API SERVICE CLASS SJ The symbol may show additional categories such as SH SG CC or CD The center portion shows the viscosity grade such as SAE 10W 30 If the bottom portion shows Energy Conservi
79. e solvent when cleaning Wipe clean using a soft cloth or use compressed air 7 29 Section 7 Electrical System and Components e hee P P b ie Seck Ke Exell a Ka S Armature _ ii niihi lt Frame amp Field Brush Holder Figure 7 49 Delco Remy Starter Inspection Drive Pinion Check and inspect the following areas a The pinion teeth for abnormal wear or damage b The surface between the pinion and the clutch mechanism for nicks or irregularities which could cause seal damage Wear limit length 7 6 mm 0 300 in c Check the drive clutch by holding the clutch housing and rotating the pinion The pinion should rotate in one direction only Figure 7 50 Checking Brushes Brushes and Springs Inspect both the springs and brushes for wear fatigue Armature or damage Measure the length of each brush The 1 Clean and inspect the commutator outer minimum length for each brush is 7 6 mm 0 300 in surface The mica insulation must be lower than See Figure 7 50 Replace the brushes if they are worn the commutator bars undercut to ensure proper undersize or their condition is questionable operation of the commutator See Figure 7 51 7 30 Section 7 Electrical System and Components Brush Replacement Commutator O D The brushes and springs are serviced as a set 4 Use Brush and Spring Kit Kohler Part No 25 221 01 5 if replacement is necessary 1 Perfor
80. eal in Oil Pan Inspect the main bearing surface for wear or damage refer to Section 1 Specifications and Tolerances Replace the oil pan assembly if required Governor Assembly Internal Inspection Inspect the governor gear teeth Replace the gear if it is worn chipped or if any teeth are missing Inspect the governor weights They should move freely in the governor gear Disassembly The governor gear must be replaced once it is removed from the oil pan NOTE The governor gear is held onto the shaft by small molded tabs in the gear When the gear is removed from the shaft these tabs are destroyed and the gear must be replaced Therefore remove the gear only if absolutely necessary 1 Use two small screwdrivers and carefully pry upward to remove the regulating pin and governor gear assembly See Figure 9 12 Figure 9 12 Removing Governor Gear 2 Remove the locking tab thrust washer located under the governor assembly 3 Carefully inspect the governor gear shaft and replace it only if it is damaged After removing the damaged shaft press or lightly tap the replacement shaft into the closure plate to the depth shown in Figure 9 13 Section 9 Inspection and Reconditioning Gear Shaft 34 0 mm 1 3386 in 33 5 mm 1 3189 in Figure 9 13 Governor Shaft Press Depth Reassembly 1 Install the locking tab thrust washer on the governor gear shaft with the tab down 2 Position the regulating pin w
81. ed RPM speed is obtained retighten the lock nut NOTE When the throttle and choke control cables are routed side by side especially under a single clamp there must be a small gap between the cables to prevent internal binding After the high speed setting has been completed check that there is a gap of at least 0 5 mm 0 020 in between the control cables Throttle Control Lever Choke Control Lever Choke Control Cable Throttle Control Cable Dual Control High Speed Lever Stop Screw Do Not Remove High Speed Adjusting Choke Linkage Throttle Control Cable Choke Control Cable High Speed Control Lever Screw Right Side Pull Figure 5 35 Governor Control Connections 5 19 Section 5 Fuel System and Governor 5 20 Section 6 Lubrication System General This engine uses a combination pressure Splash lubrication system delivering oil under pressure to the crankshaft connecting rod and main bearing surfaces Other component areas are splash lubricated A high efficiency gerotor pump is located in the oil pan The oil pump maintains oil flow and oil pressure even at low speeds and high operating temperatures A pressure relief valve in the oil pump limits the maximum pressure of the system service The oil pan must be removed to service the oil pump or oil pickup Refer to the appropriate procedures in Section 9 Inspection and Reconditioning Oil Recommendations Using th
82. el rotates the magnet erouping passes the input coil L1 The corresponding magnetic field induces energy into the input coil L1 The resultant pulse is rectified by D1 and charges capacitor Cl As the magnet assembly completes its pass it activates the triggering device L2 which causes the semiconductor switch SCS to turn on With the device switch ON the charging capacitor C1 is directly connected across the primary P of the output transformer T1 As the capacitor discharges the current initiates a fast rising flux field in the transformer core A high voltage pulse is generated from this action into the secondary winding of the transformer This pulse is delivered to the spark plug gap Ionization of the gap occurs resulting in an arc at the plug electrodes This spark ignites the fuel air mixture in the combustion chamber Kill Switch or Off Position of Key Switch r l L Section 7 Electrical System and Components 0 28 0 33 mm We 0 011 0 013 in Air Gap Ignition Modules a Spark Plug Magnet Flywheel Figure 7 4 Capacitive Discharge Fixed Timing Ignition System The timing of the spark is controlled by the location of the flywheel magnet group as referenced to engine top dead center Spark Plug amp Figure 7 5 Capacitive Discharge CD Ignition Module Schematic Troubleshooting CD Ignition Systems The CD ignition systems are designed to be trouble free
83. em Clogged fuel line Spark plug lead s disconnected Key switch or kill switch in off position Faulty spark plugs Faulty ignition module s DSAI or DSAM malfunction applicable models Carburetor solenoid malfunction Diode in wiring harness failed in open circuit mode Vacuum fuel pump malfunction or oil in vacuum hose 13 Vacuum hose to fuel pump leaking cracked 14 Battery connected backwards SSeS aS SS m GA M Engine Starts But Does Not Keep Running 1 Restricted fuel tank cap vent 2 Poor fuel dirt or water in the fuel system 3 Faulty or misadjusted choke or throttle controls 4 Loose wires or connections that short the kill terminal of ignition module to ground 5 Faulty cylinder head gasket 6 Faulty carburetor 7 Vacuum fuel pump malfunction or oil in vacuum hose 8 Leaking cracked vacuum hose to fuel pump 9 Intake system leak 10 Diode in wiring harness failed in open circuit mode Engine Starts Hard 1 y E 13 14 pS ee oO ee PTO drive is engaged Dirt or water in the fuel system Clogged fuel line Loose or faulty wires or connections Faulty or misadjusted choke or throttle controls Faulty spark plugs Low compression Faulty ACR mechanism equipped models Weak spark Fuel pump malfunction causing lack of fuel Engine overheated cooling air circulation restricted Quality of fuel Flywheel key sheared Intake system leak Engine Will Not
84. enter screw into the removal tool until you feel resistance Use a wrench 1 1 8 or adjustable to hold the base of the removal tool Use another wrench or socket 1 2 or 13 mm to turn the center screw clockwise see Figure 7 32 The resistance against the center screw will tell you when the retaining ring has popped out of the groove in the armature shaft Figure 7 32 Holding Tool and Turning Center Screw Clockwise to Remove Retaining Ring 6 Remove the drive components from the armature shaft paying attention to the sequence If the splines are dirty clean them with solvent Section 7 Electrical System and Components Retaining Ring Installation 1 Figure 7 33 Splines on Armature Shaft The splines should have a light film of lubricant See Figure 7 33 Lubricate as necessary with Kohler starter drive lubricant Kohler Part No 52 357 01 S Reinstall or replace the drive components assembling them in the reverse order they were removed Position the retaining ring in the groove in one of d the inner halves Assemble the other half over the top and slide on the outer collar Be certain the drive components are installed in correct sequence onto the armature shaft Slip the tool over the end of the armature shaft so the retaining ring inside is resting on the end of the shaft Hold the tool with one hand exerting slight pressure toward the starter Tap the top of the tool with a hammer until yo
85. eplace flywheel if it is cracked Replace the flywheel the crankshaft and the key if the flywheel key is sheared or the keyway is damaged Inspect the ring gear for cracks or damage Kohler does not provide ring gears as a serviceable part Replace the flywheel if the ring gear is damaged Cylinder Head and Valves Inspection and Service After cleaning check the flatness of the cylinder head and the corresponding top surface of the crankcase using a surface plate or piece of glass and feeler gauge as shown in Figure 9 3 The maximum allowable out of flatness is 0 076 mm 0 003 in Figure 9 3 Checking Cylinder Head Flatness Carefully inspect the valve mechanism parts Inspect the valve springs and related hardware for excessive wear or distortion Check the valves and valve seat area or inserts for evidence of deep pitting cracks or distortion Check clearance of the valve stems in the guides See Figure 9 4 for valve details and specifications 9 3 Section 9 Inspection and Reconditioning EXHAUST Seat Angle Insert O D Guide Depth Guide I D Valve Head Diameter Valve Face Angle 45 Valve Margin Mim 1 5 mm 0 0591 in Valve Stem Diameter Figure 9 4 Valve Details 4 mm 0 1575 in A B C D E F G H Hard starting or loss of power accompanied by high fuel consumption may be symptoms of faulty valves Although these symptoms could also be attributed to worn rings remove and check the va
86. er hole Stop pouring when the oil reaches the bottom of the threads Allow a minute or two for the oil to be absorbed by the filter material 6 Apply a thin film of clean oil to the rubber gasket on the new oil filter 7 Install the new oil filter to the filter adapter Hand tighten the filter clockwise until the rubber gasket contacts the adapter then tighten the filter an additional 3 4 1 turn 8 Fill the engine with the proper oil to the FULL or F mark on the dipstick Always check the oil level with the dipstick before adding more oil 9 Reinstall the oil fill cap dipstick 10 Start the engine and check for oil leaks Recheck oil level before placing the engine into service Stop the engine correct any leaks and allow a minute for the oil to drain down then recheck the level on the dipstick service Oil Cooler Some engines are equipped with an optional oil cooler Inspect and clean the oil cooler annually or every 100 hours of operation more frequently under severe conditions Oil cooler must be kept free of debris Section 6 Lubrication System Figure 6 7 Cleaning Outside of Oil Cooler To service the oil cooler clean the outside of fins with a soft brush See Figure 6 7 Remove the mounting screws holding the cooler unit to the blower housing Tilt the cooler outward as shown in Figure 6 8 Clean the inside of the cooler with a brush or with compressed air After cleaning reinstall the
87. es Repair replace restricted muffler exhaust system If the flywheel end is more accessible use a breaker bar and socket on the flywheel nut screw to hold it in position An assistant may be needed to hold the breaker bar during testing If the engine is mounted in a piece of equipment it may be possible to hold it by clamping or wedging a driven component Just be certain that the engine cannot rotate off of TDC in either direction Install the adapter into the spark plug hole but do not attach it to the tester at this time Connect an air source of at least 50 psi to the tester Turn the regulator knob in the increase direction clockwise until the gauge needle is in the yellow set area at the low end of the scale Connect the tester quick disconnect to the adapter hose while firmly holding the engine at TDC Note the gauge reading and listen for escaping air at the carburetor intake exhaust outlet and crankcase breather Check the test results against the following table Section 3 Troubleshooting Leakdown Test Results Alr Osca pig Irom Crank Case eege Rings or cylinder worn Air escaping from exhaust system E Defective exhaust valve improper seating Alr CS Capi Mom CAT OU e Defective intake valve improper seating Gauge reading in low EE Piston rings and cylinder in good condition Gauge reading in moderate yellow zome ee eee eseeseeeseeeeeeaeeeees Engine is still usable but there is some
88. ew and remove the mounting stud retainer e gure and breather reed See Figure 8 42 Figure 8 44 Removing Oil Pan Governor Assembly eg The governor gear assembly is located inside the Figure 8 42 Removing Stud Retainer and oil pan If service is required refer to the service Breather Reed procedures in Section 9 Governor Assembly Remove Oil Pan Assembly Oil Pump Assembly 1 Remove the ten hex flange screws securing the oil The oil pump is mounted inside the oil pan If service pan to the crankcase See Figure 8 43 is required refer to the service procedures under Section 9 Oil Pump Assembly 8 11 Section 8 Disassembly Remove Camshaft and Valve Tappets 1 Position the crankcase so the flywheel side is down Remove the camshaft and shim See Figure 8 45 i i F F ba I ty i W H Camshaft ee 7 _ i V i Fi a W at Ga K Be 4 E 2 HN Figure 8 45 Removing Camshaft 2 Remove the valve tappets from the crankcase and mark them by their location as either intake or exhaust and cylinder 1 or 2 Tappets should always be reinstalled in the same position See Figure 8 46 Figure 8 46 Removing Valve Tappets Remove Governor Cross Shaft 1 Remove the retainer and washer from the governor cross shaft See Figure 8 47 8 12 Figure 8 47 Removing Governor Cross Shaft Retainer 2 Remove the cross shaft with the small inner washer through the inside of the crankc
89. ew gaskets when servicing or reinstalling carburetors Repair kits are available which include new gaskets and other components Service repair kits available for Keihin carburetors N and affiliated components are AG Carburetor Repair Kit Float Kit Turn Carburetor Solenoid Assembly Kit Upside Down Choke Repair Kit Figure 5 32 Proper Float Level High Altitude Kit 1525 3048 m 5 000 10 000 ft High Altitude Kit Over 3048 m 10 000 ft 6 Turn the carburetor body upside down and check the float level as shown in Figure 5 32 With the float needle valve fully seated 16 5 mm 0 65 in should be measured from the body to the float as indicated Don t attempt to adjust by bending the tab replace the float with a kit if the level is wrong 5 15 Section 5 Fuel System and Governor G 8 Pull the float hinge pin and remove the float with the inlet needle attached to inspect the needle and seat If dirty blow out with compressed air Replace the float components as needed with the kit Using new gaskets reinstall the bowl and tighten the bowl retaining screw or solenoid to 5 1 6 2 N m 45 55 in Ib Reinstall the carburetor on the engine reconnect the fuel line control linkages and air intake components Retest operation Disassembly Use the carburetor repair kit and the float repair kit if float components are to be replaced Refer to Figure 5 33 for parts identification The Koh
90. final position allowing the brushes to contact the commutator Do not remove the protective tape and shipping strip holding the washer cup until the part is ready to be installed 7 26 Commutator Service Clean the commutator with a coarse lint free cloth Do not use emery cloth If the commutator is badly worn or grooved turn it down on a lathe or replace the starter Starter Reassembly 1 Insert the armature into the starter frame Make sure the magnets are closer to the drive shaft end of the armature The magnets will hold the armature inside the frame 2 Install the drive end cap over the drive shaft and align with cutout the starter frame See Figure 7 35 pore Alignment Notches Figure 7 35 Aligning End Cap and Frame 3 Installing new brushes carefully remove the tape holding the thrust washer cup in place against the brushes Do not allow the thrust washer cup to move out of this position Align the terminal stud block with the notch in the starter frame and start the brush holder end cap assembly onto the end of the armature See Figure 7 36 uz d 4 Thin Shipping Strip 4 Figure 7 36 Assembling Commutator End Cap onto Armature F SC k b 4 Pull out the thin shipping strip from behind the thrust washer cup and slide the brush holder end cap into position See Figure 7 36 5 Install the thru bolts and torque to 4 5 5 7 N m 40 50 in Ib See Figure 7 37 Fig
