Home

Koher Engines - Model K361 Service Manual

Contents

1. 4 9 Idle Speed Adjustment 4 9 lgnitlon RR ERE ees 5 15 Ignition Coil ssim iex eee C YO en e ew ron E esr e e o 17 Ignition Coil and Baffling Installation TM d B 43 Ignition Coil Check we 5 17 Ignition System Operational 5 15 Ignition System Service 5 15 Ignitlon Timing does IA CREAR ad Weide e a ves 25 18 Static Method sre da a wane s A O 19 Timing Light 5 19 Main Fuel Adjustment iii ds a 4 9 A ener aet en eme Sn a9 TN 3 Oil ees B 40 Oil skye 71 3 Oil Seals iis aaa AO 40 E or E T Varese aie veas d 3 Pistons and Rings Inspection and Service i 32 Piston and Rod 8 39 Push Rods and Tubes Assembly VENUES 8 41 Ring TAN 5 24 Rocker Arm Assembly and Valve Adjustment 8 41 Safety Warnings 1 2 Service S
2. 0 2 22 008 030 0 203 0 762 mm WEAR TOLERANCES Cylinder Bore New Diameter scarico ERE NE NAR e Yu y eh Ro 3 750 95 25 mm Cylinder Bore Maximum Wear Diameter 3 753 95 33 mm Cylinder Bore Maximum Taper 2 4 2 0015 0 038 mm Cylinder Bore Maximum Out of Round 2 005 0 127 mm Crankshaft Crankpin New Diameter 0 2 22 1 500 38 1 mm Crankshaft Crankpin Maximum Out of Round 0005 0 013 mm Crankshaft Crankpin Maximum Taper 0 0 0 02 001 0 025 mm Connecting Rod Big End Maximum Diameter 1 5025 38 164 mm Piston Thrust Face Maximum Wear Diameter 3 7425 85 060 mm Valve to Guide Maximum Clearance 1 0065 0 165 mm All dimensions in inches unless stated otherwise 47 TORQUE SETTINGS Special Spark Plug ft lbs Cylinder Head ft lbs 18 22 24 30 Nm 2 5 3 1 Kgm 30 35 41 48 Nm 4 2 4 9 Kgm Gonnecting Rod OS bi a A a o AA aa 300 34 Nm 3 5 Kgm Flywheel Nut ft lbs 60 70 81 95 Nm 8 3 9 7 Kgm Grass Screen Screws
3. 0005 002 0 013 0 051 mm Piston to Cylinder Bore Clearance Thrust Face Bottom of Skirt 0030 0045 0 076 0 114 mm Piston to Cylinder Bore Clearance Thrust Face Top of Skirt 007 0095 0 178 0 241 mm Bearing Plate to Cylinder Block Pilot Clear 001 005 0 025 0 127 mm Ball Bearing to Cylinder Block Interference Fit 0006 0022 0 015 0 056 mm Ball Bearing to Bearing Plate Interference Fit 84 0012 0028 0 030 0 071 mm Ball Bearing to Crankshaft 2 Interference 0004 0 010 mm Loose 0005 0 013 mm Valve Clearance Intake Cold 005 0 13 mm Valve Clearance Exhaust Cold 4 2 2 005 0 13 mm Spark Plug Gap Breaker Point Gap Nominal ASES 035 0 89 mm TO 020 0 51 mm Spark Timing In Degrees ors riad serie hare hee re ed id AA a a i a da ada 20 B T D C Starter Pinion to Ring Gear Backlash 005 025 0 127 0 635 mm Governor Cross Shaft End Play 005 030 0 127 0 762 mm Gear Reduction Shaft End Play
4. 7 27 Engine General Inspection 7 27 Engine Shutdown Control Fix 4 12 Engine Shutdown Control Function 4 12 Engine Tests 2 6 Exhaust and Intake Manifolds 8 40 Exterior Engine Components 7 27 8 42 Fuel PUMP cise e ev ecu cre emma mper ei hd rum edi da ate da a eB ca rd 4 12 SUBJECT SECTION PAGE Fuel Recommendations as OF 3 Fuel cnn iaa 4 9 General Information 1 1 General Specifications S 4 1 General Specifications sw 9 47 Grass Screen Installation 8 45 Governor Adjustments 4 13 Governor Arm and Carburetor Assembly 44 Governor Gear Removal dec T 35 Governor Gear Assembly 8 37 Governor E 13 Governor System een 4 13 Idle Fuel Adjustment
5. 2 Use only the gasket provided in the kit If a thick in sulating gasket was used with the metal pump discard it It is not only unnecessary but could cause distor tion of the flange while tightening the mounting cap screws 3 Make sure the flat washers provided in the kits are in stalled next to the flange to prevent the lockwasher from damaging the flange The lockwashers and mounting screws from the old pump can be reused with the new pump but make sure the screws are tightened to 70 in Ibs overtightening can also damage the flange GOVERNOR SYSTEM The K361 engine is equipped with a centrifugal flyweight mechanical governor The governor gear flyweight me chanism is mounted within the crankcase and driven offa gear on the camshaft Governor Operation Centrifugal force causes the flyweights to move outward with increase in speed and inward with decreasing speed As the flyweights move outward they force the rod por tion of the assembly to push outward Tension of the gov ernor spring pulls the flyweights back inward with de crease in engine speed The rod in turn contacts a tab on the governor cross shaft causing it to rotate with chang ing speed One end of the cross shaft protrudes through the side of the crankcase Through externai linkage the action of the cross shaft is transmitted to the throttle or butterly valve in the carburetor When the engine is at rest with throttle in Fast position the tens
6. IDS 2 2 115 13 Nm 1 3 Kgm Fuel Pump Screws Plastic Pump 169 2 2 70 8 Nm 8 Kgm Lubricate with oil at assembly General CONVERSIONS Tightening Torque Into Cast tron or Steel in Ibs x 083 ft Ibs ft lbs x 12 in Ibs Size Grade 2 Grade 5 Grade 8 ft lbs x 1383 kgm 8 32 20 in Ib 25 in Ib ft Ibs x 1 3558 Nm 10 24 32 in Ib 40 in Ib 10 32 32 in Ib 32 in Ib 1 4 20 70 in Ib 115 in Ib 165 in Ib 1 4 28 85 in Ib 140 in Ib 200 in Ib 5 16 18 150 in Ib 250 in Ib 350 in Ib 5 16 24 165 in tb 270 in Ib 30 ft Ib 3 8 16 260 in Ib 35 tt Ib 50 ft ib 3 B 24 300 in Ib 40 ft tb 60 ft Ib 7 16 14 35 ft Ib 55 ft Ib 80 ft Ib 7 16 20 45 ft Ib 75 ft Ib 105 ft Ib 1 2 13 50 ft Ib 80 ft Ib 115 ft Ib 1 2 20 70 ft Ib 105 ft Ib 165 ft Ib 9 16 12 75 ft ib 125 ft Ib 175ft Ib 9 16 18 100 ft Ib 165 ft Ib 230 ft Ib 5 8 11 110 ft Ib 180 ft lb 260 ft Ib 5 8 18 140 ft lb 230 ft Ib 330 ft Ib 3 4 10 150 ft Ib 245 ft Ib 350 ft Ib 3 4 16 200 ft Ib 325 tt Ib 470 ft Ib Tightening Torque Into Aluminum Size Grade 2 Grade 5 8 32 20 in Ib 20 in Ib 10 24 32 in Ib 32 in Ib Figure 9 1 Headbolt Torque Sequence 1 4 20 70 in Ib 70 in Ib 5 16 18 150 in Ib 150 in Ib 48 SPECIAL TOOLS Dimension
7. 3 3 4 95 mm 3 1 4 83 mm Displacement Cubic Inches 2 35 89 588 cc Horsepower at 3600 RPM 2 4 18 13 4 kw Weight Approximate Pounds 2 2 0 27 2 124 55 8 kg Hi Capacity 0 8 Quarts o eise a SOLE s ULT SO GLa VU Reo D OG RR 2 1 9 1 Spark Plug Gap Standard Spark Plug Gap Resistor Guid ERG dad 035 0 89 mm AN 035 0 89 mm Spark Plug Size Millimeters 5 e hentia td 14 Breaker Point Gap Nominal 2 2 2 020 508 mm TOLERANCES PARTS FITTED Balance Gear End Play 002 010 0 051 0 254 mm Crankshaft Free End Play ene tni oo Pus te dies ones a Fra a Cen EUER 003 020 0 076 0 508 mm Crankshaft Connecting Rod Journal Size 1 5000 1 4995 38 100 38 087 mm Connecting Rod to Crankpin Running Clearance 001 002 0 025 0 051 mm Connecting Rod Side Play on Crankpin Connecting Rod to Wrist Pin peg tds 007 0175 0 178 0 444 mm 0003 0008 0 008 0 020 Wrist Pin to Pisto
8. 12mm diameter drift punch press guide into head until clip ring bottoms out in head See figure 3 5 Machine down the exhaust port guide to be flat with the aluminum machined surface using a drill Intake Valve 22222222 press and a 11 16 6875 17 5mm diameter spotface Do not machine further than the alum inum surface 6 Finish ream the guide using a 5 16 3125 reamer Position the valves in the head and check for proper seating If necessary rework seats Exhaust Valve Seal Installation 1 Place valve guide seal on guide pressing only on metal band of seal See figure 3 CAUTION Press ONLY on metal band when install ing valve guide seal Pressing on teflon body or spring will distort seal and result in seal failure Assemble and install cylinder head as explained in the service manual Valve Guide e Seal 7 Metal Band Valve Seats FIGURE 3 KOHLER 154 ames service i A bulletin UE HOUSING GA HOUSING GASKET ISSUE DATE REVISION DATE 10 82 K361 ROCKER ARM HOUSING GASKET A new rocker arm housing gasket has been designed for the K361 overhead valve engine This gasket will prevent oil leakage between the rocker arm housing and the cylinder head Kohler part No 45 041 14 has been assigned to the new gasket which replaces old gaskets 45 041 08 and 45 041 13 Refer to Parts Bulletin No 126 for disposition of stock Use the following procedure to install the
9. ata temperature of about 75 F As the temperature decreases the choke valve will close even more 5 Check choke function by removing the spark plug lead and cranking the engine The choke valve should close a minimum of 45 at a temperature about 75 F The valve will close more at lower temperatures Engine Shutdown Control Function The engine shutdown control is a device which prevents the engine from running on after the ignition is turned off This is accomplished by a solenoid operated valve which is energized when the ignition is turned on caus ing the valve to open In this open position normal bowl venting is permitted from the air cleaner to the air space above the fuel in the bowl When the ignition is turned off the valve closes and normal bowl venting is prohibited and no fuel will flow The engine shutdown control has only one wire and it is connected to the positove terminal on the ignition coil In order to make the control effective the throttle lever should not be in the OFF or IDLE position when the igni tion switch is turned off Shut down Control Test Disconnect shut down control from carburetor body by loosening the main fuel adjusting screw so the bracket that holds the control can be shifted from it Do not dis connect the lead wire from the ignition coil Pull the shut down control solenoid and plunger out of the carbure tor and ground the case of the solenoid on the carburetor or other c
10. bearing is straight and true in bore and bottomed prop erly If cocked crankshaft end play will be adversely af fected Crankshaft end play is determined by thickness of gas kets used between block and bearing plate Initial use of one 020 and one 010 gasket should bring end play within limits this must be checked after bearing plate is installed Install with thicker gasket next to block see Figure 8 7 Place bearing plate on crankshaft and carefully press plate onto shaft and into position on block Install re taining capscrews and lockwashers and secure bear ing plate to block Draw screws up evenly to avoid dis tortion of bearing plate PISTON AND ROD ASSEMBLIES 1 Lubricate piston pin then assemble piston to connect ing rod and secure piston pin with retainer rings Al ways use new retainer rings Be sure retainer rings are fully engaged in grooves in piston bosses Ring instal lation procedure described on page 32 2 After making sure rings are in proper position in cor rect grooves oil complete assembly stagger ring gaps so they are not in line and insert complete assembly into cylinder bore Be sure connecting rod match mark is toward flywheel side of engine Use a ring compres sor to prevent ring breakage during installation Gent ly push piston into bore with wooden or plastic ham mer handle Do Not Pound see Figure 8 9 NOTE 1020 gt crankshaft to prevent rod from
11. dipstick before inserting it all the way into the tube then remove the dipstick to observe the level En gine must be level for accurate reading Bring the oil level up into the SAFE range but do not exceed the F mark NOTE overfiling can cause engine to overheat K361A engine models have a 1 1 2 quart 1 4 li ters capacity FUEL RECOMMENDATIONS WARNING Explosive Fuel Gasoline is extremely flammable and its vapors can explode is ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from fiamss P General Recommendations Purchase gasoline smali quantities and store in clean approved containers A container with a ca pacity of 2 galons or lass with a pouring spout is recommended Such a container is easier ic handle anc helps eliminate spoilage during refueling Do not use gasoline left over from the previous sea son to minimize gum deposits in your system and to insure easy starting Do not add oil to the gasoline Do not overfill the fuel tank Leave room for the fuel to expand Fuel Type For best results use only clean fresh unleaded gasoline with a pump sticker octane rating of 87 or higher In countries using the Research method it should be 90 octane minimum Unleaded gasoline is recommended as it leaves less combustion chamber deposits Leaded gaso line may be used in areas where unleaded is not available and
12. 6 Point Gap Adjustment Method 2 Timing Light Several different types of timing lights are available fol low manufacturer s instructions for type used The fol lowing timing procedure can be used with most timing lights A Remove high tension lead at spark plug wrap one end of a short piece of fine wire around spark plug termi nal Reconnect lead to terminal free end of wire must protrude from under boot NOTE Step A tor timing lights with alligator clips some lights have sharp prongs on spark lead on these simply push prong through boot until it contacts metal connector B Connect one timing light ead to the wire that has just been wrapped around spark plug terminal C Connect second timing light ead to hot ungrounded side of battery see timing light instructions for bat tery size wiring etc Connect third timing light ead to ground E Rotate by hand engine until S mark visible chalk S line for easy reading F Start engine run at 1200 1800 RPM aim timing light into sight hole lightshould flash just as S mark is cen tered in sight hole or even with center mark on bearing plate or blower housing see Figure 5 7 Figure 5 7 Timing Light Method G Iftiming is off remove breaker point cover loosen gap adjusting screw shift breaker plate until S mark is ex actly centered Retighten adjusting screw and re check timing before replacing breaker point cover ALTERNATOR CHARG
13. Always use a new gasket to prevent oil leakage Assemble oil pan to block with four screws and torque to specifica tion as shown in Section 9 OIL SEALS Installing oil seals requires the use of two special tools a seal sleeve and a seal driver A description of these tools and how they are constructed is shown in Section 9 These tools permit careful installation by preventing the seal lip from rolling and creasing 1 To install seals place seal sleeve over crankshaft Ap ply a liberal amount of light grease such as Lubriplate on the seal lip area and slide the seal down over the sleeve see Figure 8 11 Figure 8 11 Installing Oil Seals 40 2 After oil seals are started on shaft place block on its side Slide the seal driver over the sleeve and drive the seal squarely into bearing plate and cylinder block Drive seals to the specified depth as shown in Figure 8 12 27 32 84 Bearing i e Plate Figure 8 12 Drive Oil Seal to Specified Depths EXHAUST AND INTAKE MANIFOLDS Screw intake and exhaust manifolds onto the cylinder head Always use new manifold gaskets when these parts have been removed for service CAUTION Units using the exhaust manifold elbow also use a heat tube This heat tube is placed in the exhaust port before the elbow is fastened to the cylinder head If heat tube is left out cyl inder head damage will result NOTE Heat tube is a loose fit in exhau
