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Kohler CV1000 User's Manual

1. Figure 8 5 Removing Cylinder Shrouds 2 Remove the four mounting screws and separate the blower housing from the backing shroud assembly One screw also secures the oil fill dipstick tube See Figure 8 6 The fixed guard equipped models may be removed with the blower housing E EL 1 E ol j g 2 _ a Figure 8 6 Removing Blower Housing 3 Remove the lower mounting screw and pull the oil fill tube out of the crankcase Oil Fill Tube Lower Mounting Screw Location Figure 8 7 Removing Oil Fill Tube Remove Electric Starter Motor 1 Disconnect the leads from the starter 2 Remove the two hex flange screws and starter See Figure 8 8 Figure 8 8 Removing Electric Starter Remove Air Cleaner Assembly 1 Disconnect the breather hose from the air cleaner and the formed vent hose from the vent port on the carburetor 2 Remove the four hex flange nuts and ground lead from the mounting studs See Figure 8 9 Section 8 Disassembly Temi itis Sven Hose Ground Lead Breather Hose Figure 8 9 Air Cleaner Mounting Details 3 Remove the two screws securing the air cleaner and main control bracket to the intake manifold bosses See Figure 8 10 Mounting Screws Figure 8 10 Mounting Screws 4 Remove the air cleaner from the engine as an assembly See Figure 8 11 Figure 8 11 Removing Air Cleaner Assembly 8 3 Section 8 Disas
2. Float level is set too high Separate carburetor air horn from carburetor body adjust float according to Float Replacement procedure Dirt under the fuel inlet needle Remove needle clean needle and seat and blow with compressed air Bowl vent or air bleeds plugged Remove low idle fuel adjusting needle Clean vent ports and air bleeds Blow out all passages with compressed air Leaky cracked or damaged float Submerge float to check for leaks Engine runs lean indicated by Low idle fuel mixture is improperly adjusted Adjust low idle misfiring loss of speed and power fuel needle some models governor hunting or excessive Float level is set too low Separate carburetor air horn from throttle opening carburetor body adjust float according to Float Replacement procedure Idle holes plugged dirt in fuel delivery channels Remove low idle fuel adjusting needle Clean main fuel jet and all passages blow out with compressed air 4 Fuelleaks from carburetor Float level set too high See Remedy 2d Dirt under fuel inlet needle See Remedy 2e Bowlvents plugged Blow out with compressed air Carburetor bowl gasket leaks Replace gasket 5 4 High Altitude Operation When operating the engine at altitudes of 1500 m 5000 ft and above the fuel mixture tends to get over rich This can cause conditions such as black sooty exhaust smoke misfiring loss of speed and power poor fuel economy and
3. 7 14 NOTE A flashing LOW light can also occur as a result of an inadequate ground lead connection Make certain the connection location is clean and the clamp is secure 15 Amp Rectifier Regulators 1 Connect the tester ground lead with spring clamp to the body of the rectifier regulator being tested 2 Connect the tester red lead to the B terminal of the rectifier regulator and the two black tester leads to the two AC terminals See Figure 7 19 Figure 7 19 Tester Connected to 15 Amp Rectifier Regulator 3 Plug the tester onto a 110 volt outlet and turn on the power switch See Figure 7 17 The POWER light should be illuminated and one of the four status lights may be on as well This does not represent the condition of the part 4 Press the TEST button until a click is heard and then release See Figure 7 18 Momentarily on of the four status lights will illuminate indicating the condition of the part a Ifthe OK green light comes on and stays steady the part is good and may be used b Ifany other light is displayed the rectifier regulator is faulty and should not be used NOTE A flashing LOW light can also occur as a result of an inadequate ground lead connection Make certain connection location is clean and clamp is secure Troubleshooting Guide 15 20 25 Amp Battery Charging Systems When problems occur in keeping the battery charged or the battery charges at too high a r
4. Adjustments NOTE Do not tamper with the governor setting Overspeed is hazardous and could cause personal injury General The governed speed setting is determined by the position of the throttle control It can be variable or constant depending on the engine application Initial Adjustment Procedure Make this adjustment whenever the governor arm is loosened or removed from the cross shaft See Figure 5 36 and adjust as follows 1 Make sure the throttle linkage is connected to the governor arm and the throttle lever on the carburetor 2 Loosen the hex nut holding the governor lever to the cross shaft 3 Move the governor lever toward the carburetor as far as it will go wide open throttle and hold in this position 4 Insert a long thin rod or tool into the hole on the cross shaft and rotate the shaft clockwise viewed from the end as far as it will turn then torque the hex nut to 7 3 N m 65 in Ib High Speed RPM Adjustment Refer to Figure 5 37 1 With the engine running move the throttle control to fast Use a tachometer to check the RPM speed 2 Turn the inner upper screw outward to decrease or inward to increase the RPM speed Check RPM with a tachometer 5 15 Section 5 Fuel System and Governor 3 Stop when the desired RPM speed is obtained I FulliThrottlez positions E High Speed RPM m gt Mrs djustment Screw Figure 5 37 Adjusting High Speed RPM Air Cleaner R