91. fitted with a secondary air induction system SAI Operation The intake pulse of the engine activates the secondary air valve Air is drawn through an inlet screen of the secondary air valve The air is then drawn into the exhaust manifold and muffler where it mixes with any unburned hydrocarbons which then burn with the in the heat of the muffler A hose is connected between a carburetor port and a diaphragm chamber in the secondary air valve The carburetor vacuum moves the diaphragm to close the valve when air induction is not required primary idle See Figure 11 2 Maintenance The air inlet screen in the secondary air valve can be removed cleaned and reinstalled If inspection of the system reveals any damage or decomposition of the hoses secondary air valve or exhaust system the parts should be replaced Hose To Hose To Exhaust Exhaust wc Manifold Manifold Secondary Air Valve Assembly Carburetor Secondary Air Valve Assembly Figure 11 2 Secondary Air Induction System Diagram KOHLER ENGINES FOR SALES AND SERVICE INFORMATION IN U S AND CANADA CALL 1 800 544 2444 KohlerEngines com ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 FORM NO TP 2574 A ISSUED 1 06 REVISED 12 07 LITHO IN U S A
92. flat Spring choke return Nut M5x0 8 lock Washer nylon Washer shoulder Section 10 Reassembly Install Electric Starter Motor and Oil Fill Blower Housing Mounting Screw Locations Dipstick Tube eT eS H 1 Install the starter motor lift bracket and oil fill dipstick tube if not separated from bracket using the two hex flange screws Position the lift bracket as shown to also secure the dipstick tube See Figure 10 79 2 Torque the two hex flange screws to 15 3 N m 135 in Ib See Figure 10 79 Figure 10 79 Installing Starter Lift Bracket and Oil Fill Dipstick Tube HI LO Screws kad Figure 10 80 Blower Housing Mounting Details 3 On models with a solenoid shift starter connect the leads to the solenoid 2 Torque the screws as follows 4 If separated earlier install the dipstick tube and M5 Blower Housing Screws 6 2 N m 55 in Ib align the mounting hole with the threaded hole in a new hole or 4 0 N m 35 in 1b in a used in the lift bracket Secure with the M5 hex flange hole screw Torque the screw to 4 0 N m 35 in Ib M4 HI LO Screws 2 8 N m 25 in Ib 10 5 Install the oil fill cap dipstick Install Fuel Pump Install Blower Housing NOTE Do not completely tighten screws until all are A WARNING Explosive Fuel installed to allow shifting for hole alignment Gasoline may be present in the carburetor and fuel system Gasoline is extremely flammable and its vapors can explode
93. flywheel from the crankshaft Do not strike the crankshaft or flywheel as these parts could become cracked or damaged Striking the puller or crankshaft can cause the crank gear to move affecting crankshaft endplay 5 Remove the woodruff key See Figure 8 38 Puller Holding 28 i Tool j Flywheel TH Figure 8 37 Removing 8 10 ANAA Wijns Figure 8 38 Removing Key Remove Backing Plate and Stator 1 Remove the four mounting screws and the backing plate from crankcase See Figure 8 39 Figure 8 39 Removing Backing Plate 2 Remove the two hex flange screws and the stator See Figure 8 40 Note the routing of the stator leads Figure 8 40 Removing Stator Section 8 Disassembly Remove Outer Breather Assembly 1 RIV sealant is used between the outer breather cover and the crankcase Remove the hex nut and sealing flat washer securing the breather cover to the crankcase Carefully pry under the small tab of the cover flange to separate and remove Do not bend or distort the cover See Figure 8 41 Figure 8 43 Removing Oil Pan Screws 2 Locate the splitting tab cast into the perimeter of the oil pan Insert the drive end of a 1 2 breaker bar between the splitting tab and the crankcase and turn it to break the RTV seal See Figure 8 44 Do not pry on the sealing surfaces as this can cause leaks Figure 8 41 Removing Outer Breather Cover BT s S 2 Unscr
94. for the life of the engine Other than periodically checking replacing the spark plugs no maintenance or timing adjustments are necessary or possible Mechanical systems do occasionally fail or break down however so the following troubleshooting information is provided to help you get to the root of a reported problem A CAUTION High Energy Electric Spark The CD ignition systems produce a high energy electric spark but the spark must be discharged or damage to the system can result Do not crank or run an engine with a spark plug lead disconnected Always provide a path for the spark to discharge to ground Reported ignition problems are most often due to poor connections Before beginning the test procedure check all external wiring Be certain all ignition related wires are connected including the spark plug leads Be certain all terminal connections fit snugly Make sure the ignition switch is in the run position NOTE The CD ignition systems are sensitive to excessive load on the kill lead If a customer complains of hard starting low power or misfire under load it may be due to excessive draw on the kill circuit Perform the appropriate test procedure Test Procedure for Standard Fixed Timing CD Ignition System Isolate and verify the trouble is within the engine ignition system 1 Locate the plug connectors where the wiring harnesses from the engine and equipment are joined Separate the connectors and remove t
95. g of the float with the wire clip The formed 90 lip of the metal tang should point up with the needle valve hanging down See Figure 5 21 5 12 Figure 5 21 Float and Inlet Needle 11 Install the float and inlet needle down into the seat and carburetor body Insert the new pivot pin through the float hinge and secure with the new retaining screw See Figure 5 22 Figure 5 22 Installing Float Assembly 12 Hold the carburetor body so the float assembly hangs vertically and rests lightly against the fuel inlet needle The inlet needle should be fully seated but the center pin of the needle on retainer clip end should not be depressed Check the float height adjustment NOTE The inlet needle center pin is spring loaded Make sure the float assembly rests against the fuel inlet needle without depressing the center pin 13 The correct float height adjustment is 12 0 mm 0 472 in measured from the float bottom to the body of the carburetor See Figure 5 23 Adjust the float height by carefully bending the metal tang of the float Section 5 Fuel System and Governor 16 Install the new cover gasket and top cover on the carburetor Secure with the two large head screws and attach the ground lead if equipped with a fuel solenoid to the original screw location Torque the top cover screws to 2 5 0 3 N m 23 2 6 in Ib 17 Place the longer new spring onto the idle fuel adjusting screw and install it into th
96. gnition timing and spark remains constant regardless of the engine speed The Digital Spark Advance Ignition DSAI System See Figure 7 6 This system uses a digital microprocessor which is located in the ignition modules The ignition timing varies depending upon the engine speed with this system The Digital Spark Advance Module DSAM which was previously known as Smart Spark See Figure 7 9 This system uses a digital microprocessor that triggers the ignition modules and spark The ignition timing varies depending upon the engine speed with this system BLUE STARTER RED CARB WHITE IGNITION MODULE VIOLET CHARGING RED CARB ORANGE SOLENOID SHIFT STARTER ASS Y OPTIONAL CONNECTOR IGNITION MODULE WHITE IGNITION KILL gate ASS Y IT GN SPARK PLUG SPARK PLUG 1 CYLINDER 2 CYLINDER rN REGULATOR RECTIFIER AAN REGULATOR CONNECTOR BLOCK Se WHITE AC CHARGING LEADS SWITCH OPTIONAL Figure 7 3 Electronic CD Fixed Ignition Timing System Operation of CD Ignition Systems A Fixed Timing System This system Figure 7 3 consists of the following components e A magnet assembly which is permanently affixed to the flywheel e Two electronic capacitive discharge ignition modules which mount on the engine crankcase Figure 7 4 e A kill switch or key switch which grounds the modules to stop the engine e Two spark plugs ZA Operation As the flywhe
97. gure 10 40 Intake Valve Seal Location E E CG ell d i DW A GC d i a A S Kan ZE I fi 4 l a gi e d ER E gt ee F d Pe EE i aw A A D ff CCRA i 1 i i 2 ep D Ke a e GC E Prior to installation lubricate all components with engine oil paying particular attention to the lip of the valve stem seal valve stems and valve guides Install the following items in the order listed below using a valve spring compressor See Figures 10 41 and 10 42 Intake and exhaust valves Valve spring caps Valve springs Valve spring retainers Valve spring keepers T e Spring Retainer Keepers Figure 10 41 Valve Components 10 12 Figure 10 42 Installing Valves with Valve Spring Compressor 1 Check to make sure there are no nicks or burrs on the sealing surfaces of the cylinder head or crankcase Make sure that dowel locating pins are in the lower two cylinder bolt holes on each side 2 Install a new cylinder head gasket with printing up on each side See Figure 10 43 Figure 10 43 Installing Cylinder Head Gasket and Cylinder Head NOTE Match the numbers embossed on the cylinder heads and crankcase See Figure 10 44 Section 10 Reassembly Figure 10 44 Match Marks Location Figure 10 46 Cylinder Head Fastener Torque Sequence 3 Install each cylinder head and start the four new hex flange screws 1 Loosen the hex l
98. haft 23 Remove connecting rods with pistons and rings 24 Remove crankshaft 25 Remove inner breather assembly 26 Remove flywheel and PTO end oil seals Disconnect Spark Plug Leads 1 Disconnect the leads from the spark plugs See Figure 8 1 NOTE Pull on boot only to prevent damage to spark plug lead Figure 8 1 Disconnect Spark Plug Leads Shut Off Fuel Supply Drain Oil From Crankcase and Remove Oil Filter 1 Remove oil fill cap dipstick and the oil drain plug 8 1 Section 8 Disassembly X Drain Plug Figure 8 4 Removing Oil Filter Adapter 5 If an oil cooler is used remove the mounting screws securing the cooler unit to the blower housing See Figure 8 5 Figure 8 3 Removing Oil Filter 2 Allow ample time for the oil to drain from the crankcase and oil filter Figure 8 5 Removing Oil Cooler From Blower 3 Remove and appropriately discard the oil filter Housing See Fi 8 3 CE Tipe 6 Remove the oil pump outlet tube assembly and 4 Use an allen wrench to loosen the adapter the oil feed tube if not removed with nipple nipple Note the locating pin of the adapter and corresponding notch in the pad of the oil pan Remove the nipple washer plastic adapters only and oil filter adapter See Figure 8 4 Outlet Tube OilFeed E ra Assembly Tube Figure 8 6 Removing Oil Pump Outlet Tub Assembly and Oil Feed Tube 8 2 Remove Muffler 1 Remove the ex
99. haust system and attaching hardware from the engine Remove Fuel Pump Equipped Models A WARNING Explosive Fuel Gasoline may be present in the carburetor and fuel system Gasoline is extremely flammable and its vapors can explode if ignited Keep sparks open flames and other sources of ignition away from the engine 1 Disconnect the pulse vacuum hose and outlet fuel line from the fuel pump See Figure 8 7 2 Remove the two hex flange mounting screws unhook outlet hose from blower housing clip and remove the fuel pump from the blower housing Outlet Line Fuel Pump Mounting _ Screws Figure 8 7 Removing Pulse Pump Remove Blower Housing and Outer Baffles 1 Remove the six hex flange screws securing the blower housing See Figure 8 8 2 Remove the blower housing from the engine See Figure 8 9 3 Remove the M6 mounting screw on the bottom of each outer baffle into the cylinder and the M5 screws going into the backing plate and the cylinder head flange One screw may also secure the lift strap on one side Section 8 Disassembly Outer Baffle Mounting Screw Locations Figure 8 10 Outer Baffles Mounting Screws Remove Throttle Controls 1 Remove the four hex flange screws securing the throttle control bracket to the cylinder heads See Figure 8 11 8 3 Section 8 Disassembly 2 Disconnect the choke linkage from the choke actuator lever Unhook the governor spring and dampener
100. he white kill lead from the engine connector Rejoin the connectors and position or insulate the kill lead terminal so it cannot touch ground Try to start the engine to verify whether the reported problem is still present NOTE If the engine starts or runs during any of the testing you may need to ground the kill lead to shut it down Because you have interrupted the kill circuit it may not stop using the switch 7 5 Section 7 Electrical System and Components a If the problem is gone the electrical system on the unit is suspect Check the key switch wires connections safety interlocks etc b If the problem persists the condition is associated with the ignition or electrical system of the engine Leave the kill lead isolated until all testing is completed 2 Test for spark on both cylinders with Kohler ignition tester Kohler Part No 24 455 02 S Disconnect one spark plug lead and connect it to the post terminal of the tester Connect the clip to a good ground not to the spark plug Crank the engine and observe the tester spark gap Repeat the procedure on the other cylinder Remember to reconnect the first spark plug lead a If one side is not firing check all wiring connections and terminations on that side If wiring is okay replace ignition module and retest for spark b If the tester shows spark but the engine misses or won t run on that cylinder try a new spark plug c If neither side is
101. iameter of the valve stem at several points on the stem where it moves in the valve guide Use the largest stem diameter to calculate the clearance by subtracting the stem diameter from the guide diameter If the intake clearance exceeds 0 038 0 076 mm 0 0015 0 003 in or the exhaust clearance exceeds 0 050 0 088 mm 0 0020 0 0035 in determine whether the valve stem or guide is responsible for the excessive clearance The maximum I D wear on the intake valve guide is 7 134 mm 0 2809 in while 7 159 mm 0 2819 in is the maximum allowed on the exhaust guide The guides are not removable but can be reamed 0 25 mm 0 010 in oversize Valves with 0 25 mm oversize stems must then be used If the guides are within limits but the valve stems are worn beyond limits install new valves Valve Seat Inserts Hardened steel alloy intake and exhaust valve seat inserts are press fitted into the cylinder head The inserts are not replaceable but can be reconditioned if not too badly pitted or distorted If cracked or badly warped the cylinder head should be replaced Recondition the valve seat inserts following the instructions provided with the valve seat cutter being used A typical cutter is shown in Figure 9 5 The final cut should be made with an 89 cutter as specified for the valve seat angle in Figure 9 4 Cutting the proper 45 valve face angle as specified in Figure 9 4 and the proper valve seat angle 44 5 half of the f
102. ice class and SAE viscosity grade See Figure 1 3 Figure 1 3 Oil Container Logo 1 4 Refer to Section 6 Lubrication System for detailed procedures on checking the oil changing the oil and changing the oil filter Fuel Recommendations A WARNING Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Before servicing the fuel system make sure there are no sparks open flames or other sources of ignition nearby as these can ignite gasoline vapors Disconnect and ground the spark plug leads to prevent the possibility of sparks from the ignition system General Recommendations Purchase gasoline in small quantities and store in clean approved containers A container with a capacity of 2 gallons or less with a pouring spout is recommended Such a container is easier to handle and helps eliminate spillage during refueling Do not use gasoline left over from the previous season to minimize gum deposits in your fuel system and to ensure easy starting Do not add oil to the gasoline Do not overfill the fuel tank Leave room for the fuel to expand Fuel Type For best results use only clean fresh unleaded gasoline with a pump sticker octane rating of 87 or higher In countries using the Research method it should be 90 octane minimum Unleaded gasoline is recommended as it leaves less combustion chamber deposits and reduces harmful exhaust emissions Leaded gasoline is not recommended