14. Coil and Condenser to Side Baffle DIPSTICK ASSEMBLY If the dipstick assembly was removed for service replace it at this point Always use a new gasket when replacing the dipstick G T 2 44 overnor Arm and Carburetor Push governor arm onto governor cross shaft but do not tighten the nut which hotds arm to shaft Instali a new carburetor gasket Hold gasket in place with one of the carburetor screws Slide mounting flange of carburetor under screw then position other end of gasket beneath carburetor flange and screw car buretor to crankcase Attach choke linkage between choke control lever and choke tever on carburetor Snap throttle rod onto ball that is connected to carburetor throttle lever Attach governor spring between throttle control lever and gov ernor arm Connect the fuel line from the fuel pump out let side to the carburetor using a spring clamp See Figure 8 23 for connections Grasp end of governor cross shaft with pliers and turn counterclockwise as far as possible tab on cross shaft will stop against rod on governor gear assembly Now while holding the cross shaft in the position just mentioned pull the governor arm away from the car buretor as far as possible then tighten the governor arm nut see Figure 8 24 For further governor and carburetor adjustments see Section 4 Fuel Systems Choke Linkage Figure 8 23 Connections to Carburetor Throttle Fuel and Govern
15. If capacitance of condenser is too low metal will transfer from the stationary contact to the movable contact If ca pacitance is too high the metal will build up on stationary contact see Figure 5 2 Build Up on Build Up on Stationary Movable Contact Contact Could Indicate Excess Capacitance Could tndicate Insiffucient Capacitance Figure 5 2 Metal Transfer on Points Condenser Check The condenser can be tested with an ohmmeter or a com mercial condenser tester To check with the ohmmeter ground the condenser lead or terminal then set onmme ter on the Rx10 000 scale and connect the meter leads be tween the condenser lead or terminal and a good ground On a good condenser the indicator on the meter should bounce up into the scale and then quickly fall back to in finity On a faulty condenser the needle will either not fall back to infinity indicating a short or will not move at all when the test is performed indicating an open circuit This test is not foolproof as the condenser could be inter mittent and actually appear good when it is faulty When using a commercial condenser tester follow the instruc tions provided by the manufacturer IGNITION COIL The ignition coil functions to transform or step up the low voltage primary energy to the high voltage energy neces sary to bridge the gap between the center and side elec trodes on the spark plug There are two terminals provi
16. Size A 7 5 16 B 1 252 1 253 c Diameter of crankshaft plus 002 003 Figure 9 2 Dimensional Diagram Seal Sleeve 1 8 Drill AT Dimension Size A 8 13 16 B 1 11 16 Diameter of sleeve plus 003 004 Figure 9 3 Dimensional Diagram Seal Driver 49 KOHLER i service 142 K361 bulletin EXHAUST VALVE SEAL ISSUE DATE K361 EXHAUST VALVE SEAL Some K361 cylinder heads utilize an exhaust valve seal which is installed on the exhaust valve guide If replacing this seal use the following precaution to prevent seal failure due to improper or careless seal installation When pressing an exhaust valve seal onto an exhaust valve guide press on the seal guide retainer band only Pressing directly on this valve seal body or stem retainer spring will distort the seal and result in seal failure STEM GUIDE RETAINER RETAINER SPRING EXHAUST VALVE SEAL INTAKE EEE CYLINDER HEAD REVISION DATE KOHLER id 144 engines service As bulletin me VALVE GUIDE ISSUE DATE REVISION DATE 8 81 K361 VALVE GUIDE REPLACEMENT Two types of valve guides have been used in K361 If valve guides are worn beyond the maximum cylinder heads See figure 1 Some exhaust valve allowable specifications remove and replace the guides are machined to accommodate ateflon valve guides using the following procedure seal Tetlon Valve Seal Valve Guides Valve Guides 8 WI
17. accomplished by using a bearing plate removal tool or puller 2 The cam cover should now be unscrewed and the block turned over to rest on its barrel Loosen the oil pan screws and lift the pan off the block NOTE When turn ing block over onto barrel be sure not to damage cylin der head gasket seating surface CONNECTING ROD AND PISTON ASSEMBLY 1 Before removing the piston assembly the ridge formed at the top of the piston travel zone must be removed Use a ridge reamer to remove this ridge NOTE Re moval of piston assembly before ridge is removed could cause piston land damage 2 Remove the connecting rod screws and cap Lay the engine on its side With the butt end of a wooden or plastic handled hammer push on the connecting rod until the piston and rod are clear of the cylinder barrel see Figure 7 7 3 To disconnect the connecting rod from the piston re move the piston pin retainers and drive the pin free with a brass drift Figure 7 7 Connecting Rod and Piston Removal Inspection Pistons and Rings Scuffing and scoring of pistons and cylinder walls occurs when internal temperatures approach the melting point of the piston Temperatures high enough to do this are creat ed either by friction which is usually attributed to im proper lubrication and or overheating of the engine it self due to improper cooling Normally very little wear takes place in the piston boss pin area If the original piston a
18. assembly can now be attached tothe rocker arm housing Rest rocker arm shaft on cradle like area on housing so that adjusting screws are over Figure 8 14 Installing Push Rod Tube O Rings Adjusting 09 Z Nu Lock Nut 2 Ea Rocker Amis gt 2 Ea Rocker Arm ue Y Shaft Retainer Rings Adjusting Screws 2 Ea Rocker Arm Housing E Rocker Arm Housing e e e Socket Head 3 Screw CN Rocker Arm g o Housing Gasket Figure 8 15 Rocker Arm Assembly 41 the smaller of the four large hotes in the housing Fast en the shaft to the housing with washers and socket head screw Torque socket head screw to 180 Ibs see Figure 8 15 4 Place rocker arm housing gasket over valve springs on cylinder head always use new gasket when housing is serviced and secure rocker arm housing to cylinder head with capscrews see Figure 8 15 Valve Adjustment Valve clearance is measured between the end of the rock er arm and valve stem end Both intake and exhaust valves should be adjusted cold to 005 0 13 mm To adjust valve clearance turn engine by hand until both valves are seated or in compression TDC Loosen the valve adjusting screw locknut Screw the adjusting screw in or out until the clearance is correct Retighten locknut then check clearance again see Figure 8 16 Now rest rocker arm housing cover gasket on housing gasket surface and fasten roc
19. can cause poor performance or early failure due to loss of electrolyte 2 Keep terminals and top of battery clean Wash with bak ing soda and rinse with clear water Do not allow soda solution to enter cells as this will destroy the electro lyte IGNITION TIMING Engines are equipped with a timing sight hole inthe blow er housing Two timing marks are stamped on the fly wheel the T mark indicates Top Dead Center TDC while the S mark indicates the Spark or Spark Run point which is 20 before top dead center Two methods can be used for timing the timing light method is the more precise way of achieving exact timing Method 1 Static Timing Disconnect spark plug lead from battery ignition coil to prevent unintentional starting Remove breaker point cov er Rotate engine by hand in direction of normal rotation clockwise when viewed from front or flywheel end Points should just begin to break as the S mark appears in the center of the timing sight hole NOTE To check when points break connect an ohmmeter or continuity tester across the points Continue rotating engine until points reach maximum opening Measure gap with feeler gauge gap should be 020 fully open If necessary loosen point gap adjustment screw and readjust gap to 020 full open Maximum gap setting can vary a few thousandths 017 022 to achieve smoothest running Securely tighten ad justing screw after timing see Figure 5 6 Figure 5
20. ex plodes Never leave ignition switch On when charging battery a switch left On with the battery connected can cause the ignition coil to overheat and possibly explode Use a 12 volt negative ground battery with amp hour rat ing of 32 45 on the K361 engine Make sure the battery is maintained at full charge especially in winter Keep the engine and battery warm to insure better starts Warm bat teries have greater cranking capacity than cold batteries When removing the battery from equipment to avoid causing sparks always disconnect the negative cable first When replacing battery connect the negative cable last Battery Check Test battery voltage by connecting a DC voltmeter across the battery terminals Crank the engine if battery voltage falls below 9 volts while cranking the battery is run down or defective see Figure 5 5 18 Volt and 7 Ohmmeter Figure 5 5 Checking Battery Charge Battery Maintenance A buildup of corrosive acid across the top of the battery can cause the battery to self discharge Even a light coat ing of this grayish white substance can complete a circuit to drain and exhaust the energy in the battery especially bad when moisture is present To maintain a battery in top condition check and perform the following services at frequent intervals 1 Regularly check level of electrolyte add water as nec essary to maintain level above plates do not overfill as this
21. exhaust emissions are not regulated Be aware however that the cylinder head will re quire more frequent service Gasoline Alcohol blends Gasohol up to 10 ethyl alcohol 90 unleaded gasoline by volume is approved as a fuel for Kohler engines Other gasoline alcohol blends are not ap proved 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 2 ENGINE ANALYSIS lem could for example be attributed simply to an empty TROUBLESHOOTING fuel tank The chart below lists come common causes of When troubles occur don t overlook simple causes which engine troubles use this as a guide to locate causing might seem too obvious to be considered A starting prob factors Possible Cause Condition Faulty ignition Loose or grounded high tension or breaker point leads Improper breaker point gap and timing Defective breaker points Faulty spark plug or improper gap Battery not fully charged Faulty condenser B aog Hard Starting or Loss of Power 2 Faulty fuel system a Gasoline not getting to carburetor 1 Dirt or gum in fue line 2 Fuel pump faulty 3 Vent in fuel tank cap plugged b Dirt in carburetor c Carburetor improperly adjusted 3 Wrong lube oil 4 External loads engaged a Clutch ou
22. is virtually trouble free On rare occasions the ACR spring has be come unhooked which usually results in starting at full compression To service the spring remove the cam cov er and rehook or replace The flyweights are non service able if they become permanently stuck or excessively worn a new camshaft is required ACR Check See Figure 6 2 The ACR is checked by measuring the amount of push rod lift on the exhaust push rod The correct amount of lift is established by the height of the lifting tab in relation tothe camshaft f improper lift is suspected the setting can be checked as follows Step 1 Remove the rocker arm housing cover and spark plug Step 2 Turn the engine over by hand until you reach bot tom dead center of the intake stroke intake valve will be closing Step 3 Mount a dial indicator on the top of the exhaust clearance adjusting screw on the exhaust valve rocker arm Step 4 Position the exhaust rocker arm so the clearance adjusting screw is in direct contact with the ex haust push rod and zero the dial indicator Step 5 Slowly turn the flywheel clockwise and watch the dial indicator The push rod lift should be 051 059 If the ACR lift does not fall within the specified range re place the camshaft The ACR tab is through hardened and cannot be adjusted Figure 6 2 Checking ACR Function 25 SECTION 7 DISASSEMBLY INSPECTION OVERHAUL WORK AREA Before starting disas
23. or a very weak spark occurs ignition troubte is indicated When checking out an ignition sys tem the components most commonly requiring service or adjustment should be checked first SPARK PLUGS Engine misfire or generally poor operation is often caused by spark plugs in poor condition or with improper gap set ting Every 100 hours remove plug check condition and reset gap to 035 Do not sandblast wire brush scrape or otherwise service plug in poor condition best results are obtained with a new plug Tighten plug to 18 22 ft Ibs 2 5 3 1 Kgm When removing spark plugs always make an analysis of the firing end as the appearance gives a very good indica tion of operating conditions If the firing end has a light coating of gray or tan deposits this usually indicates good operating conditions A dead or chalk white blistered coating may indicate overheating Black sooty carbon deposits on the firing end are caused by incomplete com bustion Incomplete combustion can usually be attribut ed to an overrich condition caused by improper carbur etor adjustment If abnormal conditions are indicated always check the number of the plug if may be of the wrong heat range for the engine If the center electrode is eroded round don ttry to square it with a file for reuse re place the plug to prevent misfiring which is commonly en countered when using eroded plugs Some common fir ing end indicators are shown in the accompan
24. out The engine speed will first increase but then decrease as screw is turned out Note the position of screw when engine speed starts to decrease Set the screw midway between the two points noted above For loca tion of main fuel screw see Figure 4 1 Idle Speed Adjustment Run engine at maximum governed no load speed for a minimum of 30 seconds then allow engine speed to fall to idle or put throttle into idle position Set engine speed to 1800 RPM 75 RPM or per engine spec turning in or out on the idle speed screw See Figure 4 1 for location of idle speed screw idle Fuel Adjustment Set the idle fuel mixture by turning the idle fuel screw out trom the closed position 3 4 to 1 full turn For location of idle fuel screw see Figure 4 1 Figure 4 1 Carburetor Adjustments CARBURETOR RECONDITIONING Service difficulties with fuel systems usually originate from improper carburetor adjustment or dirt gum or var nish in components It will be necessary to completely dis assemble carburetor to clean thoroughly Normally only pre season cleaning will be required however the fre quency of cleaning will depend upon use and operating conditions All parts should be cleaned in a solvent Gum is easily re moved with acetone solvent NOTE Always follow man ufacturers instructions when using cleaning solvents Be sure all deposits are removed from bore especially where throttle plate seats in casting Blow ou