103. ick and thread until tight NOTE To prevent extensive engine wear or damage always maintain the proper oil level in the crankcase Never operate the engine with the oil level above the F or FULL mark or below the L or LOW mark on the dipstick Parc Operating Range X ertt Figure 6 4 Oil Level Marks on Dipstick Typical Changing Oil and Oil Filter Change the oil and oil filter annually or every 100 hours of operation more frequently under severe conditions Refill with service class SJ oil as specified in the Viscosity Grades table Always use a genuine Kohler oil filter Change the oil while the engine is still warm The oil will flow more freely and carry away more impurities Make sure the engine is level when filling or checking oil Change the oil and oil filter as follows 1 The drain plug is located on the starter side of the oil pan See Figure 6 5 Clean the area around the oil drain plug and the oil fill cap dipstick Oil Drain Plug Figure 6 5 Oil Drain Plug Location 2 Remove the drain plug and the oil fill cap dipstick 3 Allow the oil to drain and then reinstall the drain plug Tighten 13 6 N m 10 ft Ib 4 Remove the old filter and wipe off the filter adapter with a clean cloth See Figure 6 6 Oil Filter Figure 6 6 Oil Filter Location 5 Place anew replacement filter in a shallow pan with the open end up Pour new oil of the proper type in through the threaded cent
104. idual Components Available Design Technology Inc Pressure Tester DTI 019 Noid Light DTI 021 90 Adapter DTI 023 Oetiker Clamp Pliers DTI 025 Code Plug Red Wire DTI 027 Code Plug Blue Wire DTI 029 Flywheel Holding Tool CS Series SE Tools KLR 82407 EE SE Tools KLR 82408 To remove flywheel from engine Flywheel Strap Wrench To hold flywheel during removal See 2 1 Section 2 Tools amp Aids Tools Continued LO Source Part No Hydraulic Valve Lifter Tool To remove and install hydraulic lifters Kohler 25 761 38 5 Ignition System Tester Kohler 25 455 01 S For testing output on all systems except CD Kohler 24455 0726 For testing output on capacitive discharge CD ignition system Offset Wrench K amp M Series To remove and reinstall cylinder barrel retaining nuts BEANE Seinen EE wee Kohler 25 761 06 S To test and verify oil pressure Rectifier Regulator Tester 120 volt current Kohler 25 761 20 S Rectifier Regulator Tester 240 volt current Kohler 25 761 41 S Used to test rectifier regulators Individual Components Available Design Technology Inc CS PRO Regulator Test Harness DTI 031 Special Regulator Test Harness with Diode DTI 033 Spark Advance Module SAM Tester To test the SAM ASAM and DSAM on engines with SMART SPARK Kohler 25 761 40 5 Starter Retaining Ring Tool Inertia Drive To remove and reinstall drive retaining rings excluding FASCO starters Kohler 25 761 18 S ATI S
105. igh speed stop as necessary Make sure the maximum engine speed does not exceed 3750 RPM no load 10 26 Section 11 Emission Compliance Systems Evaporative Emission Compliance System For the engine to be Tier III compliant it may be fitted with a Kohler supplied canister vapor recovery system or a system developed and installed by the Original Equipment Manufacturer OEM Details on the Kohler system are included below Operation Fuel vapors travel from the fuel tank through tubing to the carbon canister On the intake stroke of the engine fuel vapors are drawn in through a port in the carburetor and burned with the fuel charge See Figure 11 1 Maintenance On Kohler supplied canisters the breather filter can be removed and cleaned with hot soapy water dried and reinstalled Do not oil the breather screen This is done periodically or if system operation is suspect The carbon canister is sealed and requires no maintenance See Figure 11 1 In some applications or installations the OEM will have installed a different canister or fuel vapor recovery system See the OEM equipment documentation for service or maintenance information Carbon Canister Fuel Tank Cap Fuel Tank Roll Over Valve ROV Canister Breather Filter To Carburetor Figure 11 1 Carbon Canister System Diagram Section 11 Emission Compliance Systems Secondary Emission Compliance System For the engine to be Tier III compliant it may be
106. igure 5 34 and adjust as follows 1 Make sure the throttle linkage is connected to the governor lever and the throttle lever on the carburetor 2 Loosen the hex nut holding the governor lever to the cross shaft 3 Move the governor lever toward the carburetor as far as it will move wide open throttle and hold in position 4 Insert a nail into the hole in the end of the cross shaft and rotate the shaft counterclockwise as far as it will turn then tighten the hex nut securely Sensitivity Adjustment Governor sensitivity is adjusted by repositioning the governor spring in the holes of the governor lever If speed surging occurs with a change in engine load the governor is set too sensitive If a big drop in speed occurs when normal load is applied the governor should be set for greater sensitivity See Figure 5 34 and adjust as follows Left Side Pull Section 5 Fuel System and Governor 1 To increase the sensitivity move the spring closer to the governor lever pivot point 2 To decrease the sensitivity move the spring away from the governor lever pivot point High Speed RPM Adjustment Refer to Figures 5 34 and 5 35 1 With the engine running move the throttle control to fast Use a tachometer to check the RPM speed 2 Loosen the lock nut on the high speed adjusting screw Turn the screw counterclockwise to decrease or clockwise to increase RPM speed Check RPM with a tachometer 3 When the desir
107. igure 7 5 The high voltage pulse generated here is delivered to b If any of the tests are bad determine cause the spark plug causing arcing of the spark gap and fix as required then retest and igniting the fuel air mixture in the combustion chamber As the trigger pulse is generated all C Digital Spark Advance Module DSAM associated circuits are reset their capacitors DSAM previously known as Smart Spark discharged The longer it takes the delay circuit to equipped engines utilize an electronic capacitive surpass the charge pump capacitor voltage the later discharge ignition system with electronic spark the trigger pulse will occur retarding the timing advance A typical application Figure 7 9 consists of accordingly the following components e Amagnet assembly which is permanently affixed to the flywheel e Two electronic capacitive discharge ignition modules which mount on the engine crankcase Figure 7 9 e A spark advance module which mounts to the engine shrouding Figure 7 9 e A 12 volt battery which supplies current to the spark advance module e A kill switch or key switch which grounds the spark advance module to stop the engine e Two spark plugs Operation The ignition module for this system operates in the same fashion as the fixed timing module except the trigger circuit for the semi conductor L2 Figure 7 5 is replaced by the spark advance module Figure 7 9 The pulse generated by
108. in Yellow 0 84455 0 88265 mm 0 03325 0 03475 in Green 0 89535 0 99345 mm 0 03525 0 03675 in Gray 0 94615 0 98425 mm 0 03725 0 03875 in Black 0 99695 1 03505 mm 0 03925 0 04075 in Figure 10 17 Change Shim to Obtain Correct End Play 5 Reinstall the endplay tool and recheck the end play Oil Pump Assembly The oil pump is mounted inside the oil pan If service was required and the oil pump was removed refer to the assembly procedures in Section 9 Inspection and Reconditioning Governor Assembly The governor assembly is located inside the oil pan If service was required and the governor was removed refer to the assembly procedures in Section 9 Inspection and Reconditioning 10 6 Install Oil Seal in Oil Pan 1 Check to make sure that there are no nicks or burrs in the crankshaft bore of the oil pan 2 Apply a light coat of engine oil to the outside diameter of the oil seal 3 Drive the oil seal into the oil pan using a seal driver Make sure the oil seal is installed straight and true in the bore to the depth shown in Figures 10 18 0 255 in Oil Seal Figure 10 18 Oil Seal Depth in Oil Pan Install Oil Transfer Tubes and Filter Adapter 1 Lubricate new O Rings with clean oil and install into the groove on the ends of the oil pump transfer tube See Figure 10 19 Figure 10 19 Oil Pump Transfer Tube Details Section 10 Reassembly 2 Install the transfer tube with
109. in approved containers in well ventilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent AA WARNING Cleaning Solvents can cause severe injury or death Use only in well ventilated areas away from ignition sources Flammable Solvents Carburetor cleaners and solvents are extremely flammable Keep sparks flames and other sources of ignition away from the area Follow the cleaner manufacturer s warnings and instructions on its proper and safe use Never use gasoline as a cleaning agent 1 2 A WARNING Carbon Monoxide can cause severe nausea fainting or death Avoid inhaling exhaust fumes and never run the engine in a closed building or confined area Lethal Exhaust Gases Engine exhaust gases contain poisonous carbon monoxide Carbon monoxide is odorless colorless and can cause death if inhaled Avoid inhaling exhaust fumes and never run the engine in a closed building or confined area A CAUTION K Electrical Shock can cause injury Do not touch wires while engine is running Electrical Shock Never touch electrical wires or components while the engine is running They can be sources of electrical shock AA WARNING Explosive Gas can ca
110. ing of Section 10 2 Check to make sure that there are no nicks or burrs on the sealing surfaces of the oil pan or crankcase 3 Apply a1 5 mm 1 16 in bead of Black RTV Figure 10 26 sealant to the sealing surface of the oil pan See Figure 10 25 for the sealant pattern Oil pan must be installed within five minutes of the sealant being applied for proper sealing to occur Figure 10 27 Torquing Oil Pan Fasteners Install Breather Reed and Outer Cover 1 Install the breather reed followed by the retainer over the passage hole and mounting hole in the crankcase Hold in position and secure with the Figure 10 25 Oil Pan Sealant Pattern mounting stud Torque the stud to 6 2 N m 55 in Ib into a new cored hole or 4 Make sure the end of the governor cross shaft is 4 0 N m 35 in 1b into a used hole lying against the bottom of cylinder inside the See Figure 10 28 crankcase See Figure 10 15 5 Install the oil pan to the crankcase Carefully seat the camshaft with shim and crankshaft into their mating bearings Rotate the crankshaft to help engage the oil pump and governor gear meshes 6 Install the ten hex flange screws securing the oil pan to the crankcase Torque the fasteners in the sequence shown in Figure 10 26 to 24 4 N m 216 in lb On some engines one of the ten mounting screws is plated The plated screw is typically installed in the 6 hole shown in Figure
111. inside micrometer to determine the amount of wear refer to Section 1 Specifications and Tolerances A 0 25 mm 0 010 in oversize piston is available if resizing is selected Initially resize using a boring bar then use the following procedures for honing the cylinder Honing While most commercially available cylinder hones can be used with either portable drills or drill presses the use of a low speed drill press is preferred as it facilitates more accurate alignment of the bore in relation to the crankshaft crossbore Honing is best accomplished at a drill speed of about 250 RPM and 60 strokes per minute After installing coarse stones in hone proceed as follows 1 Lower hone into bore and after centering adjust so that the stones are in contact with the cylinder wall Use of a commercial cutting cooling agent is recommended 2 With the lower edge of each stone positioned even with the lowest edge of the bore start drill and honing process Move the hone up and down while resizing to prevent the formation of cutting ridges Check the size frequently 9 2 NOTE Kohler pistons are custom machined to exacting tolerances When over sizing a cylinder it should be machined exactly 0 25 mm 0 010 in over the new diameter Section 1 Specifications and Tolerances The oversize Kohler replacement piston will then fit correctly 3 When the bore is within 0 064 mm 0 0025 in of the desired size remove the coarse stones
112. ith the rectifier regulator mounted or loose The figures show the part removed from the engine for clarity Repeat the applicable test procedure two or three times to determine the condition of the part Figure 7 20 25 Amp Stator and Rectifier Regulator 195 Amp Rectifier Regulators 1 Connect the tester ground lead with spring Stator clamp to the body of the rectifier regulator being The stator is mounted on the crankcase behind tested the flywheel Follow the procedures in Section 8 l Disassembly and Section 10 Reassembly if stator 2 Connect the tester red lead to the B terminal of replacement is necessary the rectifier regulator and the two black tester leads to the two AC terminals See Figure 7 22 Rectifier Regulator The rectifier regulator is mounted to the underside of the backing plate on the oil filter side See Figure 7 21 To replace it remove the two mounting screws and disconnect the plug NOTE When installing the rectifier regulator take note of the terminal markings and install the plug accordingly Figure 7 22 7 19 Section 7 Electrical System and Components 3 Plug the tester into a 110 volt AC outlet and turn on the power switch See Figure 7 23 The POWER light should be illuminated and one of the four status lights may be on as well This does not represent the condition of the part Dee fies Hie Figure 7 23 4 Press the TEST button until a click is heard and then releas
113. ithin the governor gear flyweights assembly and slide both onto governor shaft until assembly locks into place See Figure 9 14 Pin and Governor Gear Assembly Oil Pump Assembly Disassembly 1 Remove the two hex flange screws See Figure 9 15 2 Lift the oil pump assembly from the oil pan See Figure 9 16 9 11 Section 9 Inspection and Reconditioning E 8 e j 4 7 Eta i H d P x 1 A k T E i e ai Ft Figure 9 15 Removing Oil Pump Mounting Screws 3 The outer Gerotor gear is typically held captive in the oil pump housing If the gear becomes separated see Step 1 under Reassembly for proper reinstallation NOTE The relief valve is sealed as part the oil pump housing and not serviceable Replace the oil pump if the relief valve condition or function is questionable in any way integral P Relief valve K V7 H P A J a j 3 wl a s Figure 9 16 Oil Pump Components Oil Pickup and Integral Relief Valve Inspection Inspect the oil pump housing gear and rotors for nicks burrs wear or any visible damage Check the oil pickup screen for damage or restriction If any parts are worn or damaged replace the oil pump assembly Disassembly of oil pump is not recommended If the retaining ring of main shaft is removed for any reason a new retaining ring should be used Do not install a used ring See Figure 9 17 9 12 EN Ring Figure 9 17 Oil Pump Detai
114. ivalents Lubricate threads with engine oil prior to assembly 1 8 Section 1 Safety and General Information Connecting Rod Cap Fastener Torque torque CEET ege 11 3 N m 100 in Ib ER Connecting Rod to Crankpin Running Clearance KI 0 030 0 055 mm 0 0012 0 0022 in DNAS WV Ae E en GE 0 070 mm 0 0028 in Connecting Rod toCrankpin Side EE ee 0 26 0 63 mm 0 0102 0 0248 in Connecting Rod to Piston Pin Running Clearance eseeseeererresrrerrrrrrrrreee 0 015 0 028 mm 0 0006 0 0011 in Piston Pin End I D IK 17 015 17 023 mm 0 6699 0 6702 in TMI WV Ae E en GE 17 036 mm 0 6707 in Crankcase Governor Cross Shaft Bore I D Eege 8 025 8 075 mm 0 3159 0 3179 in IA WV at NMI E 8 088 mm 0 3184 in Breather Assembly Inner Cover TFS CINE e de nes ase nse perm nates te sagen oat pane geo ct ste E A 10 7 N m 95 in Ib into new hole 7 3 N m 65 in lb into used hole Outer Cover ee a arse co eee aos acre nec uised E E T 6 2 N m 55 in lb into new hole 4 0 N m 35 in 1b into used hole Eeer e eege 1 3 N m 11 5 in Ib ERENNERT 13 6 N m 120 in Ib Oil Pan GUD Pan Fastener Lope cee epee een en Ren er errno eurr ern errer rer arrestee nner E 24 4 N m 216 in 1b Crankshaft FC TEVA CCC E E en ghassines on cesuesatusn aa E A E AEE stewart 0 070 0 590 mm 0 0028 0 0230 in Crankshaft Bore In Crankcase EIS 40 965 41 003 mm 1 6128 1 6143 in TWEAK VV Gal E dE 41 016 mm 1 6148 in Crankshaft Dore n Oil
115. k end into the space between the captured washer and the rear of the pinion 6 Slide the armature into the drive end cap and at the same time seat the drive lever into the housing Correctly installed the center pivot section of the drive lever will be flush or below the machined surface of the housing which receives the backup washer See Figure 7 57 smaller offset of the washer faces the retainer Figure 7 57 Installing Armature and Pivot Lever collar See Figure 7 56 7 32 Section 7 Electrical System and Components 7 Install the backup washer followed by the rubber grommet into the matching recess of the drive end cap The molded recesses in the grommet should be out matching and aligned with those in the end cap See Figure 7 58 Figure 7 60 Installing Thrust Washer 10 Starter reassembly when replacing the Brushes Brush Holder Assembly eem a Hold the starter assembly vertically on the Figure 7 58 Installing Backup Washer and end housing and carefully position the Grommet assembled brush holder assembly with the supplied protective tube against the end of 8 Install the frame with the small notch forward the commutator armature The mounting onto the armature and drive end cap Align the screw holes in the metal clips must be up out notch with the corresponding section in the Slide the brush holder assembly down into rubber grommet Install the drain tube in the rear place aro
116. k the fuel tank vent fuel pickup screen in line filter shut off valve and fuel line Correct any observed problem and reconnect the line If fuel does flow from the line check for faulty carburetor Refer to the Carburetor portions of this section If fuel does not flow from the line check for a clogged fuel line If the fuel line is unobstructed check for overfilled crankcase and or oil in pulse line If none of the checks reveal the cause of the problem replace the pump Fuel Pump General On engines equipped with a pulse type fuel pump the pumping action is created by the oscillation of positive and negative pressures within the crankcase This pressure is transmitted to the pulse pump through a rubber hose connected between the pump and crankcase The pumping action causes the diaphragm on the inside of the pump to pull fuel in on its downward stroke and to push it into the carburetor on its upward stroke Two check valves prevent fuel from going backward through the pump Pulse Line Figure 5 1 Pulse Pump Connections Performance Minimum fuel delivery rate must be 7 5 L hr 2 gal hr with a pressure at 0 3 psi and a fuel lift of 24 in A 1 3 L hr 0 34 gal hr fuel rate must be maintained at 5 Hz Section 5 Fuel System and Governor Replacing the Fuel Pump Replacement pumps are available through your source of supply To replace the pulse pump follow these steps Note the orientation of
117. le When you are certain the gap is correct torque the module mounting screws to 4 0 N m 35 in 1b Repeat these 6 steps to set the other ignition module Reattach the lead wires to the ignition module s noting if resistance is felt indicating a snug fit between the male and female terminals If any connections do not feel snug disconnect the lead lightly pinch the female terminal with a pliers and recheck the fit When the integrity of all connections has been verified repeat the spark test Test 2 a If a strong steady spark is now present both 7 sides Go to Test 5 step 4 b If there is still a spark problem perform Test 5 7 13 Section 7 Electrical System and Components Test 5 Test the DSAM 1 7 14 Trace the red power source lead from the DSAM to the harness connection Separate the connector and connect the red lead of a DC voltmeter to the harness terminal Trace the ground lead green from the SAM to the grounding screw Connect the black voltmeter lead to the eyelet terminal of the ground lead or the ground screw bolt Check the voltage with the key switch in both the START and RUN positions A minimum of 7 25 volts must be present a If correct voltage is not measured connect black voltmeter lead directly to the negative post of the battery and test voltage again in both key positions If correct voltage is now indicated check the ground circuit connectio
118. ler part number and the Nikki lot number are stamped on the choke side flange on top of the carburetor body Refer to the parts manual for the carburetor involved to ensure the correct repair kits and replacement parts are used Disassemble carburetor as follows after removal from the engine See Figure 5 33 1 5 16 Remove the fuel bowl retaining screw or solenoid assembly then remove the bowl and bowl gasket On solenoid equipped carburetors the main jet is mounted in the tip of the solenoid pin Be careful that it does not get damaged while the solenoid is separated from the carburetor Pull the float hinge pin and remove the float with the inlet needle attached Remove the vent plug from the column on fuel solenoid equipped carburetors Remove the screws holding the throttle plate to the throttle shaft pull the throttle shaft from the carburetor body Remove the screws securing the choke plate to the choke shaft assembly and pull the choke shaft assembly out of the carburetor body Disassemble the self relieving parts from shaft as needed Remove the three screws holding the passage cover to the body remove the cover gasket Remove the idle fuel adjusting needle and spring if it does not have a limiter Remove the idle speed screw and spring Except for the slow jet nozzle main jet and emulsion tubes which are considered non serviceable the carburetor is now completely disassembled and re
119. les Baffle Mounting Screws Lift Strap 1 Attach the outer cylinder baffles and secure with the M6 screw lower cylinder location and M5 Figure 10 64 Installing Inner Baffles and Lift Strap screw into the backing plate See Figure 10 63 Tighten the screws as listed following Step 2 10 18 3 Install the spark advance module DSAM if equipped onto the outer cylinder baffle See Figure 10 65 Figure 10 65 SAM Mounting Install Carburetor A WARNING Explosive Fuel Gasoline may be present in the carburetor and fuel system Gasoline is extremely flammable and its vapors can explode if ignited Keep sparks and other sources of ignition away from the engine 1 Install a new carburetor gasket Make sure all holes align and are open 2 Install the carburetor throttle linkage and governor lever as an assembly See Figure 10 66 Figure 10 66 Installing Carburetor Throttle Linkage and Governor Lever Section 10 Reassembly 3 If the carburetor is equipped with a fuel solenoid connect the red power lead Attach the eyelet terminal of ground lead to the inner top carburetor cover mounting screw See Figure 10 67 Fuel Solenoid Lead L FS Ground t Figure 10 67 Connecting Fuel Solenoid and Ground Lead Install External Governor Controls 1 Install the governor lever onto the governor cross shaft if disconnected previously See Figure 10 68 Figure 10 68 Installing Governor Lever to
120. level in the engine side is less than specified low no vacuum or the level in the engine side is lower than the level in the open side pressure check for the conditions in the table on page 3 4 Close the shut off clamp before stopping the engine To test the crankcase vacuum with the Vacuum Pressure Gauge Kit Kohler Part No 25 761 22 S ih zA Remove the dipstick or oil fill plug cap Install the adapter into the oil fill dipstick tube opening Push the barbed fitting on the gauge solidly into the hole in the adapter Start the engine and bring it up to operating speed 3200 3600 RPM Check the reading on the gauge If the reading is to the left of 0 on the gauge vacuum or negative pressure is indicated If the reading is to the right of 0 on the gauge positive pressure is present Crankcase vacuum should be 4 10 inches of water If the reading is below specification or pressure is present check the table on page 3 4 for possible causes and remedies if 3 3 Section 3 Troubleshooting No Crankcase Vacuum Pressure in Crankcase Possible Cause 1 Crankcase breather clogged or inoperative Seals and or gaskets leaking Loose or improperly torqued fasteners Piston blow by or leaky valves confirm by inspecting components Restricted exhaust Compression Test Some of these engines are equipped with an automatic compression release ACR mechanism Because of th
121. loose terminals or broken wires Disconnect the leads from the ignition module s and clean all of the terminals male and female with aerosol electrical contact cleaner to remove any old dielectric compound dark residue dirt or contamination Disconnect the spark plug leads from the spark plugs Remove one of the mounting screws from each of the ignition modules Look in the mounting hole with a flashlight and use a small round wire brush to remove any loose rust from the laminations inside the mounting hole Refer to the following table and use a digital ohmmeter to check the resistance values of the ignition modules and compare them to the table When testing resistance to the laminations touch the probe to the laminations inside the screw hole as some laminations have a rust preventative coating on the surface which could alter the resistance reading a If all of the resistance values are within the ranges specified in the table go to Step 5 b If any of the resistance values are not within the ranges specified in the table that module is faulty and must be replaced 7 12 NOTE The resistance values apply only to modules that have been on a running engine New service modules may have higher resistance until they have been run 24 584 36 S Test 2 1 16 in High Use 24 584 36 S Digital 2 1 16 in High Ohmmeter From No 590 to 1 to 4 616 ohms Ignition Module Resistance Table 5 Check and
122. ls Pre ignition or ignition of the fuel charge before the timed spark can cause damage similar to detonation Pre ignition damage is often more severe than detonation damage Pre ignition is caused by a hot spot in the combustion chamber such as glowing carbon deposits blocked cooling fins an improperly seated valve or wrong spark plug s See Figure 9 6 for some common types of piston and ring damage iar Mag E eem Scored Piston and Rings Section 9 Inspection and Reconditioning Replacement pistons are available in STD bore size and 0 25 mm 0 010 in oversize Replacement pistons include new piston ring sets and new piston pins Replacement ring sets are also available separately for STD and 0 25 mm 0 010 in oversize pistons Always use new piston rings when installing pistons Never use old rings Some important points to remember when servicing piston rings 1 The cylinder bore must be de glazed before service ring sets are used Figure 9 8 Measuring Piston Ring Side Clearance 2 If the cylinder bore does not need re boring and if the old piston is within wear limits and free Install New Piston Rings of score or scuff marks the old piston may be To install new piston rings proceed as follows reused NOTE Rings must be installed correctly Ring 3 Remove the old rings and clean up the grooves installation instructions are usually included Never reuse old rings with new ring sets Follow in
123. ls Reassembly 1 Lubricate the outer Gerotor gear with oil If the outer gear was separated from the oil pump housing examine the outer edges On the Gerotor Gears one edge contains small molding marks or dots which must be matched to those on the inner gear If the dots are not visible on the inner gear install the outer gear with the dots down or in If the dots are visible the outer gear should be installed with the dots up or out Not matching the molding dots will result in reduced pump output efficiency 2 Install the oil pump inserting the center shaft into the corresponding recess in oil pan Secure the oil pump by torquing the hex flange screws in the indicated sequence to 11 2 N m 100 in Ib in new as cast holes or 7 3 N m 65 in Ib into used holes See Figures 9 18 and 9 19 Figure 9 19 Oil Pump Torque Sequence a Start fastener 1 into hole apply only minimal torque to position the pump b Torque fastener 2 to full value c Torque fastener 1 to full value d After torquing rotate the gear and check for freedom of movement Make sure there is no binding If binding occurs loosen the screws reposition the pump retorque the hex flange screws and recheck the movement Breather Design The breather system is designed to control the amount of oil in the head area and still maintain the necessary vacuum in the crankcase The system consists of an inner chamber with a mesh filter inside the cr
124. lves first After removal clean the valve heads faces and stems with a power wire brush Then carefully inspect each valve 9 4 36 987 7 013 mm 1 4562 1 4572 in 7 038 7 058 mm 0 2771 0 2779 in 33 37 3 63 mm 1 3138 3240 in 6 982 7 000 mm 0 2749 0 2756 in INTAKE VALVE d EXHAUST G INSERT INTAKE INSERT 32 987 83 013 mm 1 2987 1 2997 in 6 5 mm 0 2559 in 7 038 7 058 mm 0 2771 0 2779 in 29 37 29 63 mm 1 1563 1 1665 in 45 1 5 mm 0 0591 in 6 970 6 988 mm 0 2744 0 2751 in for defects such as warped head excessive corrosion or worn stem end Replace valves found to be in bad condition A normal valve and valves in bad condition are shown in the accompanying illustrations Section 9 Inspection and Reconditioning Normal Even after long hours of operation a valve Leakage A poor grind on face or seat of valve will can be reconditioned and reused if the face and allow leakage resulting in a burned valve on one side margin are in good shape If a valve is worn to where only the margin is less than 12 do not reuse it The valve shown was in operation for almost 1000 hours under controlled test conditions Bad Condition The valve depicted here should be Coking Coking is normal on intake valves and is not replaced Note the warped head margin damaged harmful If the seat is good the valve could be reused and too narrow These conditions could be attributed after cleani
125. m steps 1 5 in Starter Disassembly 2 Remove the two screws securing the brush holder assembly to the end cap plate Note the orientation for reassembly later See Figure 7 53 Discard the old brush holder assembly Mica Insulation Figure 7 51 Commutator Mica Inspection 2 Use an ohmmeter set to the Rx1 scale Touch the probes between two different segments of the commutator and check for continuity See Figure 7 52 Test all the segments Continuity must exist between all or the armature is bad Insulation Check Figure 7 53 Removing Brush Holder 3 Clean the component parts as required 4 The new brushes and springs come preassembled in a brush holder with a protective sleeve that Armature will also serve as an installation tool See Figure Coil 7 54 Figure 7 52 Checking Armature 3 Check for continuity between the armature coil segments and the commutator segments See Figure 7 52 There should be no continuity If continuity exists between any two the armature is bad 4 Check the armature windings insulation for shorting Shift Fork Check that the shift fork is complete and the pivot and contact areas are not excessively worn cracked or broken Figure 7 54 Service Brush Kit 5 Perform Steps 10 13 in the Starter Reassembly sequence Installation must be done after the armature drive lever and frame are installed if the starter has been disassembled 7 31 Section 7 Electri
126. minimize gum deposits in your fuel system and to ensure easy starting e Do not add oil to the gasoline e Do not overfill the fuel tank Leave room for the fuel to expand Fuel Type For best results use only clean fresh unleaded gasoline with a pump sticker octane rating of 87 or higher In countries using the Research Fuel Rating Method it should be 90 octane minimum Unleaded gasoline is recommended as it leaves less combustion chamber deposits and reduces harmful exhaust emissions Leaded gasoline is not recommended Gasoline Alcohol blends Gasohol up to 10 ethyl alcohol 90 unleaded gasoline by volume is approved as a fuel for Kohler engines Other gasoline alcohol blends including E20 and E85 are not approved Gasoline Ether blends Methyl Tertiary Butyl Ether MTBE and unleaded gasoline blends up to a maximum of 15 MTBE by volume are approved as a fuel for Kohler engines Other gasoline ether blends are not approved 5 1 Section 5 Fuel System and Governor Fuel Filter Most engines are equipped with an in line filter Periodically inspect the filter and replace annually or every 100 hours with a genuine Kohler filter Fuel Line In compliance with CARB Tier II Emission Regulations these engines use Low Permeation SAE 30 R7 rated fuel line certified to meet CARB requirements Standard fuel line may not be used Order replacement hose by part number through a Kohler Engine Service Deale
127. mpensate for the effects of high altitude special high altitude jet kits are available The kits include a new main jet slow jet where applicable necessary gaskets and O Rings Refer to the parts manual for the correct kit number Fuel Shut off Solenoid Most carburetors are equipped with a fuel shut off solenoid See Figure 5 4 The solenoid is installed in place of the bowl retaining screw The solenoid has a spring loaded pin that retracts when 12 volt current is applied to the lead When it is extended the main fuel jet is blocked preventing normal carburetor operation Below is a simple test made with the engine off that can determine if the solenoid is functioning properly 1 Shut off the fuel and remove the solenoid from the carburetor When the solenoid is loosened and removed gas will leak out of the carburetor Have a container ready to catch the fuel 2 Wipe the tip of the solenoid with a shop towel or blow it off with compressed air to remove any remaining fuel Take the solenoid to a location with good ventilation and no fuel vapors present A 12 volt power source that can be switched off and on is also needed 3 Besure the power source is switched off Connect the positive power source lead to the red lead of the solenoid Connect the negative power source lead to the solenoid body 4 Turn the power source on and observe the pin in the center of the solenoid The pin should retract with the power on a