25. pump operates off a cam on the cam shaft The fue pump lever rides on the cam and transmits this mechanical action to a diaphragm within the pump body see Figure 4 5 Some mechanical pumps have an external lever for priming Camshaft Diaphragm Figure 4 5 Fuel Pump Function Fuel Pump Check WARNING When performing this test be sure to wipe up any spilled fuel and make sure no sources of heat flame or sparks are near as these can cause gasoline fumes to explode Ta check the operation of the fuel pump disconnect the spark plug lead Remove the fuel line at the carburetor and crank the engine If no fuel comes out of fuel line check the fuel flow into pump This can be done by removing the fuel line at the inlet side of the fue pump and holding the line lower than the gas tank If fuel flows freely from the fuel line the pump is faulty and should be replaced The replacement fuel pumps are of a thermoplastic de sign which effectively insulates and prevents fuel from va porizing inside the pump The pumps are interchange able with the metal pumps and are available in kit form The kits include the pump new mounting gasket and two flat washers Some important points regarding the non metallic bodied pumps are as follows 1 FUEL FITTINGS Apply small amount of Permatex 300 or Hercules GRIPP sealant on threads then turn fit tings into pump 5 full turns and continuein same direc tion until required position is attained
26. the stub shafts 34 Inspection Balance Gears Balance gears should be checked for worn cracked or broken teeth and for damaged or worn needle bearings If any of these cases are noted replace the gear or needle bearing The balance gear stub shafts can also be removed and should be replaced if excessively worn see Specifica tions Wear Tolerances Torques and Special Tools Sec tion 9 CRANKSHAFT CAMSHAFT AND TAPPETS 1 Remove crankshaft through hole in crankcase on bear ing plate side of the engine Remove oil seals from crankshaft 2 Using a small punch drive camshaft pin out from power take off PTO side of engine Pin will slide out easily after it is driven free of block see Figure 7 12 Lift camshaft out of crankcase 3 Oncethe camshaft is removed the tappets can be lifted out of the case Inspection Crankshaft and Camshaft Inspect the gear teeth on both the crankshaft and cam shaft If the teeth are badly worn chipped or some are AAA 2 L Figure 7 12 Camshaft Removal missing replacement of the damaged components will be necessary Also inspect the crankshaft bearings One bearing is pressed into the cylinder block the other is located in the bearing plate Do not remove bearings unless they show signs ot damage NOTE Remove rear main bearing when boring or honing cylinder f bearings turn easily and noiselessly and there is no evidence of scoring or groov ing on
27. the bottom balance gear if these marks cannot be lined up timing is off and must be corrected see Figure 8 6 Crankshaft Timing Mark j Secondary Timing Mark Figure 8 6 Final Check for Crankshaft to Balance Gear Timing if the assembly tool is not available use the following pro cedure to time the balance gears to the engine 1 Crankshaft Press crankshaft into block align pri mary timing mark on top balance gear with standard timing mark next to crankgear press shaft until crank gear is engaged 1 16 into top gear narrow side Ro tate crankshaft to align timing marks on crankgear and cam gear then press crankshaft remainder of the way into the block Bottom Balance Gear Bearing Assembly Rotate crankshaft until it is approximately 15 past BDC then slip one 010 spacer over stub shaft before installing bottom gear bearing assembly Align secondary tim ing mark on this gear with secondary timing mark on counterweight of crankshaft then install gear bearing on shaft Secondary timing mark will also be aligned with standard timing mark on crankshaft after installa tion if properly timed see Figure 8 6 Use one 005 spacer and one 020 spacer largest next to retainer to obtain proper end play of 002 to 010 Install snap ring retainer then recheck and adjust end play as needed STATOR AND BEARING PLATE 1 Press front main bearing into bearing plate Make sure
28. the races the bearings can be reused Check crankshaft keyways If worn or chipped replace ment of the crankshaft may be necessary Also 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 Specifications Wear Toler ances Torques and Special Tools Section 9 are exceed ed by more than 002 it will be necessary to either replace the crankshaft or regrind the crankpin to 010 undersize reground the 010 undersize connecting rod big end must then be used to achieve proper running clearance GOVERNOR GEAR To remove the governor gear unscrew and remove the governor stop pin then slide the governor gear off the stub shaft and out of cylinder block see Figure 7 13 Now re move the governor cross shaft by unscrewing the gover nor bushing nut and removing the shaft from the inside of the cylinder block Inspection Governor Gear and Cross Shaft Inspect governor gear for worn chipped or broken teeth Check tab on governor cross shaft It may be broken Re place either of these parts if any of these conditions are noted CYLINDER BLOCK Check all gasket surfaces to make sure they are free of gasket fragments and sealer materials Surfaces must also be free of deep scratches cr nicks Figure 7 13 Governor Gear Removal If the cylinder bore is badly scored excessively worn or tapered out of round m
29. Choke Service Guide 4 11 Balance Gears Assembly 8 37 Balance Gears Disassembly 7 34 5 18 Bearings Assembly 8 37 Bearing Plate Cam Cover and Oil Pan 7 31 Breaker Point Assembly 8 43 Breaker Points 5 17 Breather Assembly 8 43 Brush Replacement 5 24 Cam Cover and Fuel Pump Installation 8 43 Camshaft and Tappets Assembly 8 37 4 9 Carburetor Adjustments 4 9 Carburetor Assembly 4 10 Carburetor Disassembly 4 10 Carburetor Reconditioning 4 9 Compression Test 2 6 Condenser 5 17 Condenser 5 17 Connecting Rod Inspection 7 33 Connecting Rod and Piston Assembly 7 32 Cooling System Service 3 7 Crankcase Vacuum Test 2 6 How Make Tube Manometer 2 6 Crankshaft Assembly 8 38 Crankshaft Camshaft and Tappets Disassembly 7 34 Cylinder Block inspection and Reboring 7 35 Cylinder Head Assembly 8 41 Cylinder Head Rocker Arms and Push Rods Disassembly 7 28 Dipstick Assembly Installation 8 44 Disassembly Inspection and Overhaul 7 27 Drive Assembly 5 23 Electrical System 4 9 Engine Analysis 2 5 Engine Disassembly
30. ING SYSTEMS 3 amp 3 or 6 amp and 15 amp alternator charging systems are used on the K361 engine The 15 amp system has a rectifier regulator mounted on the starter motor side of the blower housing while the 3 amp and 3 or 6 amp sys tems do not use a rectifier regulator Besides the recti fier regulator other components of the three systems dif fer therefore there can be no interchangeability of parts between the systems No adjustments are possible on these alternator systems and fieid service on these sys tems is not recommended Ali faulty parts should be re placed The systems are described separately in the fol lowing pages 3 Amp Alternator Charging System The 3 amp alternator system consists of three major com ponents a permanent magnet ring with five or six mag nets on the inside rim of the flywheel an alternator stator assembly which is affixed to the engine bearing plate and a diode which is located in the charging output lead from the stator The accompanying test guide can be used to pinpoint any source of trouble CAUTION 1 Battery polarity must be correct Negative ground systems are used with Kohler En gines 2 Prevent alternator leads AC from touch ing or shorting This could permanently damage the stator 19 3 Disconnect rectifier regulator plug before electric welding is done on equipment powered by the engine and in common ground with engine 4 Do not operate for any length of time wi
31. KOHLER engines model K361 service manual Section 1 GENERAL INFORMATION Section 2 ENGINE ANALYSIS Section 3 AIR INTAKE AND Section 4 FUEL 65 8 Section 5 ELECTRICAL Section 6 AUTOMATIC COMPRESSION RELEASE Section 7 DISASSEMBLY INSPECTION OVERHAUL Section 8 Section 9 SPECIFICATIONS WEAR TOLERANCES TORQUES AND SPECIAL TOOLS Section 10 SERVICE BULLETINS Nos 142 144 and 154 SUBJECT INDEX SUBJECT SECTION PAGE ACR Automatic Compression 6 25 ACR Operation 6 25 ACR Check 6 25 ACR Service 6 25 Air Cleaner Assembly 8 44 Air Cleaner Service 3 7 Air Intake and Cooling 3 7 Alternator Charging Systems 5 19 S Amp ses aca ors 5 19 3 6 Amp 5 21 15 5 22 Alternator Systems Service 5 Amp 5 20 3 6 Amp 5 21 15Amp 5 22 Assembly Procedures 8 37 Automatic Choke and Shutdown Control 4 11 Automatic Choke Function 4 11 Automatic
32. THOUT WITH Exhaust Valve Seal Exhaust Valve Seal FIGURE 1 Valve Guide Removal 1 Remove cylinder head from engine disassemble and clean as explained in the service manual 2 Heat cylinder head in a 400 F 205 C oven no less than 30 minutes WARNING Use extreme care when working with hot oven Carelessness in working area can result in serious burns 3 Remove head from oven using fireproof insulated gloves pliers etc Position on an arbor press table with the valve seats up and the valve guides inside two pieces of pipe 1 25mm 1 D x 1 3 4 45mm long with straight cuts See figure 2 4 Center a 1 2 12mm diameter drift punch onthe valve guide Press guide from head CAUTION Misalignment of drift punch on guide during removal could damage cylinder head Valve Guide Installation 1 Heat cylinder head in a 400 F 205 C oven no less than 30 minutes Install clip ring on guide with the flat edge side toward the chamfered end of guide See figure 3 Place guide in a freezer compartment or on dry ice no less than 30 minutes 3 Remove head from oven using fireproof insulated gloves pliers etc Place head valve seat down on a flat piece of wood WARNING Cylinder head is extremely hot Use extreme care in handling to avoid ser ious burns 4 Place chamfered end of cooled valve guide into cylinder head valve guide bore Using an arbor press and a 1 2
33. ad KOHLER engines ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 FOR SALES AND SERVICE INFORMATION IN U S AND CANADA CALL 1 800 544 2444 LITHO IN U S A
34. aker point information and ignition timing procedure see Section 5 Electrical Systems 4 Secure breaker point cover Be sure breaker point lead grommet is in place in cover BREATHER ASSEMBLY Atl breather components must be clean and in good con dition Use new gaskets reed and filter when recondition ing Assemble breather according to sequence as shown in Figure 8 21 Cover must be securely tightened to pre vent oil leakage Breaker Push Rod Figure 8 20 Breaker Wire Installation Gasket Breather Plate Figure 8 21 Assembling Sequence Breather STARTING MOTOR Attach starting motor to engine block Make sure the spe cial shouldered capscrews and lockwashers are used In addition to securing the starter to the machined surface on the crankcase these special capscrews properly align the pinion to the ring gear on the engine Use of ordinary cap screws will allow starter to shift which could result in clashing of the gears IGNITION COIL AND BAFFLING Attach the ignition coil and condenser to the cylinder baf fle as in Figure 8 22 Now secure the rest of the baffling in this order blower housing side baffle and head baffle When the engine baffling is in place the wiring connec tions to the coil breaker points condenser and rectifier regulator should be made Follow the wiring diagram in Section 5 Electricat Systems for the particular ignition system used 43 Figure 8 22 Securing
35. alve seats become worn or damaged the entire cylinder head must be replaced Valve Guides Seating surfaces should be held between 037 and 045 width Seats with more than 045 must be reconditioned with a 45 cutter and overcutting or undercutting with 30 and 60 cutters to obtain the proper seat width is recom mended see Figure 7 5 for valve seat details 031 Min T t o eo T DETAIL VALVE SEAT D S Stem Figure 7 5 Valve Details Reground or new valves must be lapped in to provide proper 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 grind er Continue grinding until smooth surface is obtained on seat and on valve face see Figure 7 6 IMPORTANT Always readjust valve tappet clearance after resurfacing valves and seats VALVE SPRINGS Intake and exhaust springs on the K361 are identical Both springs are progressively wound that is coils are tighter on one side than the other Both springs have a free length of 1 965 Valve springs seldom wear out and if they do they will usually break Broken springs should be re placed BEARING PLATE CAM COVER AND OIL PAN 1 Remove the stator from the bearing plate and then re move the bearing plate The bearing plate must be re Figure 7 6 Lapping Valves 31 moved evenly to avoid distorting the plate This can best be
36. ansferring insulation bushing from old unit To replace insulated brushes simply remove capscrew and lockwasher Always use new brushes and springs Assemble brushes with chamfered side away from springs Keep brush leads away from contact with metal of end cap 8 To keep brushes in position so that they will fit over the commutator as the end cap is reinstalled use a brush holder tool as shown which can easily be cut out of thin sheet metal see Figure 5 12 E Brush Holder in Place Over Brushes and End Cap Sheet Metal Brush Holder Tool Figure 5 12 Brush Holder Tool SECTION 6 AUTOMATIC COMPRESSION RELEASE ACR ACR OPERATION ACR is the trademark for the Automatic Compression Re lease mechanism patented by Kohler Co The Model K361 is equipped with ACR The ACR mechanism functions to release compression at low cranking speeds to alleviate the amount of energy necessary to start an engine The ACR is comprised of a centrifugal flyweight mechan ism which is attached to the gear hub of the engine cam shaft The ACR mechanism is shown in the starting and running positions in Figure 6 1 The flyweights are spring held in the inner position while the engine is at low crank ing speeds In this position the tab on the larger flyweight protrudes above the profile of the exhaust cam and thus lifts the exhaust valve off its seat during the first part of compression stroke The compression pressures thus re l
37. any liquid or attempt to blow dirt off with air hose as this will puncture filter ele ment When replacing element use only genuine Kohler element Carefully handle new element do not use if gas ket surfaces are bent or twisted Check the following when installing new element 1 Back plate must be securely tightened to carburetor Replace back plate if bent or cracked Replace air horn gasket if damaged see Figures 3 1 and 3 2 for air horn gasket installation instructions Element Carburetor Air Horn Gasket 1 Peel backing off gasket to expose adhesive Position on car buretor so that holes in gasket and carburetor are aligned Figure 3 2 Air Horn Gasket Installation 2 Gasket surfaces of element must be flat against back plate and cover to seal effectively 3 Seal on cover must be in place to reduce noise and vi bration of the cover Vibration can cause stud hole in cover to enlarge thus permitting dirt to enter car buretor 4 Wing nut must be finger tight do not overtighten 5 Angled end of tube must be installed into blower hous ing short end of tube length up and tong end length down see Figure 3 3 for tube position Lips on other end of tube must form tight seal on back plate Figure 3 3 Air Cleaner Tube Installation COOLING SYSTEM SERVICE Air is drawn into the cooling shroud by fins on the fly wheel The grass screen and cooling fins on the block and cylinder head mus
38. ation is normal Excessive sludge formation could indicate several things The most common cause is perhaps too infrequent oil changes It can also indicate operation with improper ignition timing or overrich carburetor adjustment Scoring of the cylinder wall Unburned fuel not only adds to sludge formation but can in severe cases cause scuf fing and scoring of the cylinder walls As raw fuel seeps down the cylinder walls it washes the necessary lubricat ing oils off the piston and cylinder walls so that the piston rings make metal to metal contact with the walls Scoring of the cylinder walls can also be caused by localized hot spots resulting from blocked cooling fins or from inade quate or contaminated lubrication Severe piston damage Major damage to pistons and rings can take various forms The top of the piston ring may be burned through or the top groove may be excessively worn and the ring broken or stuck in the groove This can be attributed to abnormal combustion If ignition timing is overadvanced ignition will occur while the piston still has a long distance to travel on its compression stroke As a re sult the combined heat of compression plus the heat of preignited fuel raises temperatures to values comparable to that of an acetylene torch This of course acts mainly on the top land and top ring of the piston and results in ear ly failure Evidence of external oll leakage If excessive oil leakage is evident this ma
39. chedule OO 1 3 Spark Plug8 5 15 Special 9 49 Starting 5 23 Starting Motor Oper OO sey diese Ra ER aie 5 23 Starting Motor Service 5 24 Starting Motor 8 43 Stator and Bearing Plate Assembly 8 38 Tolerances Parts Fitted 9 47 Tolerances 9 47 TORQUES 556 df TE YN GR Sn 9 48 Torque Conversions 9 48 Torque Settings 9 48 Troubleshooting reer eevee eee ee 2 Valve 8 42 Valve 8 41 Valve Guides 7 30 Valves Inspection and Service 7 29 Valve 7 28 Valve Seats 7 31 Valve Springs 7 31 SECTION 1 GENERAL INFORMATION This manual covers the Kohler single cylinder horizontal crankshaft overhead valve engine When ordering re placement parts and in any communication involving an engine always report the MODEL SPECIFICATION and SERIAL numbers as found on the nameplate which is mounted on top of engine blower housing see Figure 1 1 The significance of these numbers is explained as foll
40. cuit should be noted In the other instance the needle should read about mid scale with meter set at Rx1 If both resistance readings are low the diode is shorted If both resistance readings are high the diode or stator are open Test 5 Cut the sleeving on both the battery charge lead and auxiliary load lead to expose the diode connections Check resistance on the stator side of diode to ground The reading should be 0 5 ohms If the reading is 0 ohms the winding is shorted If infinity ohms the stator winding is openor the lead wire is broken ENGINE DIAGRAM Battery Charging Load PE Diode Flywheel Alternator Automatic Choke Optional Shutdown Control Optional Ed Solenoid 12 Volt Battery Coil Condenser Figure 5 9 3 6 Amp System Wiring Diagram 21 Problem No Lighting Test 1 Disconnect lighting lead from wiring harness Measure open circuit voltage with AC voltmeter from light ing lead to ground with engine running at 3000 RPM If 22 volts or more the stator is OK if less than 15 volts wiring may be shorted Test 2 Check resistance of lighting lead to ground If 0 5 ohms the stator is OK if 0 ohms the stator is shorted and if infinity ohms the stator is open or the lead is broken 15 Amp Alternator Charging System The 15 amp alternator circuit includes three major com ponents which are a ceramic magnet ring which is per manently affixed to an inner rim of
41. ded on the ignition coil and they must be connected correctly for the coil to function properly The positive terminal must be connected to the positive side of the battery The breaker points and condenser are connected to the negative terminal Ignition Coil Check NOTE Ignition parts should be checked with the engine stopped Check the continuity of the primary winding by connecting an ohmmeter between the and termi nals of the coil The reading on the meter when set on the Rx1 scale should be 4 8 ohms see Figure 5 3 Volt and Ohmmeter _ Figure 5 3 Continuity Check in Primary of Coil 17 To check the secondary resistance connect one lead to the high tension terminal and the other to the terminal on the ignition coi The reading here should be in a range between 7 000 and 12 000 ohms on a good coil see Fig ure 5 4 If not within 10 of this the secondary is faulty and the coil should be replaced Note that a coil could pass these tests and still be breaking down under operating conditions This can only be detected by expensive la boratory instruments Voltand Ohmmeter Figure 5 4 Resistance Check in Secondary of Coil BATTERY WARNING Handle a storage battery carefully it con tains corrosive acid that can burn you Never charge a battery in an enclosed area or cause a spark near battery it gives off highly explo sive hydrogen gas that can hurt you if it
42. ded spark plugs Resistor or shielded plugs lessen interference to radio transmissions while standard spark plugs do not Check the laws in your area so you can be sure of using the right plug Use Champion spark plugs RH 10 resistor H 10 stan dard or equivalent plug when making replacement BREAKER POINTS Engine operation is greatly affected by breaker point con dition and adjustment If points are burned or badly oxi dized little or no current will pass As a result the engine may not operate at all or if it does run it is likely to miss particularly at full throttle Adjusting breaker point gap af fects the time that the contacts are opened and closed If points are adjusted to a wider gap the ignition spark will be advanced and the engine may knock or kick back dur ing starting if the points are set too close the ignition spark will be retarded and the engine will lose power Breaker points can become dirty or oxidized if the engine is stored for any length of time Dirty or oxidized paints provide poor continuity and should be cleaned with 600 grit sandpaper before start up CONDENSER If the condenser shorts out the coil will be unable to pro duce output voltage On the other hand if it opens or de creases in capacitance the output voltage will be re duced and the ignition points will burn excessively If badly burned breaker points occur too frequently the condition of the condenser should be suspected
43. diode to ground The reading should be 1 ohm If the reading is 0 ohms the winding is shorted If infinity ohms the stator winding is open or the lead wire is broken Problem No Lighting Test 1 Disconnect lighting lead from wiring harness Measure open circuit voltage with AC voltmeter from light ing lead to ground with engine running at 3000 RPM If 15 volts or more the stator is OK if less nan 15 volts wiring may be shorted Test 2 Check resistance of lighting lead to ground If 0 5 ohms the stator is OK if O ohms the stator is shorted and if infinity ohms the stator is open or the lead is broken ENGINE DIAGRAM Diode Charging Lighting AC Flywheel Alternator Shutdown 22 Solenoid Optional Condenser Figure 5 8 3 Amp System Wiring Diagram 20 3 6 Amp Alternator Charging System The 3 6 amp alternator charging system is similar to the 3 amp system It has three major components a perman ent magnet ring with six magnets on the inside rim of the flywheel an alternator stator assembly which is affixed to the engine bearing plate and two diodes one of which is located in the battery charging lead and the other in the auxiliary load lead Use the test procedure below to check for failed parts CAUTION 1 Battery polarity must be correct Negative ground systems are used with Kohler En gines 2 Prevent alternator leads AC from touch ing or shorting This could permanently damage the sta
44. e This type of problem can result from a poor grind on face or seat al lowing leakage Coking Coking as shown in View F is normal on intake valves and is not harmful If the seat is good this valve could be reused after cleaning 30 Gum Gum deposits usually result from using stale gaso line This condition is often noted in applications where fuel is not drained out of tank during the off season Also check carburetor if gummy substance is found on the valve stem 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 H Carbon Cut Excessive build up of carbon in the combus tion chamber may result in valve damage as shown in View H Carbon can become hard enough to cut the valve Cleaning of the cylinder head at proper intervais could prevent such damage VALVE GUIDES If valve guides become sufficiently worn to allow the valve stem to guide clearance to exceed the limits stated in Specifications Wear Tolerances Torques and Special Tools Section 9 the cylinder head must be replaced Valve guides may be cleaned using a valve guide reamer so long as the specified tolerance for inside diameter is maintained see Figure 7 5 Make sure valve guide is cleaned thoroughly after reaming VALVE SEATS The valve seats in the K361 engine are hardened steel in serts that are permanently cast into the head If the v
45. e prescribed intervals cannot be overemphasized un der the operating conditions usually encountered wiin most air cooled engine applications To obtain maximum service life perform these services at recommended intervals Oil Type Use high quality detergent oil of API American Pe troleum Institute service class SF or SG Select the viscosity based on the air temperature at the time of operation as shown below Recemmeaded SAE Viscosity Grades A a es gue 30 10W 40 Use straight weight oils as specified Do not use SW 20 5W 1 33 multi viscosity oils above 32 F as considerable in creases in consumption and combustion deposits will result Oil Change On a new engine change oil after the first 5 hours of operation and then at 25 hour operating intervals thereafter Change oil more frequently under dirty dusty conditions Drain the engine oil when the engine is warm for it flows more freely thus carrying away more impuri ties After completely draining oil reinstall drain plug then remove oil filler cap and add 2 quarts 1 9 li ters of oil Check the oil level on the dipstick be fore adding more oil On engines with the threaded type plug dipstick turn the plug all the way out of crankcase wipe oil off dipstick then reinsert DO NOT turn plug in to check oil level After checking turn plug all the way into the crankcase With the oil fill tube and dipstick arrangement wipe off the
46. eased result in an effective ratio of about 2 to 1 during cranking After the engine speed increases to about 500 RPM cen trifugal force moves the flyweights to the outer position dropping the tab into the recess in the exhaust cam Inthe retracted position the tab is below the surface of the cam and has no effect on the exhaust valve which allows the en gine to operate at full compression with no loss of power When the engine stops the spring returns the flyweights into the retracted position ready for the next start STARTING POSITION RUNNING POSITION Push Rod M E o c on Camshaft Figure 6 1 ACR Operation Benefits In addition to lowering the cranking effort ACR elimin ates the need tor aspark retard mechanism Spark retard is necessary on engines without ACR to prevent kickback since ACR releases compression kickback cannot oc cur To the engine operator the ACA mechanism offers less critical choking in the event of flooding excess fuel is blown out through the lifted exhaust valve and does not hamper starting Faster starting is also achieved in cold weather on ACR engines Tests also revealed that ACR en gines can be started on spark plugs in very bad condition whereas engines without ACR could not be started with these same plugs Service Extensive testing and consequent use of ACR has proved that the mechanism is extremely rugged and
47. ess Carefully clean carbon de posits from cylinder head if it is to be reused Use a block of wood to scrape deposits see Figure 7 3 Be careful not to nick or scratch aluminum especially in gasket seat area Figure 7 3 Cleaning Cytinder Head Cylinder head flatness can be checked with a surface plate and a teeler gauge If a surface plate is not handy a piece of plate glass may be substituted Cylinder head flatness should not vary more than 003 in If it does replace the cylinder head and screws see Figure 7 4 Cylinder Feeler Gauge Figure 7 4 Checking Cylinder Head Flatness It is also important to replace the head bolts for if they were exposed to high temperature gas they will become ductile and stretch when torque is applied Inspection and Service Valves Carefully inspect valve mechanism parts Check valves and valve seat area or inserts for evidence of deep pitting cracks or distortion Check clearance of valve stems in guides see Specifications Wear Tolerances Torques and Special Tools Section 9 Hard starting or loss of power accompanied by high fuel consumption may be symptoms of faulty valves these symptoms could also be attributed to worn rings Remove and check valves first After removal clean valve head face and stem with power wire brush then carefully in spect for defects such as warped head excessive corro sion worn stem ends Replace vaives found to be in bad condit