128. n Test Connect one 12 volt test lead to the flat spade S start terminal on the solenoid and the other lead to the body or mounting surface of the solenoid Then manually push the plunger in and check if the Hold In coil holds the plunger retracted See Figure 7 70 Do not allow the test leads to remain connected to the solenoid for a prolonged period of time If the plunger fails to stay retracted the solenoid should be replaced Manually Push Plunger In 12 volt Test Leads Connect Only Long Enough to Test Figure 7 70 Testing Hold In Coil Function Test 7 36 Test 4 Solenoid Hold In Coil Contact Continuity Test Use an ohmmeter set to the audible or Rx2K scale and connect the two ohmmeter leads to the two large post terminals Perform the preceding test 3 and check for continuity See Figure 7 71 The meter should indicate continuity if no continuity is indicated the solenoid should be replaced Repeat test several times to confirm condition VOM Meter Leads Plunger Pushed In 12 volt Test Leads Figure 7 71 Testing Hold In Coil Solenoid Contact Continuity Section 8 Disassembly A WARNING Accidental Starts Disabling engine Accidental starting can cause severe injury or death Before working on the engine or equipment disable the engine as follows 1 Disconnect the spark plug lead s 2 Disconnect negative battery cable from battery Clean all parts thoroughly as the engine
129. nd return to its original position with the power off Test several times to verify operation Section 5 Fuel System and Governor Fuel Shut off Solenoid gt it off Solenoid Location eg Figure 5 4 Fuel Shut Carburetor Adjustments General The carburetor is designed to deliver the correct fuel to air mixture to the engine under all operating conditions The high speed mixture is preset at the factory and cannot be adjusted The low idle fuel adjusting screw some models is also set at the factory and normally does not need adjustment See Figure 5 5 Engines in this series depending on the model and application may also be equipped with a Governed Idle System If the engine is equipped with a Governed Idle System refer to Models with Governed Idle System when performing any carburetor adjustment as an additional step to the listed procedure s is required NOTE Carburetor adjustments should be made only after the engine has warmed up NOTE Some carburetors may have a fixed idle or limiter cap on the idle fuel adjusting needle Do not attempt steps 1 and 2 below Proceed directly to step 3 Step 5 can only be performed within the limits allowed by the cap Adjusting Low Idle Fuel and Speed To adjust the carburetor idle fuel and speed see Figure 5 5 and follow these steps 1 With the engine stopped turn the low idle fuel adjusting screw in clockwise until it bottoms lightly Access thi
130. nes is 1200 RPM To ensure best results when setting the low idle fuel needle the low idle speed should be 1200 RPM 75 RPM 5 Low Idle Fuel Needle Setting Place the throttle into the idle or slow position Turn the low idle fuel adjusting screw in slowly until engine speed decreases and then back out approximately 3 4 to 1 turn to obtain the best low speed performance 6 Recheck the idle speed using a tachometer and readjust the speed as necessary Models with Governed Idle System An optional governed idle control system is supplied on some engines The purpose of this system is to maintain a desired idle speed regardless of ambient conditions temperature parasitic load etc that may change Engines with this feature contain a small secondary spring connected between the governor lever and the lower adjustment tab of the main bracket See Figure 5 7 The system requires an additional procedure for setting the idle speed If speed adjustments are required proceed as follows 1 Make any necessary speed or control adjustments following the appropriate instructions covered in this section 2 Move the throttle control to the idle position Hold the governor lever away from the carburetor or hold the throttle lever so it is tight against the idle speed adjusting screw to negate the governor activation See Figure 5 8 Check the speed with a tachometer and adjust it to 1500 RPM Section 5 Fuel System and Governor
131. ng to excessive hours or a combination of poor operating conditions 9 5 Section 9 Inspection and Reconditioning Excessive Combustion Temperatures The white deposits seen here indicate very high combustion temperatures usually due to a lean fuel mixture Gum Gum deposits usually result from using stale gasoline Gum is a prevalent cause of valve sticking The cure is to ream the valve guides and clean or replace the valves depending on their condition 9 6 Stem Corrosion Moisture in fuel or from condensation is the most common causes of valve stem corrosion Condensation occurs from improper preservation during storage and when engine is repeatedly stopped before it has a chance to reach normal operating temperatures Replace corroded valves Overheating An exhaust valve subject to overheating will have a dark discoloration in the area above the valve guide Worn guides and faulty valve springs may cause this condition Also check for clogged air intake and blocked fins when this condition is noted Valve Guides If a valve guide is worn beyond specifications it will not guide the valve in a straight line This may result in burnt valve faces or seats loss of compression and excessive oil consumption To check valve guide to valve stem clearance thoroughly clean the valve guide and using a split ball gauge measure the inside diameter of the guide Then using an outside micrometer measure the d
132. ng it means that oil is intended to improve fuel economy in passenger car engines 6 1 Section 6 Lubrication System Checking Oil Level The importance of checking and maintaining the proper oil level in the crankcase cannot be overemphasized Check oil BEFORE EACH USE as follows 1 Make sure the engine is stopped level and cool so the oil has had time to drain into the sump 2 Clean the area around and the under side of the oil fill cap dipstick before removing it This will help to keep dirt grass clippings and other foreign matter out of the engine See Figure 6 2 Oil Fill Cap Oil Fill Tube Figure 6 2 Oil Fill Cap Dipstick and Oil Fill Tube 3 Unthread and remove the oil fill cap dipstick wipe off oil Reinsert the dipstick into the oil fill tube and rest the oil fill cap dipstick on the oil fill tube Turn it counterclockwise until the oil fill cap drops down to the lowest point of the thread leads Do not thread the oil fill cap onto the tube See Figure 6 3 Oil Fill Cap Dipstick D Oil Fill Cap Dipstick Oil Fill Tube Correct Figure 6 3 Oil Fill Cap and Oil Fill Tube Threads Incorrect 6 2 4 Remove the oil fill cap dipstick and check oil level The oil level needs to be within the operating range See Figure 6 4 If low add oil of the proper type up to the full mark If oil is above F or FULL mark drain oil to reach proper level Reinstall the oil fill cap dipst
133. ns If the ground screw bolt or any other fasteners in the ground circuit are black oxide coated replace them with zinc plated silver colored fasteners b If correct voltage is still not indicated check the harness connector terminal for a good connection and crimp to the lead Then trace the power source circuit back through the harness key switch etc looking for any poor connections or faulty circuits Disconnect all of the DSAM leads isolating it from the engine Test the DSAM with tester 25 761 40 S using the instructions following or use TT 5152 provided with the tester If the DSAM tests bad replace it Reattach the DSAM leads verifying a snug fit at the ignition module terminals If any connections do not feel snug disconnect the lead lightly pinch the female terminal with a pliers and recheck the fit Seal the base of the ignition module connections with GE Novaguard G661 Kohler Part No 25 357 11 S or Fel Pro Lubri Sel dielectric compound The beads should overlap between the two connections to form a solid bridge of compound Do not put any compound inside the connectors Test for spark Test 2 to be sure the system is working before you reinstall the blower housing If there is still a spark problem on one side replace that ignition module and recheck spark Use the following procedure to test the digital DSAM module previously known as Smart Spark To Test Using 25 761 40 S Tester N
134. ocking nut and back off the l adjusters for the rocker arms If the adjusters for MOE en tale Cy eer nea NEN Nex the rocker arms were removed reinstall them flange screws should always be used into the threaded end of arm approximately three New screws are supplied in the gasket threads and screw the hex locking nut onto the Sets adjuster from the underside Screw adjuster flush with the bottom of the nut as an initial setting Do not tighten the locking nut at this time final adjustment will be made later See Figure 10 47 a ier Hex Locking Nut Figure 10 45 Torquing Cylinder Head Fasteners 4 Torque the hex flange screws in two stages first to 22 6 N m 200 in lb then finally to 41 8 N m Figure 10 47 Loosing Nut and Backing Off 370 in Ib following the sequence in Figure Adjuster 10 46 2 Apply grease to the contact surfaces of the adjusters rocker arms and rocker arm pivots Install the rocker arms and rocker arm pivots onto the appropriate cylinder head and start the two hex flange screws 3 Hold the rocker arms in aligned position and torque the hex flange screws to 11 3 N m 100 in Ib See Figure 10 48 10 13 Section 10 Reassembly End Adfusiment Style la Figure 10 48 Torquing Rocker Arm Screws Center Pivot Adjust 4 Note the mark or tag identifying the push rod Style as either intake or exhaust and cylinder 1 or 2 Check that each push rod is straight and not bent
135. of the end gap 3 Top Compression Ring Top Groove Install the top ring using a piston ring expander tool Make sure the identification mark is up or the dykem stripe if contained is to the left of the end gap Connecting Rods Offset stepped cap connecting rods are used in all these engines Inspection and Service Check the bearing area big end for excessive wear score marks running and side clearances see Section 1 Specifications and Tolerances Replace the rod and cap if scored or excessively worn 9 10 Service replacement connecting rods are available in STD size and 0 25 mm 0 010 in undersize The 0 25 mm 0 010 in undersized rods have an identification marking on the lower end of the rod shank Always refer to the appropriate parts information to ensure that correct replacements are used Valve Tappets Inspection Check the base surface of the valve tappet s for wear or damage Replace tappet s if condition is questionable in any way The corresponding camshaft lobe s should also be checked for wear or damage Whenever tappets are replaced apply a liberal coating of Kohler lubricant 25 357 14 S to the base of each new tappet before it is installed Figure 9 11 Valve Tappet Oil Pan Assembly Inspection Inspect the oil seal in the oil pan and remove it if it is worn or damaged The new oil seal is installed after the oil pan is assembled to the crankcase See Section 10 Reassembly Oil S
136. of two revolutions to check longblock assembly and overall proper operation Install Valve Covers The valve covers contain integral bolt hole spacers molded in place Sealing is accomplished using a yellow colored O Ring 1 Make sure the sealing surfaces of valve covers and cylinder heads are clean and free of any nicks or burrs 2 Install anew O Ring in the groove of each cover Do Not use gaskets or RTV sealant Figure 10 51 Adjusting Valve Clearance and Tightening Locking Nut End Adjustment Style 3 Position the covers on the cylinder heads If a pulse style fuel pump is used the valve cover with the pulse fitting hole must be installed on the 2 side Install the four hex flange screws in each cover and finger tighten 4 Torque the valve cover fasteners to 6 2 N m 55 in lb using the sequence shown in Figure 10 53 Adjuster 4 and Lock Setscrew ei Figure 10 52 Adjusting Valve Clearance Center Pivot Adjustment Style 4 Repeat the procedure for the other valve on the 1 side 5 Viewed from the PTO end rotate the crankshaft 270 3 4 turn counterclockwise and align the crankshaft keyway with the 2 cylinder which now puts that cylinder at TDC on the compression stroke Figure 10 53 Valve Cover Fastener Torque Sequence 6 Repeat steps 3 4 for setting the valve clearance on the 2 side 7 Rotate the crankshaft to check for free operation of the valve train Che
137. oil cooler to the blower housing with the mounting screws Figure 6 8 Cleaning Inside of Oil Cooler Oil Sentry General Some engines are equipped with an optional Oil Sentry oil pressure monitor switch If the oil pressure drops below an acceptable level the Oil Sentry will either shut off the engine or activate a warning signal depending on the application The pressure switch is designed to break contact as the oil pressure increases above 3 5 psi and make contact as the oil pressure decreases below 3 5 psi 6 3 Section 6 Lubrication System On stationary or unattended applications pumps generators etc the pressure switch can be used to eround the ignition module to stop the engine On vehicular applications lawn tractors mowers etc the pressure switch can only be used to activate a low oil warning light or signal NOTE Make sure the oil level is checked before each use and is maintained up to the FULL or F mark on the dipstick This includes engines equipped with Oil Sentry Installation The pressure switch on Oil Sentry equipped models is mounted to the oil filter or oil cooler adapter See Figure 6 9 Pressure Switch Adapter for Oil Cooler or Oil Filter Figure 6 9 Oil Sentry Location 6 4 To install the switch follow these steps 1 Apply pipe sealant with Teflon Loctite No 59241 or equivalent to the threads of the switch 2 Install
138. ovided in the 1 Apply camshaft lubricant Kohler Part No service rod package See Figures 10 10 and 10 11 25 357 14 S to the contact surface of the valve tappets Note the mark or tag identifying the NOTE Align the chamfer of the connecting tappets and install them in their appropriate rod with the chamfer of its mating end crankcase locations See Figure 10 12 A small cap When installed the flat faces of the amount of grease applied to the stems will connecting rods should face each other hold the valve tappets up until the camshaft is The faces with the raised rib should be installed toward the outside IC aul Rod End Cap Figure 10 12 Applying Camshaft Lubricant to Figure 10 10 installing Connecting Rod End Cap Valve Tappets NOTE The exhaust valve tappets are located on the output shaft side of the engine while the intake valve tappets are located on the fan side of the engine The cylinder number is embossed on the outside of each cylinder on the crankcase Valve tappets should always be installed in the same position as before disassembly 10 4 2 Ka Figure 10 13 Installing Valve Tappets i V i Se ma F i d SP Liberally apply camshaft lubricant to the lobes of the camshaft Lubricate the camshaft bearing surfaces of the crankcase and camshaft with engine oil See Figure 10 14 Figure 10 14 Apply Camshaft Lubricant to Cam Lobes 3 Position the timing mark of the crankshaf
139. problems remove the carburetor from the engine to check and or replace the float Use a float kit to replace float pin and inlet needle or valve 1 Remove the air cleaner and air intake components from the carburetor as described in Section 4 2 Disconnect the fuel inlet line from the carburetor Figure 5 31 Choke Shaft and Spring Details 3 Disconnect governor throttle linkage from the 10 Slide the choke shaft and spring into the carburetor carburetor Pivot preload the shaft and set the inner leg of the spring against the formed stop 4 within the choke lever as originally assembled See Figures 5 31 and 5 28 The opposing leg of the spring must still be between the formed stops of 5 the choke shaft Disconnect lead wires from fuel solenoid equipped carburetor Slide the carburetor off the retaining studs Remove the fuel bowl retaining screw or fuel shut off solenoid and drain the fuel into a safe 11 Place a drop of the Loctite on the threads of each BE Remorse he bow E EE E new screw Install the new choke plate to the flat body side of the choke shaft and start the two screws The larger cutout must be on the right Close the choke and check the plate alignment within the carburetor throat then tighten the screws securely Do not overtighten 16 5 mm E 12 Check for proper operation and free movement of 0 65 in z the parts Install the new cap a Q T Always use n