48. ey properly in keyway as shown in Figure 8 17 and carefully guide key slot in flywheel hub over the key to avoid pushing the key inward 3 Use a torque wrench and tighten the flywheel retaining nut to 60 70 ft lbs Use a strap wrench to hold flywheel while torquing nut see Figure 8 18 Figure 8 18 Torquing Flywheel CAM COVER AND FUEL PUMP 1 Install cam cover gasket and cam cover Also install lead wire as shown in Figure 8 19 and secure itwith ca ble clamp held by cam cover screw Thread one end of lead wire around fuel pump mounting pad and up along bearing plate Thread the wire through at the top of bearing plate to the other side of the engine so it emerges along with the stator wires 2 Connect fuel line to outlet elbow on fuel pump with spring clamp 3 Install fuel pump and new fuel pump gasket On plastic fuel pumps make sure flat washer is installed next to mounting flange on pump Torque screws on plastic pumps to 70 in Ibs see Figure 8 19 For further information on fuel pumps see Section 4 Fuel System Figure 8 19 Cam Cover and Fuel Pump Installation BREAKER POINT ASSEMBLY 1 Install push rod and then fasten breaker in place with two screws 2 Place cover gasket in position and attach lead that is attached at cam cover to breaker point screw as shown in Figure 8 20 3 Adjust breaker point gap with a feeler gauge to 020 full open as a preliminary setting For further bre
49. f electrical shock Electrical shock can severely injure or kill you Overspeeding can cause equipment parts to exceed design limitations resulting in component failures Parts breaking under excess stress can become tethal missiles if thrown off by the equipment These broken parts flying through the air can injure or kill you WARNING Before working on engine or equipment al ways remove spark plug leads to prevent engine from starting accidentally SERVICE SCHEDULE Service Check Oil Level Replenish Fuel Supply Change Lube Check Air Cleaner Replace if Dirty Clean Cooling Fins and External Surfaces Service or Replace Spark Plugs E mom Have Breaker Points Cnecked Serviced Have ignition Timing Checkea nave valve Tappei Clearance Have Service Cylinder Heads Serviced Tt Have ihese services done oualii ec specialist Daily Every Every Pre start Clean Air Intake Screen Every Every 25 Hours 50 Hours 100Hours 500 Hours NOTE Intervals stated are for good clean operating condition only service more frequently even daily if extremely dus ty or dirty conditions prevail t ii leaded gasoline is used service cylinder head every 250 hrs RECOMMENDATIONS The importance af checking and changing ai ih
50. her Lead to Starter Side of Starter Solenoid Shatt Lever Choke Plate Terminal Automatic Choke Unit To Positive Side of Coil Adjusting Slot Figure 4 3 Carburetor With Thermo Electric Automatic Choke and Shutdown Solenoid Change lead wires or replace choke Reposition flat of gasket to provide clearance for choke shaft lever Check continuity with ohmmeter between the two solenoid terminals Replace choke unit if open circuit Choke Will Not Fully Open Choke lever lacks sufficient travel or smooth movement Choke spring not properly adjusted Choke shaft fails to move freely Faulty choke adjustment Manually move choke lever to fully closed Replace if choke does not move freely Remove spring and with choke wide open wind up spring 1 2 turn Replace carburetor Adjust choke 11 Choke Unit Replacement and Adjustments see Figure 4 3 1 Position the choke unit on the two mounting screws so that it is slightly loose 2 Hold the choke plate in the wide open position 3 Rotate the choke unit clockwise on the carburetor viewed from the choke side with a slight pressure until it can no longer be rotated Make sure the choke shaft lever is below the choke unit lever 4 While holding the choke unit in the above position tighten the two mounting screws NOTE With engine not running and before any cranking the choke valve will be closed 5 to 10
51. his could be attributed to one or more of the fol lowing factors the condition easiestto remedy should be checked first A A clogged crankcase breather or plugged or kinked breather tube can cause positive pressures to build up in the crankcase Disassemble breather assembly thoroughly clean then recheck pressure after reas sembling B Worn oil seals can cause lack of vacuum Oil leakage is usually evident around worn oil seals See Oil Seal Re placement Instructions C Blowby and leaky valve stems can also cause positive pressures D Faulty seal in oit dipstick cap Construction U Tube Manometer Vacuum gauges mercury and water manometers are available commercially A water U tube manometer see Figure 2 1 is simple to construct if limited usage does not warrant purchase of commercial product To construct water manometer proceed as follows A Procure length of clear plastic tubing Bend tube to form U and mount on board as shown in accom panying illustration Make gradual rather than sharp bend in tube B Measure inside straight section of tube and mark inch increments from 0 to 12 C Procure rubber stopper having outside diameter which will be a snug fit in the oil fili hole Drill hole in center of Stopper to receive one end of tube D Pour water colored for easier reading into tube until level reaches the approximate halfway mark on scale Measure Difference Between Columns
52. ion Some of the conditions that may be found are depicted in the accompanying valve diagrams an ex planation of each condition follows see Figure 7 5 for valve details Normal Even after long hours of operation a valve can be reconditioned and reused if the face and margin are in good shape as shown in View A If a valve is worn to where the margin is less than 1 32 do not reuse it The valve shown was in operation for almost 1000 hours under con trolled test conditions Bad Condition The valve depicted in View B should be re placed Note the warped head margin damaged and too narrow These conditions could be attributed to exces sive hours or a combination of poor operating conditions Stem Corrosion Moisture in fuel or from condensation are the most common causes of valve stem corrosion as shown in View C Condensation occurs from improper preservation during storage and when the engine is re peatedly stopped before it has a chance to reach normal operating temperatures Replace corroded valves 29 Overheating An exhaust valve subject to overheating will have dark discoloration in area above valve guide Worn guides and faulty valve springs may cause this condition Also check for clogged air intake blocked fins and lean fuel mixture when this valve condition is noted Leakage Here is another example of a burned valve In this case however it is only burned on one sid
53. ion of the gover nor spring should hold the throttle valve in open position When a normai load is applied and engine and governor speed tends to decrease the resulting rotation of the cross shaft acts against the governor spring to open the throttle valve wider which in turn admits more fuel and restores engine speed With governor properly adjusted this ac tion takes place so rapidly that a reduction in speed is hardly noticed As speed again reaches governed setting the shaft rotates to either open or close the throttle valve to maintain speed at a relatively constant level see Figure 4 6 Governed speed may be at a fixed point as on constant speed type settings or variable as determined by the throt tle lever on variable speed type governor settings Adjustments Governors are adjusted at the factory and further adjust ment should not be necessary unless governor arm or link age works loose and becomes disconnected Governor re adjustment may be indicated if engine speed surges or hunts with changing load or if speed drops considerably when normal load is applied Speed Adjustment Maximum allowable speed under load for the K361 is 3600 RPM no load speed is 3800 RPM Check operating speed with a hand tachometer Do not exceed this speed If ad justment is necessary tighten or loosen the governor speed adjusting screw until proper engine speed is at tained see Figure 4 6 Sensitivity Adjustment Governor sens
54. itivity can be adjusted by repositioning the governor spring in the holes on the governor arm and throttle control lever If set too sensitive speed surging will occur with change of load If a big drop in speed oc curs when normal load is applied the governor should be set for greater sensitivity Normally the governor spring is placed in the third hole from the bottom on the governor arm and in the second hole from the top on the throttle control lever To make governor control more sensitive increase governor spring tension by moving the spring end upward in governor arm Conversely decreasing spring tension by moving the spring end downward in governor arm allows broader gov ernor control but less sensitivity 2 7 8 75 025 mm Throttle Governor Rod Governor Cross Shaft ee Governor Choke Control Lever Throttle Control Governor Speed Adjusting Screw Do Not Exceed 3800 RPM No Load Governor Spring Figure 4 6 Governor Components Automatic Choke Models Will Not Have Choke Control Lever 13 SECTION 5 ELECTRICAL SYSTEMS BATTERY IGNITION The K361 engine uses a battery ignition system This type of system uses the electrical charge stored in the battery to induce high voltage current in the ignition coil This high voltage current is conducted to the spark plug where it jumps the gap producing a spark which then ignites the air fuel mixture in the cylinder The basic compo
55. ker arm cover to housing Figure 8 16 Adjusting Valve Clearance FLYWHEEL WARNING Improper procedures for installation of fly wheels can lead to cracked flywheels and broken crankshafts This not only results in extensive damage to an engine but presents serious threat to the safety of persons close to the engine When installing the flywheel DO NOT use impact wrenches to install the flywheel retaining nut as this may overstress the nut and crack the flywheel hub DO NOT apply grese oil or any lubricant to the taper of the crankshaft or hub of the tly wheel as this will cause excessive stress and possible cracking of the flywheel while tightening DO NOT allow the key to be pushed inward on the keyway while installing the flywheel If 42 the key rides up on the rounded surface at the end of the keyway as shown in Figure 8 17 it will act as a wedge and crack the flywheel hub DO NOT reuse a flywheel if it has been dropped or damaged in any way DO NOT use a steel bar or any other object between the flywheel fins to hold the fly wheel when the fly wheel nut is being torqued as this practice could break or crack fly wheel fins Figure 8 17 Right and Wrong Way to Install Flywheel Key To install engine flywheel follow these steps 1 Make sure the flywheel hub and taper of the crankshaft are clean dry and completely free of any lubricant be fore installing flywheel 2 Position k
56. m the crankcase 5 Exterior component removal is almost complete ex cept for the dipstick and oil fill tube breaker point as sembly and fuel pump Remove these components CYLINDER HEAD ROCKER ARMS AND PUSH RODS 1 Remove the rocker arm housing cover and rocker arm housing 2 The rocker arm assembly can be further dismantled in case of rocker arm breakage Remove the retaining rings that secure the rocker arm to the shaft and slide the arm off the shaft Pull the push rods and tubes out of their sockets in the crankcase There should be an O ring at the top and bottom of each tube Examine each ring for signs ofde 28 terioration and replace if necessary when reas sembling 4 Loosen the cylinder head bolts and remove the cylin der head VALVE ASSEMBLY The valves on the K361 are located in the cylinder head They can be removed by using a valve spring compressor Compress the valve spring until the valve keepers can be removed then release the compressor and remove the valve retainers and spring see Figure 7 2 Figure 7 2 Disassembly of Valve Components Inspection and Service Cylinder Head Blocked cooling fins often cause localized hot spots which can result in blown cylinder head gaskets If gas ket fails in area surrounding one of the retaining cap screws high temperature gases can burn away portions of aluminum alloy head If no evidence of this is found head should be checked for flatn
57. matic Choke Plug Optional Flywheel Alternator i a Shutdown 1 hon 5 Control Optional Spark i Plug Points Coil Condenser Starter Figure 5 10 15 Amp System Wiring Diagram 22 load of 5 amps on battery to reduce voltage If the charge rate increases the alternator is OK and battery was fully charged If charge rate does not increase check for de fective stator or rectifier regulator Test 2 Turn lights on if 60 watts or more or simulate load by plac ing a 2 5 ohm 100 watt resistor across battery terminals Test 2 At 3600 RPM no load unplug both AC leads at rec tifier regulator connect AC voltmeter across leads check AC voltage If voltage less than 28 the stator is defective If voltage more than 28 the rectifier regulator is defective Problem Battery Continuously Charging at High Rate Test 1 At 3600 RPM no load check B to ground with DC voltmeter If less than 14 7 volts the alternator is OK but battery unable to hold charge check specific gravity of battery If more than 14 7 volts the rectifier regulator is not functioning properly STARTING MOTOR A permanent magnet starting motor is used on the K361 engine The magnets are of ceramic construction and can be damaged quite easily if the starting motor is dropped or struck sharply Starting Motor Operation When the starting circuit is closed and the armature starts to rotate the drive pi
58. mczococrmzo gt Figure 2 1 U Tube Water Manometer When using manometer place stopper into oil fill hole other end open to atmosphere and measure difference between columns If water column is higher in tube con nected to engine vacuum or negative pressure is indicat ed If the higher column is on the atmospheric side of man ometer positive pressure is present Compression Test To check compression on the K361 engine rotate the fly wheel backwards counterclockwise against the power stroke if little or no resistance is felt compression is faul ty If low or faulty compression is indicated one or several of the conditions listed here may be the cause Possible Cause A Cylinder head gasket blown B Cylinder head warped or loose C Piston rings worn blowby occurring D Valves leaking Remedy Remove head replace gasket reinstall head recheck compression Remove head check for flatness see cylinder head service reinstall and secure in proper sequence to specified torque value Check heat baffle tube in exhaust manifold Recondition engine Recondition head assembly SECTION 3 AIR INTAKE AND COOLING AIR CLEANER SERVICE This engine is equipped with a dry type air cleaner ele ment which should be checked every 50 operating hours and replaced if dirty It should be checked and if neces sary replaced more often under extremely dirty dusty conditions Do not wash element in