140. r Fuel System Tests When the engine starts hard or turns over but will not start it is possible that the problem is in the fuel system To find out if the fuel system is causing the problem perform the following tests Troubleshooting Fuel System Related Causes Test Conclusion Check the following a Make sure the fuel tank contains clean fresh proper fuel Make sure the vent in fuel tank is open Make sure the fuel valve is open Make sure vacuum and fuel lines to fuel pump are secured and in good condition Check for fuel in the combustion chamber a Disconnect and ground spark plug leads b Close the choke on the carburetor c Crank the engine several times d Remove the spark plug and check for fuel at the tip Check for fuel flow from the tank to the fuel pump a Remove the fuel line from the inlet fitting of fuel pump b Hold the line below the bottom of the tank Open the shut off valve if so equipped and observe flow Check the operation of fuel pump a Remove the fuel line from the inlet fitting of carburetor b Crank the engine several times and observe flow 5 2 If there is fuel at the tip of the spark plug fuel is reaching the combustion chamber If there is no fuel at the tip of the spark plug check for fuel flow from the fuel tank Test 3 If fuel does flow from the line check for faulty fuel pump Test 4 If fuel does not flow from the line chec
141. r On Pro models the door can be removed 2 Unhook the latch and remove the precleaner from the air cleaner element or remove as an assembly for servicing Make sure the base and the sealing area is clean before reassembly is performed 3 Wash the precleaner in warm water with detergent Rinse the precleaner thoroughly until all traces of detergent are eliminated Squeeze out excess water do not wring Allow the precleaner to air dry 4 Saturate the precleaner with new engine oil Squeeze out all excess oil 5 Reinstall the precleaner over the paper air cleaner element Secure the element with the latch 6 Close and latch the door Element WW P Latch aay y Precleaner Figure 4 2 Precleaner on Air Cleaner 4 1 Section 4 Air Cleaner and Air Intake System Paper Element Service Clean the paper element every 50 hours or replace if necessary Replace the paper element annually or every 100 hours of operation more often under extremely dusty or dirty conditions See Figure 4 1 and follow these steps 1 Open the door on the blower housing to access the air cleaner element See Figures 4 1 and 4 2 2 Unhook the latch and remove the air cleaner element and precleaner if equipped See Figure 4 2 3 Remove the precleaner if so equipped from the paper element Service the precleaner as described in Precleaner Service Air Cleaner Element Base Precleaner Some Models Air Cleaner
142. r or damage Always use new gaskets 23 Install external governor controls 24 Install air cleaner element Make sure all traces of any cleaner are removed before 25 Install throttle and choke controls the engine is assembled and placed into operation 26 Install electric starter motor and oil fill tube Even small amounts of these cleaners can quickly 27 Install blower housing break down the lubricating properties of engine oil 28 Install fuel pump 29 Install muffler Check the oil pan crankcase cylinder heads and 30 Install oil filter and oil valve covers to be certain that all old sealing material 31 Connect spark plug leads has been removed Use gasket remover lacquer thinner or paint remover to remove any remaining Install Flywheel End Oil Seal traces Clean the surfaces with isopropyl alcohol 1 Make sure that the seal bore of the crankcase is acetone lacquer thinner or electrical contact cleaner clean and free of any nicks or burrs See Figure 10 1 Typical Reassembly Sequence The following sequence is suggested for complete engine reassembly This procedure assumes that all components are new or have been reconditioned and all component subassembly work has been completed The sequence may vary to accommodate options or special equipment Detailed procedures follow Install flywheel end oil seal Install breather filter and inner cover Install governor cross shaft Install crankshaft Install connecting
143. r damage Hydraulic lifter malfunction Quality of fuel Incorrect grade of oil Engine Loses Power LA 3 2 Low crankcase oil level High crankcase oil level Dirty air cleaner element Dirt or water in the fuel system Excessive engine load Engine overheated Faulty spark plugs Low compression Exhaust restriction DSAI or DSAM malfunction applicable models Low battery Incorrect governor setting Engine Uses Excessive Amount of Oil 1 Incorrect oil viscosity type Clogged or improperly assembled breather Breather reed broken Worn or broken piston rings Worn cylinder bore Worn valve stems valve guides Crankcase overfilled Blown head gasket overheated oe SS a Oil Leaks from Oil Seals Gaskets 1 Crankcase breather is clogged or inoperative Breather reed broken Loose or improperly torqued fasteners Piston blowby or leaky valves Restricted exhaust Ol ye o gt e External Engine Inspection Before cleaning or disassembling the engine make a thorough inspection of its external appearance and condition This inspection can give clues to what might be found inside the engine and the cause when it is disassembled Check for buildup of dirt and debris on the crankcase cooling fins grass screen and other external surfaces Dirt or debris on these areas are causes of higher operating temperatures and overheating Check for obvious fuel and oil leaks and damaged components Excessi
144. rdware and separate the solenoid from the starter for testing Test 1 Solenoid Pull In Coil Plunger Actuation Test Use a 12 volt power supply and two test leads Connect one lead to the flat spade S start terminal on the solenoid Momentarily connect the other lead to the lower large post terminal See Figure 7 68 NOTE DO NOT leave the 12 volt test leads connected to the solenoid for any time over what is necessary for performing each of the individual tests Internal damage to the solenoid may otherwise occur When the connection is made the solenoid should energize audible click and the plunger retract Repeat the test several times If the solenoid fails to activate it should be replaced H 12 volt Test Leads Momentary Connection Only Figure 7 68 Testing Pull In Coil Plunger Actuation 7 35 Section 7 Electrical System and Components Test 2 Solenoid Pull In Coil Contact Continuity Test Use an ohmmeter set to the audible or Rx2K scale and connect the two ohmmeter leads to the two large post terminals Perform the preceding test 1 and check for continuity See Figure 7 69 The ohmmeter should indicate continuity if no continuity is indicated the solenoid should be replaced Repeat test several times to confirm condition 12 volt Test Leads Momentary Connection Only VOM Leads Ka a Figure 7 69 Testing Pull In Coil Solenoid Contact Continuity Test 3 Solenoid Hold In Coil Functio
145. reas Section 4 Every 100 Hours Check oil cooler fins clean as necessary if equipped Section 6 Replace fuel filter Section 5 Check spark plug condition and gap Section 7 Every 300 Hours e Have valve lash checked Adjusted Every 500 Hours e Have bendix starter drive serviced Section 7 e Have solenoid shift starter disassembled and cleaned Section 7 Perform these maintenance procedures more frequently under extremely dusty dirty conditions Have a Kohler Engine Service Dealer perform these services Daily Or Before Starting Engine Storage Fill the fuel tank with clean fresh gasoline Run If the engine will be out of service for two months or the engine for 2 to 3 minutes to get stabilized more use the following storage procedure fuel into the rest of the system Close the fuel shut off valve when the unit is being stored or 1 Clean the exterior surfaces of the engine Avoid transported spraying water at the wiring harness or any of the electrical components To empty the system run the engine until the tank and the system is empty 2 Change the oil and oil filter while the engine is still warm from operation See Section 6 Change 4 Remove the spark plugs and add one tablespoon Oil and Oil Filter of engine oil into each spark plug hole Install the spark plugs but do not connect the plug leads 3 The fuel system must be completely emptied Crank the engine two or three revolutions or the gasoline must
146. ret EES 11 3 N m 100 in 1b Reval Anm Stud Torgue AV RE 11 3 N m 100 in Ib Recker Arm Valve Adjustment Jam Nut Torque v s c sisscasssssoisonnesaoosssssspenctinconsenna 7 3 N m 65 in Ib Rocker Arm alve Adjustment Setscrew Torque AVT ccccccssseesseeeeeees 7 9 N m 70 in Ib Fan Flywheel Piyw neci E Vr MEG npn n EA A acioanst 74 5 N m 55 ft Ib Governor Governor Cross Shaft to Crankcase Running Clearance esec 0 025 0 126 mm 0 0009 0 0049 in Governor Cross Shaft O D KSE 7 949 8 000 mm 0 3129 0 3149 in Mar VV a EU pssst eee EE E EEA S eae eee 7 936 mm 0 3124 in Governor Gear Shaft to Governor Gear Kavu Ey Dantas Ee 0 015 140 mm 0 0006 0 0055 in Governor Gear Shaft O D KI 5 990 6 000 mm 0 2358 0 2362 in IVA WEAN NaF E 5 977 mm 0 2353 in 1 10 Section 1 Safety and General Information Governor Continued Governor E AN Ke E 6 8 N m 60 in Ib ER Ignition park Plug Type Chanipion or Bergerie RC12YC XC12YC or Platinum 3071 Oe Eege 0 76 mm 0 030 in PTE en reagent E coca eterna E eeetessaae 24 4 29 8 N m 18 22 ft 1b Karten E ee EU 0 28 0 33 mm 0 011 0 013 in En ee ale Fastener et ET 4 0 6 2 N m 35 55 in Ib Muffler Muffler Fasteners Torque BV TIN e A E gad etatse E E E E E E A D 24 4 N m 216 in lb ea E e a E A ee er A E ee eee 16 9 N m 150 in 1b Oil Filter RN Ee Te EE 3 4 1 Turn After Gasket Contact Nipple Torque Oil Filter Qil Cooler laien 33 9 N m 300 in Ib Piston
147. rews to 6 2 N m 55 in Ib See Figure 10 32 Sealing Washer e a p Figure 10 30 Installed Breather Cover and RTV Z I S e z a e Details E FNE 4 Crankcase Recess Figure 10 32 Installing Stator 10 9 Section 10 Reassembly 4 Route the stator leads in the crankcase recess then install the backing plate Secure with the four hex flange screws See Figures 10 32 and 10 33 Torque the screws in the indicated sequence to 7 3 N m 65 in Ib Mounting Screws Figure 10 33 Installing Backing Plate Install Flywheel and Fan A WARNING Damaging Crankshaft and Flywheel Can Cause Personal Injury Using improper procedures to install the flywheel can crack or damage the crankshaft and or flywheel This not only causes extensive engine damage but can also cause personal injury since broken fragments could be thrown from the engine Always observe and use the following precautions and procedures when installing the flywheel NOTE Before installing the flywheel make sure the crankshaft taper and flywheel hub are clean dry and completely free of lubricants The presence of lubricants can cause the flywheel to be overstressed and damaged when the flange screw is torqued to specifications 10 10 1 Install the woodruff key into the keyway of the crankshaft Make sure that the key is properly seated and parallel with the shaft taper See Figure 10 34 NOTE Make sure the flywheel key is installe
148. ring gear teeth The bosses will lock the tool and flywheel in position for loosening tightening or removing with a puller Figure 2 1 Flywheel Holding Tool Rocker Arm Crankshaft Tool A spanner wrench to lift the rocker arms or turn the crankshaft may be made out of an old junk connecting rod 1 Find a used connecting rod from a 10 HP or larger engine Remove and discard the rod cap 2 4 Remove the studs of a Posi Lock rod or grind off the aligning steps of a Command rod so the joint surface is flat Find a 1 in long capscrew with the correct thread size to match the threads in the connecting rod Use a flat washer with the correct I D to slip on the capscrew and approximately 1 O D Kohler Part No 12 468 05 S Assemble the capscrew and washer to the joint surface of the rod as shown in Figure 2 2 Figure 2 2 Rocker Arm Crankshaft Tool Section 3 Troubleshooting Troubleshooting Guide When troubles occur be sure to check the simple causes which at first may seem too obvious to be considered For example a starting problem could be caused by an empty fuel tank Some general common causes of engine troubles are listed below Use these to locate the causing factors Refer to the specific section s within this service manual for more detailed information Engine Cranks But Will Not Start 1 Empty fuel tank Fuel shut off valve closed Poor fuel dirt or water in the fuel syst
149. s screw through the air cleaner base See Figures 5 5 and 5 6 5 7 Section 5 Fuel System and Governor NOTE The tip of the idle fuel adjusting screw is tapered to critical dimensions Damage to the needle end and the seat in the carburetor body will result if it is forced Low Idle Fuel iy Adjustment Some Models Low Idle Speed RPM Adjustment lixture d e i We Fe ebe SL p pams d ms Adjustment Screw Some Models wie Speed RPM Adjustment Screw Air Cleaner Element Figure 5 6 Carburetor Adjustment Screw Locations 2 Preliminary Settings Turn the adjusting screw out counterclockwise from lightly bottomed 2 1 4 turns 3 Start the engine and run at half throttle for 5 to 10 minutes to warm up The engine must be warm before making final settings Check that the throttle and choke plates can fully open NOTE If the carburetor has a self relieving choke the choke plate and shaft assembly is spring loaded Check to make sure the plate moves freely and is not binding affecting idle fuel delivery 5 8 4 Low Idle Speed Setting Place the throttle control into the idle or slow position Set the low idle speed to 1200 RPM 75 RPM by turning the low idle speed adjusting screw in or out Check the speed using a tachometer NOTE The actual low idle speed depends on the application Refer to the equipment manufacturer s recommendations The low idle speed for basic engi
150. start again with more hot water and detergent Following the scrubbing rinse the cylinder with very hot clear water dry it completely and apply a light coating of engine oil to prevent rusting Measuring Piston to Bore Clearance Before installing the piston into the cylinder bore it is necessary that the clearance be accurately checked This step is often overlooked and if the clearances are not within specifications engine failure will usually result NOTE Do not use a feeler gauge to measure piston to bore clearance it will yield inaccurate measurements Always use a micrometer Use the following procedure to accurately measure the piston to bore clearance 1 Use a micrometer and measure the diameter of the piston 6 mm 0 24 in above the bottom of the piston skirt and perpendicular to the piston pin See Figure 9 2 6 mm 0 24 in Measure 6 mm above the Bottom of Piston Skirt at Right Angles to Piston Pin Figure 9 2 Measuring Piston Diameter 2 Use an inside micrometer telescoping gauge or bore gauge and measure the cylinder bore Take the measurement approximately 63 5 mm 2 5 in below the top of the bore and perpendicular to the piston pin 3 Piston to bore clearance is the difference between the bore diameter and the piston diameter step 2 minus step 1 Section 9 Inspection and Reconditioning Flywheel Inspection Inspect the flywheel for cracks and the flywheel keyway for damage R
151. structions carefully Use a piston ring expander to 4 Before installing the new rings on the piston install rings see Figure 9 9 Install the place the top two rings each in turn in its bottom oil control ring first and the top running area in the cylinder bore and check the compression ring last Refer to Figure 9 10 end gap See Figure 9 7 Compare the ring gap to the measurments in Section 1 Specifications and Tolerances Piston Ring Piston Rin Expander Figure 9 9 Installing Piston Rings Figure 9 7 Measuring Piston Ring End Gap 5 After installing the new compression top and middle rings on the piston check the piston to ring side clearance Compare the clearance to specifications listed in Section 1 Specifications and Tolerances If the side clearance is greater than specified a new piston must be used Refer to Figure 9 8 9 9 Section 9 Inspection and Reconditioning Piston Ring Dykem End Gap Stripe Identification Compression Ring Center Compression Ring Ie ke Expander Oil Control Ring Three piece Figure 9 10 Piston Ring Installation 1 Oil Control Ring Bottom Groove Install the expander and then the rails Make sure the ends of the expander are not overlapped 2 Middle Compression Ring Center Groove Install the center ring using a piston ring expander tool Make sure the identification mark is up or the dykem stripe if contained is to the left