59. n HE DIC dec e e e RE Fre E dins Dry Slide Fit Ring Side Clearance Top Ring 002 004 0 051 0 102 mm Ring Side Clearance Middle Ring 002 004 0 051 0 102 mm Ring Side Clearance Oil Ring ACER VA EA tele KEY 001 003 0 025 0 076 mm Ring End Gap vice catia scare geh m Exe ba a eek Mabe RE NE EATER EV nie 010 020 0 254 0 508 mm Camshaft Pin to Camshaft 001 0035 0 025 0 089 mm Camshaft Pin to Block Bearing Plate End 0005 002 0 013 0 051 mm Camshaft Pin to Block P T O E Interference Fit 0015 003 0 038 0 076 mm End Play O 005 010 0 127 0 254 mm Tappet In Guide sse walle SAG ERRARE RR RE RARE E 0005 0024 0 013 0 061 mm Valve Stem in Guide Exhaust 0029 0056 0 074 0 142 mm Valve Stem in Guide Intake 001 0027 0 025 0 069 mm Guide in Head Interference Fit 0015 003 0 038 0 076 mm Governor Bushing to Governor Cross Shaft 001 0025 0 025 0 064 mm Governor Gear to Governor Shaft
60. n by engine The following sequence is suggested for complete disas sembly of the engine EXTERIOR COMPONENTS Follow the steps below when removing external compo nents Refer to the appropriate sections in this manual when servicing these parts 1 Disconnect spark plug lead then remove cylinder baf fle and coil assembly 2 Remove head baffle air cleaner and carburetor assem blies and side air baffle 3 Remove the blower housing and flywheel Use a strap wrench to hold the flywheel when loosening the fly wheel nut Use a flywheel puller to extract the flywheel from the crankshaft see Figure 7 1 WARNING mproper procedures for removal of the fly wheel can lead to a cracked flywheel and bro ken crankshafts This not only results in ex tensive engine damage but presents a serious threat to the safety of persons close to the engine When removing the flywheel DO NOT strike end of the crankshaft to re move the flywheel as this practice can seri ously weaken the threaded end of the shaft When thus weakened the end of the shaft along with the retaining nut could later break off while the engine is running allowing the flywheel to come off the shaft 27 Figure 7 1 Removing the Flywheel DO NOT use any type of bar between the fly wheel fins when loosening the flywheel screw This practice can crack flywheel fins which may fly off when the engine is running 4 Disconnect the starter motor fro
61. nd connecting rod can be re used after new rings are installed the original can also be reused but new piston pin retainers are required Pis ton pins are included as part of the piston assemblies if the pin boss in piston or pin are worn or damaged anew piston assembly is required 32 Ring failure is usually indicated by excessive oil con sumption and blue exhaust smoke When rings fail oil is allowed to enter the combustion chamber where it is burned along with the fuel High oii consumption can also occur when ring gap is incorrect as rings cannot properly conform to the cylinder walls Oil controt is also lost when ring gaps are not staggered during installation When cylinder temperatures get too high lacquer and var nish collect on pistons causing rings to stick which re sults in rapid wear A worn ring takes on a shiny or bright appearance Scratches on rings and pistons are caused by abrasive material such as carbon or pieces of hard metal see Figure 7 8 Detonation damage occurs when a portion of the fuel charge ignites spontaneously from heat and pressure shortly after ignition This creates two flame tronts which meet and explode to create extreme hammering pres sures on a specific area of the piston Detonation general ly occurs from using fuels with too low an octane rating Preignition or ignition of the fuel charge before the timed spark can cause damage similar to detonation Preigni tion damage is of
62. nents of the battery ignition system are the battery ignition coil condenser breaker points and spark plug see Figure 5 1 2 Primary Circuit dam Secondary Circuit ignition Switch High Tension Lead N Primary Secondary Spark 4 Connection Plug amp Condenser Ignition H Coil Figure 5 1 Schematic of a Typical Battery Ignition System Ignition System Service Several factors contribute to the overall performance of an ignition system all components must be in good condi tion and the spark must be properly timed Hard starting low power and erratic operation can often be attributed to faulty ignition If poor ignition is suspected first deter mine if the ignition system is actually at fault A simple op erational test will determine this Operational Test WARNING Wipe up spilled gasoline and cover contain ers of flammable liquids Performing this test near explosive gases could result in bodily in jury from explosion Remove the high tension lead at the spark plug bend a pa per clip and insert into boot then hold the end about 1 16 to 1 8 away from the cylinder head while cranking the en gine Make sure engine is cranked fast enough to pro duce a spark If a sharp snappy spark occurs the trouble apparently is not in the ignition coil condenser or breaker points although it could still be attributed to a poor spark plug If no spark
63. new gasket 1 Disconnect the battery negative lead 2 Remove head baffle rocker arm housing cover rocker arm housing and housing gasket from engine 3 Inspect cooling fins and clean out any dirt or debris which may have accumulated between fins 4 Check the cylinder head bolt torque values Lubricate threads with oil and sequentially torque to 30 35 ft Ibs Refer to the K361 Service Manual TP 1288 for torque sequence a Clean the gasket surfaces of the rocker arm housing and cylinder head Place new gasket over the valve springs on cylinder head Install gasket with the red silicone bead facing up and away from cylinder head 6 Secure the rocker arm housing to cylinder head with the capscrews NOTE Twodifferent sized capscrews may be used to secure the rocker arm housing to the cylinder head Certain specifications use 3 1 4 20x1 capscrews others may use 2 1 4 20x1 and 1 5 16 18x1 1 4 capscrews Torque the 1 4 20x1 capscrews to 70 in Ibs Torque the 5 16 18x1 1 4 capscrews to 150 in Ibs Lubricate the threads with oil before installing 7 Check valve clearance between end of rocker arm and valve stem using a feeler gauge Both intake and exhaust valve clearances should measure 0 005 cold adjust if necessary Refer to K361 Service Manual TP 1288 for specific valve clearance adjustment procedure 8 Secure rocker arm housing cover and head baffle to engine Reconnect the battery negative le
64. ng adjust so that stones are in contact with walls Use of a commer cial cutting cooling agent is recommended With the lower edge of each stone positioned even with the lowest edge of the bore start drill and honing proc ess Move hone up and down while reboring to prevent formation of cutting ridges Check size frequently When bore is within 0025 of desired size remove Coarse stones and replace with burnishing stones Continue with burnishing stones until within 0005 of desired size then use finish stones 220 280 and pol ish to final size A cross hatch should be observed if honing is done correctly The cross hatch should intersect at approxi mately 25 30 Too flat an angle could cause the rings to spin and not seat properly see Figure 7 14 4 After reboring carefully clean cylinder wall with soap and water then after drying thoroughly apply light coat of SAE 10 oil to prevent rust Figure 7 14 Cylinder Bore Cross Hatch After Honing SECTION 8 ASSEMBLY BEARINGS If the crankshaft bearings were removed or are being re placed it will be necessary to press them into place one in the bearing plate and one in the cylinder block GOVERNOR GEAR 1 If the governor gear stub shaft was damaged or worn press the replacement shaft into the block until it pro trudes 3 8 above the boss 2 The governor cross shaft spacer and bushing nut should now be installed 3 Place the thrust washer o
65. ngine is running or immediately after engine shutdown Handie storage batteries care fully Never charge batteries in an en closed area or cause arcing or a spark near battery Never leave ignition switch on when charging Never touch any electrical wires or components while engine is running Never tamper with governor settings to increase the maximum speed of the engine Approved containers can be readily identified preventing mix ups Exposing gasoline to sources of heat may result in explosion Ignition spark or hot exhaust gases could ignite gas fumes resulting in an explosion All exhaust contains poisonous carbon monoxide gas Protonged breathing will result in death Hands feet clothing and hair can get caught in moving parts resulting in injury to you Engine could accidently start if turned over while you are working on equipment These engine components become extremely hot when engine is run ning and remain so for a short time after engine is shut down These hot parts can burn you Storage batteries contain corrosive acid that can burn you Storage batteries give off highly explosive hydrogen gas Accumula tions of this gas exposed to heat or spark can explode and hurt you A switch left on with the battery connected can cause the ignition coil to overheat and possibly explode Electrical wires and components may be sources o
66. nion moves laterally on a splined sleeve into mesh with the flywheel ring gear When the pin ion butts against a stop washer at the enc of the armature shaft the pinion rotates along with the armature to crank the engine The armature and pinion remain in positive en gagement until the engine fires and attains the speed where the flywheel begins overriding the armature Atthis instant the greater momentum of the flywheel throws the pinion out of mesh and back into the retracted or disen gaged position After the starting circuit is opened and as the armature coasts to a stop a small anti drift spring holds the pinion in the retracted position see Figure 5 11 CAUTION In the event of false start that is if the en gine gets up sufficient speed to disengage the starter but fails to continue running the en gine must be allowed to come to a complete halt before a restart attempt is made If the fly wheel is still rotating when the starter is en gaged the pinion and ring gears may clash DO NOT attempt to crank the engine contin uously more than 10 seconds at a time if starter motor will not turn over the engine shut off starter motor immediately and make no further attempt to start engine until the condition is corrected Always allow a starter motor cool down peri od between cranking attempts if the engine does not start A 60 seccond cool down peri od is required after a 10 second cranking pe riod Failureto follow
67. ntil after the crank shaft is reinstalled Proper gear end play 002 010 is attained with one 005 spacer one 010 spacer and one 020 spacer which are installed on the snap ring retainer end of the shaft Install the thickest spacer 020 next to the retainer After installing retainer re check end play see Figure 8 2 and adjust add or sub tract 005 spacers if needed NOTE Install retainer with rounded edge facing spacers Figure 8 3 Checking Camshaft End Play 37 CRANKSHAFT Assembly tool Y 357 simplifies procedure tor timing bat ance gears to crankshaft Retiming is necessary when ever the crankshaft is reinstalled 1 Turn both balance gears so that primary timing marks line up with teeth on tool then insert tool in mesh with gears see Figure 8 4 Bearing Oil Drain Hole Assembly Tool Figure 8 4 Aligning Balance Gears and Assembly Too 2 38 Hold gears with tool butted against gasket surface of block align standard marks on crankshaft with bear ing oil drain hole then lower shaft until crankgear is just started into mesh about 1 16 in balance gears Remove tool align crankshaft and camshaft timing marks then press crankshaft ali the way into crankcase see Figure 8 5 Timing Mark gs Figure 8 5 Aligning Crank Gear to Cam Gear As a final check turn crankshaft to see if standard tim ing mark on crankshaft lines up with the secondary tim ing mark on
68. ompression rings must be installed with groove or bevel up when this is on inside diameter of ring The chrome ring when used must be installed in the top groove When bevel is on outside of ring install in down N position or toward skirt see Figure 7 10 Ring instal lation instructions are usually included with new ring sets Follow instructions carefully Use ring expander to install rings and check side clearance of each ring after installation see Figure 7 11 For side clearances see Specifications Wear Tolerances Torques and Special Tools Section 9 Inspection Connecting Rod Check bearing area big end tor excessive wear score marks running and side clearance see Specifications Wear Tolerances Torques and Special Tools Section 9 Replace rod and cap if scored or excessively worn Con necting rods with bearing area 010 undersize are avail able for use with reground crankpin Worn Rings Shiny Surtace Figure 7 9 Checking Ring End Clearance in Bore 33 BOTTOM GROOVE MIDDLE GROOVE Install Top Ring Last Inside Bevel TOP GROOVE Install Bottom Service 4 Piece Ring First J Service 3 Piece Marking on Ring Ring With Inside Bevel Up or With Top Marking Up Lo Figure 7 11 Checking Ring Side Clearance BALANCE GEARS The balance gears can be separated from the engine block by removing the retaining ring that holds the gears to
69. onvenient engine surface Hold the plunger ap proximately 1 4 in front of the solenoid then turn igni tion switch to ON Release the plunger If the plunger is drawn into the solenoid the shut down control is func tioning properly The solenoid is faulty and must be re placed if the plunger is not drawn in Refer to Figure 4 4 for identification of parts As a temporary fix the plunger can be removed from the shut down control and the solenoid reinstalled minus plunger until a replacement solenoid can be obtained NOTE Do not discard plunger as it must be reused with replacement solenoid After replacing solenoid reset main fuel adjusting screw according to specification see Carburetor Adjustments Section 4 The removal of the plunger will not affect normal car buretor function however it is important to reinstall de fective solenoid over shut down control vent hole after plunger removal to prevent unfiltered air from entering the carburetor 12 Main Fuel Adjusting Screw Solenold Retaining Bracket Shutdown Control To Ignition Coil Side DA Shutdown Solenoid Shutdown Control Components Figure 4 4 Engine Shutdown Control FUEL PUMP The K361 has a mounting pad and provision on crankcase tor a mechanically operated fuel pump On some applica tions with gravity feed systems the pad is covered and the fuel pump is not used Fuel Pump Operation The mechanical