152. t Collar gt lt Drive End Cap e Drive Nut Collar Figure 7 29 Drive Components Inertia Drive Starter Armature 2 Grasp the spring retainer with a pliers and push it toward the starter compressing the anti drift spring to expose the retaining ring See Figure 7 29 3 Remove the retaining ring from the armature shaft using either a retaining ring pliers or snap ring removal tool Kohler Part No 25 761 18 S as described in Steps 4 and 5 See Figures 7 30 7 31 and 7 32 Do not reuse the old retainer Commutator End Cap with Brushes Figure 7 28 Inertia Drive Electric Starter Drive Service 1 The rubber dust cover has a molded lip on the inside that snaps over a lip on the front of the drive pinion See Figure 7 29 Turn the drive pinion clockwise until it reaches the fully extended position While holding it in the extended position grasp the tip of the dust cover with a pliers or vise grip and pull it free from the pinion Figure 7 30 Removing Retaining Ring with Pliers 7 24 4 Holding the spring retainer in the retracted position assemble the inner halves of the removal tool around the armature shaft with the retaining ring in the inner groove see Figure 7 31 Slide the collar over the inner halves to hold them in position Lag _ Y 4 F 8 e BW Figure 7 31 Assembling Inner Half of Removal Tool Around Armature Shaft and Retaining Ring 5 Thread the c
153. t gear at the 12 o clock position Turn the governor cross shaft clockwise until the lower end blade is laying against the bottom of the cylinder Make sure the cross shaft remains in this position while installing the camshaft See Figure 10 15 Slide the camshaft into the bearing surface of the crankcase positioning the timing mark of camshaft gear at the 6 o clock position Make sure the camshaft gear and crankshaft gear mesh with both timing marks aligned See Figure 10 15 Section 10 Reassembly Governor Cross Shaft Figure 10 15 Aligning Crankshaft and Camshaft Timing Marks Determining Camshaft End Play 1 Ifa camshaft shim was used install the shim removed during disassembly onto the camshaft 2 Position the camshaft endplay checking tool on the camshaft See Figure 10 16 Figure 10 16 Checking Camshaft End Play 3 Apply pressure on the endplay tool pushing camshaft toward crankshaft Use a feeler gauge to measure the camshaft endplay between the shim if used and the endplay tool Camshaft endplay should be 0 076 0 127 mm 0 003 0 005 in 10 5 Section 10 Reassembly 4 Ifthe camshaft endplay is not within the specified range remove the endplay tool and shim accordingly See Figure 10 17 Shims are color coded by thickness and listed below White 0 69215 0 73025 mm 0 02725 0 02875 in Blue 0 74295 0 78105 mm 0 02925 0 03075 in Red _0 79375 0 83185 mm 0 03125 0 03275
154. t on equipment with hydrostatic drive The transmission must be exactly in neutral to prevent resistance which could keep the engine from starting 2 Check for seized engine components such as the bearings connecting rod and piston Transmission or Engine Operation Inertia Drive Starters Starter Drive Service When power is applied to the starter the armature Every 500 hours of operation clean and lubricate the rotates As the armature rotates the drive pinion splines on the starter drive shaft If the drive pinion moves out on the drive shaft splines and into mesh is worn or has chipped or broken teeth it must be with the flywheel ring gear When the pinion reaches replaced See Figure 7 28 the end of the drive shaft it rotates the flywheel and cranks the engine When the engine starts the flywheel rotates faster than the starter armature and drive pinion This moves the drive pinion out of mesh with the ring gear and into the retracted position When power is removed from the starter the armature stops rotating and the drive pinion is held in the retracted position by the anti drift spring 7 23 Section 7 Electrical System and Components Dust Cover nN Dust Cover wf Retaining Ring e Spring Retainer gt Anti Drift Ride A Retaining D Ring Anti Drift Spring r Dust Cover A a Spacer Drive Pinion a R A N a A N X l N Drive Pinion Drive Nu
155. t the inlet and outlet fuel lines to the pump Route inlet hose through the fuel line clamp if used as shown and seat outlet hose in the blower housing clip See Figure 10 82 NOTE If anew fuel pump is being installed make sure the orientation of the new pump is consistent with the removed pump Internal damage may occur if installed incorrectly Outlet Hose Figure 10 83 Installed Drain Plug 2 Prefill a new oil filter following the instructions in Section 6 Lubrication System en a er ES yee AB Bag e te EAN T 7 I n Y ee ne Fuel Filter Clamp Inlet Fuel Line Figure 10 82 Fuel Pump Details 10 24 3 Apply a thin film of clean oil to the rubber gasket on the oil filter and thread it onto the adapter nipple See Figure 10 84 4 Hand tighten the filter until the rubber gasket contacts the adapter then tighten the filter an additional 3 4 1 turn Figure 10 84 Installing New Oil Filter 5 Add oil to bring the level up to the F Full mark Turn the oil fill cap dipstick counterclockwise until the oil fill cap drops down to the lowest point of the thread leads Do not thread the oil fill cap onto the tube See Figure 10 85 and 10 86 The oil level needs to be within the operating range See Figure 10 87 If low add oil of the proper type up to the full mark If oil is above F or FULL mark drain oil to reach proper level Reinstall the oil fill
156. t the spark test on the opposite cylinder if cylinders are being tested individually a If both cylinders have good spark but the engine runs poorly or existing plug s condition or appearance is questionable install new spark plugs gapped at 0 76 mm 0 030 in and retest engine performance If problem persists go to Test 3 b If one cylinder had good spark but the other cylinder had no spark or intermittent spark go to Test 4 c If there was spark on both cylinders but power is suspect go to Test 3 Test 3 Check for Timing Advance 1 Make a line near the edge of the flywheel screen with a marking pen or narrow tape See Figure 7 7 2 Connect an automotive timing light to cylinder that had good spark ee Flywheel Screen Mark Figure 7 7 Check For Timing Advance 3 Run the engine at idle and use the timing light beam to locate the line on the screen Draw a line on the blower housing next to the line on the screen Accelerate to full throttle and watch for movement of the line on the screen relative to the line on the blower housing If both cylinders had good spark repeat the test on the other cylinder See Figure 7 8 7 8 Figure 7 8 Check for timing advance a Ifthe line on the screen moved away from the line on the blower housing during acceleration the DSAI ignition module for the cylinder being tested is working properly If it didn t move away go to Test 4 b If you were able
157. tarter Servicing Kit A Starters SE Tools KLR 82411 To remove and reinstall drive retaining rings and brushes Individual Component Available SE Tools KLR 82416 Starter Brush Holding Tool Solenoid Shift SE Tachometer Digital Inductive Design Technology Inc For checking operating speed RPM of an engine DTI 110 Vacuum Pressure Tester Kohler 25 761 22 S Alternative to a water manometer 2 2 Section 2 Tools amp Aids Bids Dielectric Grease Fel Pro Electric Starter Drive Lubricant Inertia Drive Electric Starter Drive Lubricant Solenoid Shift RTV Silicone Sealant Kohler 25 597 07 S Loctite 5900 Heavy Body in 4 oz aerosol dispenser Only oxime based oil resistant RTV sealants such as those listed are approved for use Loctite Nos 5900 or 5910 are recommended for best sealing characteris tics Loctite 5910 Loctite Ultra Black 598 Loctite Ultra Blue 587 Loctite Ultra Copper Spline Drive Lubricant Kohler 25 357 12 S 2 3 Section 2 Tools amp Aids Special Tools You Can Make Flywheel Holding Tool A flywheel holding tool can be made out of an old junk flywheel ring gear as shown in Figure 2 1 and used in place of a strap wrench 1 Using an abrasive cut off wheel cut out a six tooth segment of the ring gear as shown 2 Grind off any burrs or sharp edges 3 Invert the segment and place it between the ignition bosses on the crankcase so that the tool teeth engage the flywheel
158. the O Rings Push in until seated into the outlet of oil pump Make sure the inner O Ring is not unseated or damaged when installing See Figure 10 20 Oil Pump Outlet Figure 10 22 Oil Filter Adapter and O Ring 5 Position the adapter aligning the locating pin with the corresponding recess in oil pan Install the flat washer plastic adapters only onto the adapter nipple then insert through the adapter surrounding the oil feed tube and finger tighten See Figures 10 23 and 10 24 Tighten the nipple Figure 10 20 Installing Oil Pump Outlet Tube 3 Slide the oil feed tube through the oil pan and into the hole for the main bearing See Figure d t to 33 9 N m 300 in 1b Do not 10 21 A small amount of grease applied to the ee nes On eae outside forward end of the tube will hold the tube in position until the adapter is installed overtighten Figure 10 21 Installing Oil Feed Tube 4 Apply asmall amount of grease and install a new O Ring into the groove of the adapter for oil filter or oil cooler See Figure 10 22 Figure 10 24 Torquing Nipple 10 7 Section 10 Reassembly Install Oil Pan Assembly RTV sealant is used as a gasket between the oil pan and the crankcase Refer to Section 2 Special Tools for a listing of approved sealants Always use fresh sealant Using outdated sealant can result in leakage 1 Be sure the sealing surfaces have been cleaned and prepared as described at the beginn
159. the input coil of the ignition module L1 Figure 7 5 is fed to the input of the conditioning circuit The conditioning circuit shapes this pulse putting it in a useable form for the additional circuits This pulse starts the charge pump which charges a capacitor in a linear fashion that is directly related to the engine speed At the same time the pulse resets the delay circuit for the length of the pulse width The capacitor is off during this period and no output is generated As soon as the original pulse drops back to zero the capacitor in the delay circuit begins to charge 7 9 Section 7 Electrical System and Components VIOLET ORANGE ORANGE RED CONNECTOR ORANGE GROUND YELLOW EEN SOLENO l D T UHI CARBURETOR RE A ASS Y ail SOLENOID i d SPARK PLUG OPTIONAL ui i aer 1 CYLINDER OLARITY RIB iP IGNITION ai MODULE L ii FLYWHEEL VIOLET e A STATOR ORANGE i i i ASS Y Q ORANGE PINK TRIGGER BROWN ii RECTIFIER AC CHARGING HU LEADS OIL PRESSURE Ge SWITCH ffi SPARK PLUG 2 CYLINDER Ee bh H REGULATOR I i EE CONNECTOR GREEN D u n 11 u 11 11 i Ge BLOCK VIOLET CHARGING Figure 7 9 Digital Spark Advance Module DSAM Ignition System The timing of the spark is controlled by the location of the flywheel magnet group as referenced to engine top dead center and the delay created by the spark
160. the pump before removing 1 Disconnect the fuel lines from the inlet outlet and pulse fittings on fuel pump 2 Remove the two mounting screws and take off the pump 3 Connect the pulse line to the new fuel pump and make sure opposite end is properly connected into valve cover NOTE Make sure the orientation of the new pump is consistent with the removed pump Internal damage may occur if installed incorrectly 4 Attach the new fuel pump using the hex flange screws Torque the screws to 2 3 N m 20 in Ib 5 Connect the fuel lines to the inlet and outlet fittings and secure with the clamps Carburetor General Engines in this series are equipped with either a Keihin or Nikki fixed main jet carburetor Most carburetors utilize a fuel shut off solenoid and feature a self relieving choke These carburetors include three main circuits which function as follows Float Circuit The fuel level in the bowl is maintained by the float and fuel inlet needle The buoyant force of the float stops fuel flow when the engine is at rest When fuel is being consumed the float will drop and fuel pressure will push the inlet needle away from the seat allowing more fuel to enter the bowl When demand ceases the buoyant force of the float will again overcome the fuel pressure and stop the flow 5 3 Section 5 Fuel System and Governor Slow Circuit See Figure 5 2 At low speeds the engine operates only on the slow circuit As
161. the switch into the tapped hole in the adapter See Figure 6 9 3 Torque the switch to 4 5 N m 40 in Ib Testing the Switch Compressed air a pressure regulator pressure gauge and a continuity tester are required to test the switch 1 Connect the continuity tester across the blade terminal and the metal case of the switch With 0 psi pressure applied to the switch the tester should indicate continuity switch closed 2 Gradually increase the pressure to the switch As pressure increases through the range of 3 0 5 0 psi the tester should indicate a change to no continuity switch open The switch should remain open as the pressure is increased to 90 psi maximum 3 Gradually decrease the pressure through the range of 3 0 5 0 psi The tester should indicate a change to continuity switch closed down to 0 psi 4 Replace the switch if it does not operate as specified Section 7 Electrical System and Components This section covers the operation service and repair of the electrical system components Systems and components covered in this section are e Spark Plugs e Battery and Charging System e Electronic CD Ignition System e Electric Starter Spark Plugs Engine misfire or starting problems are often caused by a spark plug that has improper gap or is in poor condition The engine is equipped with the following spark plugs The standard spark plug is a Champion RC12YC Kohler Part No 12 132 02 S
162. tion The engine should kill completely If not or only one cylinder is affected go to Test 4 but also check the white kill harnesses from the engine and equipment are lead connection for the affected DSAI module joined Separate the connectors and remove the white kill lead from the engine connector Rejoin the connectors and position or insulate the kill lead terminal so it cannot touch ground Try to start the engine to verify whether the reported problem is still present Test 2 Test for Spark 1 With the engine stopped disconnect one spark plug lead Connect the spark plug lead to post terminal of spark tester Kohler Part No 25 455 01 S and attach tester clip to a good engine ground NOTE Ifthe engine starts or runs during any of the testing you may need to ground the kill lead to shut it down Because you have inturrepted the kill circut it may not stop using the switch NOTE If two testers are available testing can be performed simultaneously for both cylinders However if only one tester is available two individual tests must be performed The side not being tested must have the spark plug lead connected or grounded Do not crank the engine or perform tests with one spark plug lead disconnected and not grounded or permanent system damage may occur T T Section 7 Electrical System and Components 2 Crank the engine over establishing a minimum of 550 600 RPM and observe tester s for spark 3 Repea
163. to check timing on both cylinders the lines you made on the blower housing should be 90 apart If not go to Test 4 Test 4 Test the Ignition Modules and Connections 1 Remove the blower housing from the engine Inspect the wiring for any damage cuts bad crimps loose terminals or broken wires Check that connections are oriented properly on terminals of modules 2 Disconnect the leads from the ignition module s and clean all of the terminals male and female with aerosol electrical contact cleaner to remove any old dielectric compound dark residue dirt or contamination Disconnect the spark plug leads from the spark plugs 3 Using a multi meter check that a proper ground is established between the ground black lead of the DSAI module closest to spark plug lead and a known good ground location on the engine Section 7 Electrical System and Components 4 Turn the key switch to the ON position and When the charge on the delay capacitor exceeds the check for 12 volts at the center power red lead charge on the charge pump capacitor the capacitor terminal of the DSAI module Use the same changes state activating the pulse generator ground location for the multi meter as in Step 3 This pulse turns ON the CD ignition module a If all tests are OK and module has no spark or semi conductor Energy is then transferred to the fails to advance replace the affected module secondary output transformer T1 F