70. or Turn Cross Shaft Counterclockwise jas Far as it Will Go Tighten Governor A Arm Nut APA A Figure 8 24 Adjusting Governor Arm AIR CLEANER ASSEMBLY 1 Attach a new adhesive backed air horn gasket to car buretor Peel backing off gasket then stick gasket to carburetor making sure that holes in gasket align prop erly with holes in carburetor see Figure 8 25 Connect air cleaner back plate Make sure tube from breather assembly protrudes through hole in back plate as shown in Figure 8 26 Slide air cleaner tube through back plate and into blow er housing NOTE Make sure tube is inserted so that the longest side of the angled tube end is facing down ward as in Figure 8 26 Also make sure lips of tube are in place around back plate hole Figure 8 25 Carburetor Air Horn Gasket Installed 4 Place air cleaner element over raised area on back plate 5 Put air cleaner cover over stud and tighten wing nut Make sure cover forms a tight seal with back plate GRASS SCREEN Screw grass screen to flywheel and torque screws to 115 in Ibs Figure 8 26 Installing Air Cleaner Back Plate and Tube The engine is now completely assembled Make sure the crankcase is filled with oil before starting the engine see Qil Recommendations Section 1 45 SECTION 9 SPECIFICATIONS WEAR TOLERANCES TORQUES AND SPECIAL TOOLS GENERAL SPECIFICATIONS Bore Nominal SOK ris et ne voe ere
71. ore than 005 reboring is neces sary Use an inside micrometer to determine amount of wear see Specifications Wear Tolerances Torques and Special Tools Section 9 If cylinder bore is not damaged and is within tolerances only light deglazing with a 220 280 finishing stone will be necessary Reboring Cylinder Remove the old oil seals from the block but do not install new seals until after the crankshaft is reinstalled Check all gasket surfaces to make sure they are free of gasket fragments Gasket surfaces must also be free of deep scratches or nicks If the cylinder bore is badly scored excessively worn or tapered out of round more than 005 reboring is neces sary Use an inside micrometer to determine amount of wear see Specifications Wear Tolerances Torques and Special Tools Section 9 then select the nearest suitable oversize of either 010 020 or 030 Reboring to one of these oversizes will allow usage of the available oversize piston and ring assernblies 35 While most commercially available cylinder hones can be used with either portable drills or drill presses the use ofa low speed drill press is preferred as it facilitates more ac curate alignment of the bore in relation to the crankshaft crossbore Honing is best accomplished at drill speed of about 250 RPM at 60 strokes per minute After installing coarse stones in hone proceed as follows T 36 Lower hone into bore and after centeri
72. ows Model and Specification Numbers Serial Number Figure 1 1 Engine Identification Model Number is the model series within which the en gine is built and indicates a the cubic inch displace ment and b number of cylinders The model K361 de notes a 36 cubic inch displacement single cylinder engine Letter suffixes following the model number desig nate a specific version the letter code is as follows Suffix Designates Oil Pan Type Clutch Model Pump Model Quiet Model Electric Start Retractable Start F402910 gt Model number without a letter suffix indicates a rope start version Specification Number is the model variation and is used to indicate the combination of various parts groups used to build an engine It may have a suffix letter which deter mines supersession of parts The first three digits of the spec number designate the engine model 231 for in stance designates the K361 engine The remaining num bers are issued in numerical sequence as each new speci fication is released for example 23100 23101 23102 Serial Number is the order in which the engine was built If a change occurs to a model or specification the serial number is used to indicate the point at which this change was made The first digit in the serial number is the code designation for year of manufacture The chart following shows the year and corresponding first digit code for the serial number Year Fi
73. rmally replace defective part Possible Fault and Correction Battery check specific gravity of battery if low recharge or replace battery as necessary Problem Starter Energizes but Turns Slowly Possible Fault and Correction Battery check specific gravity of battery if low recharge or replace battery as necessary Possible Fault and Correction Brushes remove end cap check for excessively worn or dirty brushes and commu tator Use a coarse cloth not emery cloth to clean Re place brushes if excessively or unevenly worn see brush replacement procedure BRUSH REPLACEMENT The starter must be completely disassembled to service brushes and commutator however disassembly can be done quickly and easily see Figure 5 11 Proceed as follows 1 Remove drive pinion unit 2 Remove thru bolts 24 3 Remove end bracket capscrew from end cap then turn bracket so that it will not interfere with removal of mounting bracket 4 Slip mounting bracket and frame off over drive end of armature Separate end cap from armature NOTE Brush springs will probably fall out when brushes pull free of commutator Clean up commutator with a coarse lint free cloth if badly worn or grooved turn down on lathe Replace brushes as follows The input brushes are part of the termina stud assembly To replace remove nuts and pull stud out through inside of end cap Insert new stud terminal brush unit after tr
74. rst Digit Year First Digit 1969 1 1974 6 1970 2 1975 7 0 2 1971 3 1976 7 3 1972 4 1977 8 1973 5 1978 9 Both 1975 and 1976 first digit numbers are 7 however the digit following the 7 second digit starts at 0 and runs to2 for 1975 and starts at 3 for 1976 GENERAL SPECIFICATIONS Bore Nominal SUOKG bas Seba cad tas Displacement Cubic Inches 3 3 4 95 mm 3 1 4 83 35 89 588 cc Horsepower at 3600 RPM 18 13 4 kw Weight Approximate Pounds 124 55 8 kg Oil Capacity U S Quarts 2 1 9 L Spark Plug Gap Standard Spark Plug Gap Resistor Spark Plug Size Millimeters Breaker Point Gap 035 0 89 mm 035 0 89 mm Shain arate 14 A IE 020 508 mm K361A engine models have a 1 1 2 qt 1 4 L capacity SAFETY WARNINGS 1 Store gasoline only in approved containers Store gasoline away from sources of heat such as radiators open flames sparks and unventilated sunlit storage areas Do not add gasoline while engine is running or start engine around spilled gasoline Never inhale exhaust fumes or tun engine in a closed building or confined area Never operate equipment with safety guards removed Always remove spark plug lead when working on engine or equip ment it powers Never touch the engine cylinder block exhaust system cylinder head baffles and shrouds while e
75. sembly of an engine make sure work area is in clean neat condition and that adequate tools are on hand Good lighting is also essential for proper in spection and reconditioning Observe all rules of safety when working on an engine Make sure cleaning solvents and other flammable liquids are properly identified and stored in covered containers safely away from danger of combustion from open flames sparks etc The best pro tection against accidents in all situations is provided main ly through the use of good common sense INSPECTION GENERAL When disassembling an engine carefully inspect and note the physical appearance of each of the components Often the appearance of parts will indicate operation under other than ideal eonditions In observing these indicators you may be able to suggest improved service and operat ing techniques which will result in prolonged engine ser vice life Some of the things to look for are 1 Excessive sludge and varnish formation 2 Scoring of the cylinder walls 3 Severe piston damage 4 Evidence of external oil leakage These are just a few of the more common indicators Num erous others exist and are obvious to the experienced me chanic Often the cause will become apparent in view of the particular condition of the part Always look for these signs when disassembling an engine prior to recondi tioning Excessive sludge This is a natural by product of com bustion and a small accumul
76. st port and elbow VALVE ASSEMBLY The valve assembly should be installed in the following order 1 Place valves into valve guides in cylinder head Make sure exhaust valve marked EXS is on exhaust mani fold side and intake valve marked INS is on intake manitold side 2 Install retainers valve springs tight coils toward cylin der head and valve rotators in that order 3 Using a valve spring compressor compress the spring and install valve keepers see Figure 8 13 Figure 8 13 Installing Valve Springs CYLINDER HEAD Always use a new gasket when head has been removed tor service work Lubricate cylinder head capscrews then tighten evenly using the proper sequence and torque as shown in Specification Wear Tolerances Torques and Special Tools Section 9 PUSH RODS AND TUBES 1 On each end of the push rod tubes there is an O ring seal These seals must be installed into seats in the cyl inder block and rocker arm housing before the push rod tubes are installed see Figure 8 14 2 Push tubes into holes in cylinder block then insert push rod into tubes making sure rods rest on tappets ROCKER ARM ASSEMBLY AND VALVE ADJUSTMENT 1 Assemble rocker arms to rocker arm shatt with retainer rings NOTE Always install retainer rings so that rounded edge is toward rocker arm 2 Screw valve adjusting screws into ends of rocker arms and secure with locknuts see Figure 8 15 3 Entire rocker arm
77. striking crank Figure 8 7 Installing Gaskets tor Crankshaft End Play 3 Crankshaft end play is measured with feeler gauge between inner race of rear bearing P T O end and shoulder on crankshaft see Figure 8 8 If end play is not within tolerance as stated in Specification Wear Tolerances Torques and Special Tools Section 9 re move bearing plate and add or subtract gaskets to achieve proper clearance Rear PTO End Bearing Figure 8 9 Pushing Piston into Cylinder Barrel 3 After piston assembly is installed place block on end then lubricate connecting rod big end crankpin and threads on connecting rod capscrews 4 Itis important that match marks on connecting rod and cap line up Align connecting rod on crank journal so that oil hole at the base of therod dipper faces the cam shaft see Figure 8 10 Measure Crankshaft End Play Figure 8 8 Measuring Crankshaft End Play 4 Install the stator first by sliding it over crankshaft and securing it to the bearing plate and second by thread ing the lead wires through the hole in the plate and out between the plate and the cylinder block Figure 8 10 Connecting Rod Match Marks 39 5 Rod cap lockwashers and capscrews are then at tached to connecting rod Use atorque wrench to over torque capscrews to 390 in Ibs then loosen screws and retorque to 300 in Ibs OIL PAN Use pilot studs to align cylinder block gasket and oil base
78. t all passages with compressed air Replace all worn and damaged parts Al ways use new gaskets Carburetor repair kits are avail able for most carburetors They include the bowl nut gas ket if required bowl ring gasket float pin bowl baffle gasket and fuel inlet needle and seat _ Possible Cause Probable Remedy Black sooty exhaust smoke engine sluggish Engine misses and backfires at high speed Engine starts sputters and dies under cold weather starting Engine runs rough or stalls at idle speed Erratic operation engine starving for fuel Mixture too rich readjust main fuel screw Mixture too lean readjust main fuel screw Mixture too lean turn main fuel adjustment 1 4 turn counterclockwise Idle speed too low or improper idle adjustment readjust speed then idle fuel screw if needed Air horn gasket is improperly aligned or wrong gasket realign or replace gasket Shutdown control not functioning replace solenoid Disassembly of Carburetor Side Draft see Figure 4 2 for location of parts 1 Remove carburetor from engine 2 Remove bowl nut gasket and bowl 3 Remove float pin float needle and needle seat Check float for dents leaks and wear on float lip or in float pin holes 4 Remove bowl ring gasket 5 Remove idle fuel adjusting needle main fuel adjusting needle and springs 6 Do not remove choke and throttle plates and shafts If
79. t and transmission in gear 1 Insufficient cool air available 2 Dirty air intake screen shroud or cooling fins 3 Improper fuel Overheating 4 Fuel mixture too lean 5 Improper ignition timing 6 Engine overloaded 7 Tight tappet clearance 8 Too much lube oil Fuel mixture too lean Improper timing Valve sticking Backfiring 1 Spark plug gap incorrect 2 Improper carburetor setting or lack of fuel 3 Wrong type spark plug 4 5 High Speed Skip Improper timing Faulty condenser Clogged fuel line Water in fuel Faulty choke control Improper fuel mixture Loose ignition connections Air leaks in carburetor or manifold connections Vent in gas cap plugged Fuel pump faulty Operating Erratically PADUA Improper carburetor idling adjustment Carburetor clogged Spark plug gap set too close Leaking carburetor or manifold gaskets Engine Will Not Idle BASIC ENGINE TESTS Crankcase Vacuum Test A partial vacuum should be present the crankcase when engine is operating at normal temperatures An engine in good condition wil have crankcase vacuum of 5 to 10 water column as read on U tube water manometer or 3 8 to 3 4 Hg as calibrated on mercury vacuum gauge Crankcase vacuum check is best accomplished with the U tube manometer If vacuum is not in the specified range t
80. t be kept clean and unobstructed at all times IMPORTANT Never operate engine with blower housing or cooling shrouds removed These direct air flow past cooling fins Removal results in improper air circula tion overheating and engine damage External surfaces must be maintained in clean condition free of oil and dirt accumulation This is done not only for safety and appearance but because poor cooling effi ciency results from dirty external surfaces see Figure 3 4 Figure 3 4 Keep These Areas Clean and Free of Debris SECTION 4 FUEL SYSTEM CARBURETOR The K361 engine is equipped with a side draft adjustable jet carburetor It is adjusted in the factory and should not have to be reset If however one of the following condi tions is noted readjust carburetor immediately as incor rect setting can lead to fouled spark plugs overheating excessive valve wear or other problems see chart below CARBURETOR ADJUSTMENTS If readjustment becomes necessary stop the engine then turn the MAIN and IDLE fuel adjusting screws all the way in until they bottom lightly CAUTION Do not force adjusting screws closed as dam age to needle valves will result Main Fuel Adjustment Preliminary setting turn screw out 2 1 2 turns Final set ting start engine and raise engine speed to maximum governed no load speed Turn screw in just until engine speed decreases and note the position of the screw Now turn the screw