164. u feel the retaining ring snap into the groove Disassemble and remove the tool Squeeze the retaining ring with a pliers to compress it into the groove Assemble the inner halves with the larger cavity around the spring retainer see Figure 7 34 Slide the collar over them and thread the center screw in until resistance is felt 7 29 Section 7 Electrical System and Components Figure 7 34 Assembling Larger Inner Half Around Spring Retainer 6 Hold the base of the tool with a 1 1 8 wrench and turn the center screw clockwise with a 1 2 or 13 mm wrench to draw the spring retainer up around the retaining ring Stop turning when resistance increases Disassemble and remove the tool 7 Reinstall the dust cover Starter Disassembly 1 Remove the drive components following the instructions for servicing the drive 2 Remove the thru bolts 3 Remove the commutator end cap containing the brush holder brushes brush springs and thrust washer cup 4 Remove the drive end cap 5 Remove the armature from inside the starter frame End Cap Brush Replacement The brushes are contained in a plastic carrier housing attached to the end cap Replacement brushes in the brush holder come preassembled attached to the end cap with the commutator end thrust washer cup holding the brushes in the retracted position When installation is performed the end of the armature shaft will push the thrust washer cup back into
165. ull 89 angle will achieve the desired 0 5 1 0 full cut interference angle where the maximum pressure occurs on the outside diameters of the valve face and seat Section 9 Inspection and Reconditioning Valve Seat Cutter Figure 9 5 Typical Valve Seat Cutter Lapping Valves Reground or new valves must be lapped in to provide fit Use a hand valve grinder with suction cup for final lapping Lightly coat valve face with fine grade of grinding compound then rotate valve on seat with grinder Continue grinding until smooth surface is obtained on seat and on valve face Thoroughly clean cylinder head in soap and hot water to remove all traces of grinding compound After drying cylinder head apply a light coating of SAE 10 oil to prevent rusting Intake Valve Stem Seal Some engines use valve stem seals on the intake valves Always use a new seal when the valves are removed from the cylinder head The seals should also be replaced if deteriorated or damaged in any way Never reuse an old seal Pistons and Rings Inspection Scuffing and scoring of pistons and cylinder walls occurs when internal engine temperatures approach the welding point of the piston Temperatures high enough to do this are created by friction which is usually attributed to improper lubrication and or overheating of the engine Normally very little wear takes place in the piston boss piston pin area If the original piston and connecting ro
166. und the commutator and install the cutout if it was removed previously See Figure positive brush lead grommet in the cutout ECH of the frame See Figure 7 61 The protective tube may be saved and used for future servicing Figure 7 59 Installing Frame and Drain Tube 9 Install the flat thrust washer onto the commutator Figure 7 61 Installing Brush Holder Assembly with end of the armature shaft See Figure 7 60 Supplied Tube Starter reassembly when not replacing the Brushes Brush Holder Assembly a Carefully unhook the retaining caps from over each of the brush assemblies Do not lose the springs 7 33 Section 7 Electrical System and Components Figure 7 62 Removing Retaining Clips b Position each of the brushes back in their slots CH so they are flush with the I D of the brush holder assembly Insert the Brush Installation Tool with extension or use the tube described above from a prior brush installation through the brush holder assembly so the holes in the metal mounting clips are up out Install the brush springs and snap on the four retainer caps See Figure 7 63 Figure 7 63 Brush Installation Tool with Extension d 7 34 Hold the starter assembly vertically on the end housing and carefully place the tool with extension and assembled original brush older assembly onto the end of the armature shaft Slide the brush holder assembly down into place around the comm
167. ure 7 23 This does not represent the condition of the part Section 7 Electrical System and Components 6 Press the TEST button until a click is heard and b If any other light is displayed in either of the then release See Figure 7 24 Momentarily one tests the rectifier regulator is faulty and of the four status lights will illuminate indicating should not be used the partial condition of the part NOTE A flashing LOW light can also occur as a If the OK green light comes on disconnect a result of an inadequate ground lead the tester black lead attached to one AC connection Make certain the connection terminal and reconnect it to the other AC location is clean and the clamp is secure terminal Repeat the test If the OK green light comes on again the part is good and may be used Rectifier Regulator Flywheel Stator Ammeter Battery Figure 7 27 Connections for Testing Charging System 15 amp 25 amp Battery Charging Systems When problems occur in keeping the battery charged NOTE Always zero ohmmeter on each scale before or the battery charges at too high a rate the problem testing to ensure accurate readings Voltage can usually be found somewhere in the charging tests should be made with the engine running system or with the battery at 3600 RPM no load The battery must be good and fully charged 7 21 Section 7 Electrical System and Components Trace B lead from rectifier regulator to key s
168. ure 7 37 Installing and Torquing Thru Bolts 6 Lubricate the drive shaft with Kohler starter drive lubricant Kohler Part No 52 357 01 S Install the drive components following the instructions for servicing the starter drive solenoid Shift Electric Starters The following subsection covers the Delco Remy solenoid shift electric starter Much of the information in the proceeding subsection relates to this type starter also so it is not repeated here Operation Solenoid Shift Starter When power is applied to the starter the electric solenoid moves the drive pinion out onto the drive shaft and into mesh with the flywheel ring gear When the pinion reaches the end of the drive shaft it rotates the flywheel and cranks the engine When the engine starts and the start switch is released the starter solenoid is deactivated the drive lever moves back and the drive pinion moves out of mesh with the ring gear into the retracted position Section 7 Electrical System and Components Delco Remy Starters Figure 7 38 Delco Remy Starter Starter Disassembly 1 Remove the hex nut and disconnect the positive brush lead bracket from the solenoid terminal 2 Remove the three Torx head screws securing the solenoid to the starter See Figure 7 39 Torx Head Screws Figure 7 39 Removing Solenoid Screws 3 Unhook the plunger pin from the drive lever Remove the gasket from the recess in the housing See Figures 7 40
169. use fires and severe acid burns Charge battery only in a well ventilated area Keep sources of ignition away Explosive Gas Batteries produce explosive hydrogen gas while being charged To prevent a fire or explosion charge batteries only in well ventilated areas Keep sparks open flames and other sources of ignition away from the battery at all times Keep batteries out of the reach of children Remove all jewelry when servicing batteries Before disconnecting the negative ground cable make sure all switches are OFF If ON a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or gasoline vapors are present Section 1 Safety and General Information Engine Identification Numbers When ordering parts or in any communication involving an engine always give the Model Specification and Serial Numbers including letter suffixes if there are any The engine identification numbers appear on a decal or decals affixed to the engine shrouding See Figure 1 1 An explanation of these numbers is shown in Figure 1 2 Identification Decal Figure 1 1 Engine Identification Decal Location A Model No SV 730 S Courage Engine 1 SE TEE Code Vertical Crankshaft S Electric Start Numerical Designation V730 0001 Engine Model Code Complete Spec Number Incorporating Model No with Variation No of Basic Spec C Serial No 3505810334 Year Manufactured Co
170. utator install the positive brush lead grommet in the cutout of the frame See Figure 7 64 i 9 SE Si y Figure 7 64 Installing Brush Holder Assembly using Tool with Extension 11 Install the end cap onto the armature and frame aligning the thin raised rib in the end cap with the corresponding slot in the grommet of the positive brush lead 12 Install the two thru bolts and the two brush holder mounting screws Torque the thru bolts to 5 6 9 0 N m 49 79 in 1b Torque the brush holder mounting screws to 2 5 3 3 N m 22 29 in lb See Figures 7 65 and 7 66 Figure 7 65 Torquing Thru Bolts Figure 7 66 Torquing Brush Holder Screws 13 Hook the plunger behind the upper end of the drive lever and install the spring into the solenoid Insert the three mounting screws through the holes in the drive end cap Use these to hold the solenoid gasket in position then mount the solenoid Torque the screws to 4 0 6 0 N m 35 53 in Ib 14 Connect the positive brush lead bracket to the solenoid and secure with the hex nut Torque the nut to 8 11 N m 71 97 in 1b Do not overtighten See Figure 7 67 Figure 7 67 Positive Brush Lead Connection Section 7 Electrical System and Components Solenoid Test Procedure Solenoid Shift Style Starters Disconnect all leads from the solenoid including the positive brush lead attached to the lower stud terminal Remove the mounting ha
171. ve oil leakage can indicate a clogged or improperly assembled breather worn damaged seals and gaskets or loose or improperly torqued fasteners Check the air cleaner cover and base for damage or indications of improper fit and seal Check the air cleaner element Look for holes tears cracked or damaged sealing surfaces or other damage that could allow unfiltered air into the engine Also note if the element is dirty or clogged These could indicate that the engine has been under serviced Check the carburetor throat for dirt Dirt in the throat is further indication that the air cleaner is not functioning properly Check the oil level Note if the oil level is within the operating range on the dipstick or if it is low or overfilled e Check the condition of the oil Drain the oil into a container the oil should flow freely Check for metal chips and other foreign particles Sludge is a natural by product of combustion a small accumulation is normal Excessive sludge formation could indicate overrich carburetion weak ignition overextended oil change intervals or wrong weight or type of oil was used to name a few NOTE It is good practice to drain oil at a location away from the workbench Be sure to allow ample time for complete drainage Cleaning the Engine After inspecting the external condition of the engine clean the engine thoroughly before disassembling it Also clean individual components as the engine is
172. verfill the battery Poor performance or early failure due to loss of electrolyte will result Section 7 Electrical System and Components 2 Keep the cables terminals and external surfaces of the battery clean A build up of corrosive acid or grime on the external surfaces can cause the battery to self discharge Self discharge occurs rapidly when moisture is present 3 Wash the cables terminals and external surfaces with a mild baking soda and water solution Rinse thoroughly with clear water NOTE Do not allow the baking soda solution to enter the cells as this will destroy the electrolyte Battery Test To test the battery you will need a DC voltmeter Perform the following steps see Figure 7 2 1 Connect the voltmeter across the battery terminals 2 Crank the engine If the battery drops below 9 volts while cranking the battery is too small discharged or faulty DC Voltmeter lt lt Figure 7 2 Battery Voltage Test 7 3 Section 7 Electrical System and Components Electronic Ignition Systems There are three different types of ignition systems used on the Courage twin cylinder engines All systems use an ignition module which energizes the spark plug The difference in the system is in the way the ignition timing is triggered The Fixed Ignition System utilizes a Capacitive Discharge CD coil See Figure 7 3 This is a basic ignition system that uses a fixed ignition module where the i
173. w battery and mount the battery to the case with double backed tape Reinstall the faceplate and secure with the four screws Battery Charging System General Most engines are equipped with a 15 amp regulated charging system Some have a 25 amp regulated charging system See Figure 7 16 7 17 and 7 18 for the wiring charging system diagrams of ignition systems NOTE Observe the following guidelines to avoid damage to the electrical system and components e Make sure the battery polarity is correct A negative ground system is used e Disconnect the rectifier regulator plug and or the wiring harness plug before doing any electric welding on the equipment powered by the engine Also disconnect all other electrical accessories in common ground with the engine e Prevent the stator AC leads from touching or shorting while the engine is running This could damage the stator 7 15 Section 7 LEI RG OU O4AINWW 2 IN Y30N1749 I YOLOANNOD SN Id AYVdS IWNOI1dO0 TVNOILd0 HOLIMS SYNSSSY d 110 TVNOI Lei N3349 A SSV YSLYVLS L4IHS GION370S l SUR SE EE 1 AEN YSLYVLS 1 BSAIMO VILYSNI NI YYH 13701A i i I Y3ON17AI Ze i 991d MINA i ONVL V31 NI YVH DV a J GION310S 3LIHM IM H3LHN LS 490718 4O LOSNNOD HOLY 1N9SY bans al I EE GE Te 1 27719 Onis N GIONS10S i 1 ySLYV1S i i i i TUN NOILIN I 4 3LIHM SS LE i ON
174. whenever the valve is removed or if the seal is 3 Once the valve spring is compressed remove the deteriorated or damaged Never reuse following items See Figures 8 33 and 8 34 an old seal 4 Repeat the above procedure for the other cylinder head Do not interchange parts from one cylinder head to the other e Valve spring keepers e Valve spring retainers e Valve springs e Valve spring caps Remove Grass Screen Fan and Flywheel e Intake and exhaust valves mark position 1 Unsnap the grass screen from the cooling fan See e Valve stem seal intake valve some models Figure 8 35 Retainer Figure 8 35 Removing Grass Screen Keepers Figure 8 33 Valve Components NOTE Always use a flywheel strap wrench or flywheel holding tool see Section 2 Special Tools to hold the flywheel when loosening or tightening the flywheel and fan retaining fasteners Do not use any type of bar or wedge between the fins of the cooling fan as the fins could become cracked or damaged 8 9 Section 8 Disassembly 2 Remove the retaining screw washer and the fan mounting plate securing the fan and flywheel to the crankshaft See Figure 8 36 Figure 8 36 Removing Fan and Flywheel Mounting Hardware 3 Carefully lift the cooling fan to disengage the two drive pins and remove it from the flywheel 4 Remove the flywheel from the crankshaft using a puller See Figure 8 37 NOTE Always use a puller to remove the
175. witch or other accessible connection Disconnect it from switch or connection Connect an ammeter from loose end of B lead to positive terminal of battery Connect DC voltmeter from loose end of B lead to negative terminal of battery With engine running at 3600 RPM read voltage on voltmeter If voltage is 13 8 volts or more place a minimum load of 5 amps on battery to reduce voltage Observe ammeter NOTE Turn on lights if 60 watts or more Or place a 2 5 ohm 100 watt resistor across battery terminals No Charge Remove connector from rectifier regulator to Battery With engine running at 3600 RPM measure AC voltage across stator leads using an AC voltmeter With engine stopped measure the resistance across stator leads using an ohmmeter With the engine stopped measure the resistance from each stator lead to ground using an ohmmeter Perform same test as step 1 above Battery Continuously Charges at High Rate Electric Starting Motors NOTE These engines may use either an inertia drive or solenoid shift style electric starter The inertia drive starter is covered first and the solenoid shift following Starting Motor Precautions NOTE Do not crank the engine continuously for more than 10 seconds at a time If the engine does not start allow a 60 second cool down period between starting attempts Failure to follow these guidelines can burn out the starter motor 7 22 1 If voltage is 13 8 14 7 an

Courage Sv710-740

Contents

Download Pdf Manuals

Related Search

Related Contents