81. ten more severe than detonation dam age often a hole is quickly burned right through the pis ton dome by preignition Preignition is caused by a hot spot in the combustion chamber from sources such as glowing carbon deposits blocked fins improperly seated valves or wrong spark plugs Service Pistons and Rings Service ring replacement sets and piston assemblies are available in the standard size plus 010 020 and 030 oversize sets Service type rings and piston assemblies are used when the cylinderis worn out within wear and out of round limits see Specifications Wear Tolerances Torques and Special Tools Section 9 Service ring sets usually include expanders or other arrangement to pro vide uniform pressure on ring and better conformity to cyl inder wall regardless of wear Cylinder bore must be de glazed before service ring sets are used Some important points to remember when servicing pis ton rings 1 If the cylinder block does not need reboring and if the old piston is within wear limits and free of score or scuff marks it may be reused Never reuse old rings Remove old rings and clean up grooves 3 Before installing new rings on piston place top two rings each in turn in its running area in cylinder bore and check end clearance End clearance in a new bore is 010 020 Maximum end clearance in used bore is 030 see Figure 7 9 4 Rings must be installed according to markings on rings C
82. th out a battery in the system 3 Amp System Service See Figure 5 8 NOTE Always zero voltmeters and ohmmeters one each scale before testing or inaccurate readings will result Problem Battery Not Charging Test 1 Check battery voltage across the battery termi nals using DC voltmeter with engine running at 3000 RPM If voltage is 12 5 or less the stator or diode is defec tive Test 2 Disconnect battery charging lead from battery measure DC voltage from charging lead to ground with engine running at 3000 RPM If voltage is over 45 the sta tor is OK APPLICATION DIAGRAM Key Switch Fue Off Run Start Optional 5 amp buss 3 Ags fuse or equivalent CAUTION Fuse holder rating must be the same or greater than fuse used Battery charging lead should be 74 GA 125 C insulation or equivalent Ammeter Solenoid 12 Volt Battery Test 3 Disconnect battery charge lead from battery mea sure resistance of lead to ground Now reverse the ohm meter leads and take the resistance reading again In one instance a reading of infinity ohms open circuit should be noted In the other instance the needle should read about mid scale with meter set at Rx1 If both resistance readings are low the diode is shorted If both resistance readings are high the diode or stator is open Test 4 Cut the sleeving on the battery charge lead to ex pose the diode connections Check resistance on the sta tor side of
83. the flywheel the alter nator stator mounted on the bearing plate of the engine and a rectifier regulator unit which is mounted on the starter motor side of the blower housing Use the testing procedures below when servicing this system CAUTION 1 Donotattempt to run the engine without an APPLICATION DIAGRAM Key Switch Fuse Oft_Run Start Optional 30 amp buss Ags 30 fuse or equivalent Plug CAUTION Fuse holder must be same or greater rating than fuse Fuse B lead should be 14 GA 125 C insulation or equivalent ME Solenoid activated acid filled battery in the sys tem as damage to the rectifier reguiator will resuit 2 Make sure battery polarity is correct Nega tive ground systems are used 3 Prevent alternator leads AC from touch ing or shorting This could permanently damage the stator 4 Disconnect leads at rectifier regulator be fore electric welding is done on equip ment in common ground with the engine 15 Amp System Service See Figure 5 10 NOTE Always zero voltmeters and ohmmeters on each scale before testing or inaccurate readings will result Problem Battery Not Charging Test 1 At 3600 RPM no load and with B cable connect ed check B at terminal on rectifier regulator to ground with DC voltmeter If 13 8 volts or higher place minimum ENGINE DIAGRAM AC 12 Volt Battery r Rectifier B Regulator i I DE Auto
84. these guidelines may re Sult in burn out of the starter motor If the starter motor fails to start as the result of a low charged battery recharge the battery 7 Permanent Ts Magnets RY ty M A Spring Thru Bolt 7 Bip Armature E 4 Mounting s Plate t amp Drive Pinion Without Dust Shield Pinion Stop Pinion Shield Stop Retainer Nut Figure 5 11 Exploded View of Typical PM Starter Jumping the battery is not recommended however if a charger is not available jumping can be done provided the battery used does not exceed the recommended amp hour rat ing for the engine Recommended amp hour ratings for this engine are 32 through 45 NOTE If higher amp hour rated battery is used the higher amperage could damage the armature windings in the starter motor Make sure the special shouldered capscrews and lockwashers are used In addition to se curing the starter to the machined surface on the crankcase these special capscrews prop erly align the pinion tothe ring gearontheen gine Use of ordinary capscrews will allow the starter to shift which could result in clashing of the gears DRIVE ASSEMBLY If pinion is badly worn or has broken teeth replace drive as a unit see Figure 5 11 To do this hold armature shaft and remove dust shield stop nut spacer anti drift spring and shield retainer then slip drive unit off over spline and armature shaft Lea
85. these parts are worn replace carburetor assembly Main Fuel Adjusting Needle 7 Idie Fuel Adjusting 4 Idie Speed Adjusting Screw 8 Gasket Bowl C Gasket Battie Fuel Inlet Needle a and Seat Float Bend Tab With Screwdriver Blade Assembly of Carburetor Side Draft see Figure 4 2 for lo cation ot parts 1 Install needle seat needle float and float pin 2 Set float level With carburetor casting inverted and float resting lightly against needle in its seat there should be 11 64 plus or minus 1 32 of an inch clear ance between machined surface of casting and free end of float side opposite needle seat 3 Adjust by bending lip of float with small screwdriver 4 Install new bowl ring gasket bow baffle gasket new bow nut gasket when required and bowl nut Tighten securely after making sure bowl is centered on gasket Use Repair Kit for Reconditioning 11 64 Figure 4 2 Side Oraft Carburetor 10 5 Install main fuel adjustment needle and spring Turn in until needle seats in nozzle and back out 2 1 2 turns 6 Install idie fuel adjustment needle and spring Back out approximately 3 4 to 1 full turn after seating lightly against jet CAUTION Do not use force on adjustment needles AUTOMATIC CHOKE AND SHUTDOWN CONTROL Some K361 engines are equipped with an optional Thermo Electric Automatic Choke and Fuel Shutdown Solenoid The au
86. tomatic choke and shutdown solenoid function as follows Automatic Choke Function The choke valve position is determined by two systems First a thermostatic heat sensitive spring positions the choke valve based on air temperature Second a rotary solenoid electro magnet pulling on rotatable shaft is en gaged during cranking and operates through the thermo static spring to close the choke further When the crank ing circuit is de energized the rotary solenoid disengages and the choke plate is returned to a position determined by the thermostatic spring As the engine starts to run and warm up the thermostatic spring is heated by a thermis tor which fully opens the choke valve The full open valve position is maintained as the thermistor continues to heat the spring by its regulation of current flow See Figure 4 3 tor additional automatic choke information Automatic Choke Service Guide WARNING Before working on or near the carburetor or choke area or when checking choke opera tion during cranking always remove spark plug lead to prevent engine from starting ac cidentally and to avoid personal injury Use this service guide to help maintain proper choke func tion Faulty lead wires or terminals Air cleaner gasket interference with choke shaft lever Choke Won t Close When Cranking Open circuit in solenoid winding Shutdown Solenoid Choke Spring 1 2 Turn Tension One Lead to Ground the Ot
87. tor 3 Disconnect plug before electric welding is done on equipment powered by the en gine and in common ground with it 4 Do not operate for any length of time with out a battery in the system 3 6 Amp System Service See Figure 5 9 NOTE Always zero voltmeters and ohmmeters on each scale before testing or inaccurate readings will result APPLICATION DIAGRAM QM 21 Key Switch Ott use Run Start Optional 5 amp buss 3 Ags fuse or or greater than fuse Battery charge lead should be 14 GA 125 C insulation or equivalent Fuse equivalent CAUTION Fuse holder rating must be same Problem Battery Not Charging Test 1 Check battery voltage across the battery termi nals using DC voltmeter with engine running at 3000 RPM If voltage is 12 5 or less the stator or diode is defec tive Test 2 Disconnect battery charging lead from battery measure DC voltage from charging lead to ground with engine running at 3000 RPM If voltage is over 17 the sta tor is OK Test 3 Disconnect auxiliary load lead from switch mea sure DC voltage from auxiliary lead to ground with engine running at 3000 RPM If voltage is over 17 the stator is OK Test 4 Disconnect battery charge lead from battery and auxiliary load lead from switch measure resistance of both leads to ground Now reverse the ohmmeter leads and take the resistance reading again In one instance a reading of infinity ohms open cir
88. ve new drive unit off if further disas sembly of starter is required drive unit is the last part to be reinstalled Before reinstalling the drive unit thor oughly clean the drive shaft and pinion gear then apply a small amount of Lubriplate AERO grease to the shaft To reinstall the drive unit slip the pinion gear onto the arma ture shaft then replace the shield retainer anti drift spring pinion stop stop nut coat threads with Loctite retaining compound and tighten to 160 in Ibs torque and finally snap on the dust shield 23 RING GEAR If inspection of the ring gear reveals broken excessively worn or otherwise damaged teeth the flywheel must be replaced Starter Motor Service Problems that can occur during normal usage are listed in the accompanying chart The symptom possible cause and the suggested remedy are stated If these steps do not solve the problem the starting motor should be replaced Replacement of the end cap assembly which includes the negative brush and spring is the only recommended field service that requires partial disassembly of the motor Problem Starter Falls to Energize Possible Fault and Correction Wiring check for badly corroded or loose connections also broken or frayed in sulation Clean and tighten connections replace wires in poor condition Possible Fault and Correction Starting Switch or Sole noid bypass the switch or solenoid with jumper wire if starter cranks no
89. ver the stub shaft then slide the governor gear into place over the shaft Finally Screw in the governor stop pin to prevent the governor gear from sliding off the stub shaft BALANCE GEARS 1 If the stub shaft is worn or damaged press the old shaft out and install new shaft Press the shaft in until it is 1 110 above the stub shaft boss a 3 8 spacer must be used with the shaft see Figure 8 1 Figure 8 2 Checking Balance Gear End Play CAMSHAFT AND TAPPETS 1 With cylinder block upside down lubricate and insert tappets in valve guides 2 Position camshaft inside block then lubricate cam shaft pin and insert into the block from the bearing plate side of the engine Before pushing pin through cam shaft slip one 005 washer end play between end of camshaft opposite gear end and block Push rod through camshaft and tap lightly until pin just starts into bore at P T O end of block Check end play with feeler gauge If within tolerance see Specifications Wear Tolerances Torques and Special Tools Section 9 press pin into final position or remove pin and add or subtract 005 and 010 washers as necessary to at tain proper end play see Figure 8 3 010 Spacer Figure 8 1 Installing Balance Gears 2 Slip one 010 spacer on stub shaft over the 3 8 spac er then install gear bearing assembly on stub shaft with timing marks out if assembly tool is not being used do not install bottom gear u
90. y indicate improperly serviced breather systems Normally an engine operates internally at pres sures less than atmospheric or in other words with a negative crankcase pressure If positive pressures build up within the crankcase from a clogged breather or from piston blowby oil will be forced out of an engine at oil seals gaskets or any other available spot DISASSEMBLY Prior to disassembly remove drain plugs and allow ample time for complete drainage of fuel and lubricating oil It is good practice to do this outside or at a location away from the work bench to keep this area in clean condition If en gine is dirty externally it should be steam cleaned or thor oughly cleaned in some other manner before being moved to the work bench Keep the work area in cleanest possi ble condition at all times After disassembly all parts should be thoroughly cleaned dirty parts cannot be accurately gauged or inspected properly for wear or damage There are many commer cially available cleaners that quickly remove grase oil and grime accumulation from engine parts If such a cleaner is used make sure thatall trace of the cleaner is removed be fore the engine is reassembled and placed in operation Even small amounts of these cleaners quickly break down the lubricating properties of engine oils CAUTION To prevent unintentional starting discon nect battery and or spark plug leads before doing any work on engine or equipment driv e
91. ying illustrations use these as guides for spark plug analysis Normal A plug from an engine operating under good con ditions will have light tan or gray colored deposits If the center electrode is not rounded off a plug in this condi tion could be regapped and reused 15 Worn Out On a plug which has been in service too long the center electrode will be rounded off and the gap will be eroded 010 or more than the original setting Replace worn plugs as they will require excessive voltage to fire properly Carbon Fouled Soft sooty black deposits indicate in complete combustion which could be attributed to rich carburetion weak ignition retarded timing or poor com pression 16 Wet Fouled A wet fouled plug could be caused by drown ing with raw fuel or oil in the combustion chamber The raw fuel problem may be caused by operating with too much choke Oil in the combustion chamber area is usu ally caused by worn rings or valve guides Overheated Overheating will be indicated by chalk white colored deposits not burned black as might be expected This condition is also usually accompanied by excessive gap erosion Overadvanced timing lean carburetion clogged air intake and blocked cooling fins are some of the causes of overheating When changing spark plug keep thisin mind NOTE Cer tain federal state and local laws require the use of resistor or shiel

Download Pdf Manuals

Related Search

Related Contents

  Graco Inc. 1204E Pressure Washer User Manual  MANUAL DE INSTALACION Y MANTENIMIENTO  téléchargez la fiche de spécifications    

Copyright © All rights reserved. Failed to retrieve file