5. 21 22 23 24 29 26 24 28 29 30 SI 92 33 Remove spark plugs Remove valve covers Remove cylinder heads and hydraulic lifters Remove breather assembly Remove oil pan assembly Remove camshaft Remove connecting rods with pistons and rings Remove crankshaft Removal of governor gear Remove governor gear yoke cross shaft and seal Remove lifter feed chamber cover and gaskets Remove flywheel and PTO end oil seals Removal of main bearings Disconnect Spark Plug Leads 1 Disconnect the leads from the spark plugs See Figure 8 1 NOTE Pull on boot only to prevent damage to spark plug lead Figure 8 1 Disconnect Spark Plug Leads 8 1 Section 8 Disassembly Shut Off Fuel Supply Drain Oil from Crankcase and Remove Oil Filter 1 Clean the oil filter and housing area Remove and discard the oil filter See Figure 8 2 Figure 8 2 Removing Oil Filter 2 Remove the dipstick and one of the oil drain plugs Figure 8 3 Removing Dipstick from Tube Drain Plug Starter Side Shown Figure 8 4 Oil Drain Plug Location 8 2 3 Allow ample time for the oil to drain from the crankcase Remove Muffler 1 Remove the exhaust system and attaching hardware from the engine Remove Cylinder Shrouds and Blower Housing 1 Remove the top mounting screw and loosen the two shoulder screws on each side Lift off the two cylinder shrouds See Figure 8 5 Cylinder Shroud
6. 40 HP TO T 90 mm 3 54 in EMO IK 2 veseseeeese sacssraetteaaa vanes anasseniaenoosenseanesstsassesnnteeinsretenses scot ata ILE OUSDRUES ERE ERRORES 78 5 mm 3 09 in Pipa GO TI 999 cc 60 96 cu in Compro Sioe a O Me 8 8 1 EAL IG E E E E 57 6 kg 127 Ib Oil Capacity w filter approximate determmed by oil miter SB Gaonsstpdeenedustebnp i dva UO n DRU 2a Dod Angle of Operation Maximum At Full Oil Level All Directions 25 Blower Housing and Sheet Metal M6 Shoulder Screw Torque Into New Untapped Hole casting ccsssctsscssesgssosssasaccesoscoseatsontsnsecosesmtonvesteaps 10 7 N m 95 in Ib Used Tapped Hole Cast soeur idi nte ptu pU pe 7 3 N m 65 in Ib New Extruded Hole sheet metal esses 4 0 N m 35 in Ib Used Extruded Hole sheet metal s entretient parete 2 0 N m 17 7 in Ib Moun ne Clip valley DAE costo FR EH RETI EIUS CIRERSDbIS UR E erion 2 5 N m 22 1 in Ib M6 Screw Torque New Untapped Hole CAStiIng Semen nner dtes a eSER na 10 7 N m 95 in 1b Used Tapped Hole COS BIB Jesse tisse tr tep E ROUEES ior i nipa peiner 7 3 N m 65 in Ib Rectifier RKegulator Fastener Ler Ue see tiesblp Ibo IEOSS SUI PENIS NISUS 2 0 N m 18 in Ib Oil ooler Fastener POROUS neS e EEE RE 2 2 N m 20 in Ib Camshaft Iz ruv mm M M 0 3 1 3 mm 0 011 0
7. 66 4 49 81 4 60 33 9 25 M12 36 6 27 47 5 35 82 7 61 116 6 86 139 7 103 61 0 45 M14 X 583 43 76 4 55 131 5 97 184 4 136 2197 162 94 9 70 Section 1 Safety and General Information English Fastener Torque Recommendations for Standard Applications Tightening Torque N m in Ib or 20 Bolts Screws Nuts and Fasteners Assembled Into Cast Iron or Steel Grade 2 or 5 Fasteners Into Aluminum Grade 2 Grade 5 2 3 20 2 8 25 2 3 20 3 6 32 4 5 40 3 6 32 4 5 40 7 9 70 13 0 115 9 6 85 15 8 140 28 3 250 30 5 270 18 7 165 22 6 200 17 0 150 39 6 350 18 7 165 29 4 260 33 9 300 Tightening Torque N m ft Ib or 20 40 7 30 47 5 35 67 8 50 54 2 40 81 4 60 47 5 35 74 6 55 108 5 80 61 0 45 101 7 75 142 4 105 67 8 50 108 5 80 155 9 115 94 9 70 101 7 75 135 6 100 149 2 110 189 8 140 199 3 150 271 2 200 142 4 105 169 5 125 223 7 165 244 1 180 311 9 230 332 2 245 440 7 325 Torque Conversions N m in lb x 0 113 N m ft Ib x 1 356 in lb N m x 8 85 ft Ib N m x 0 737 223 7 165 237 3 175 311 9 230 352 6 260 447 5 330 474 6 350 637 3 470 Section 2 Tools amp Aids Certain quality tools are designed to help you perform specific disassembly repair and reassembly procedures By using tools designed for the job you can properly ser
8. EDowneel Rebus OCHO TOn UC enana anata REE 67 8 N m 50 ft Ib 1 9 Section 1 Safety and General Information Grass Screen FNS CL a Cm 9 9 N m 88 in Ib NIoubtus SCTEW TOn uctenie eiusd pond us diete cert er tor ter 9 9 N m 88 in Ib Governor Governor Cross Shaft to Crankcase Running Clearance 0 025 0 087 mm 0 0009 0 0034 in Governor Cross Shaft O D Qc 7 963 8 000 mm 0 3135 3149 in SP Wate TAN E M 7 936 mm 0 3124 in Governor Gear Shaft to Governor Gear Running Clearance 0 070 0 160 mm 0 0027 0 0063 in Governor Gear Shaft O D p 5 990 000 mm 0 2358 0 2362 in IIoc WY Seats DIETE soror pecie ses sats ews auacliamseashoneudancetonentbneussantscasnaseteeatanneataee 5 977 mm 0 2353 in GOVeHOP Lever N t TORCIB S uses ereee cesta ie acta ore AN uM DES UM 7 3 N m 65 in Ib Ignition Spark Plug Type Champion or Equivalent ccena on eot petens XC10YC DDOLECETUS 33D escono AI dbive d etaditetd tutem A E spent detonated 0 76 mm 0 030 in vod T os wo oT ND 24 4 29 8 N m 18 22 ft Ib Io prac Modic Air Gap srera nor meer e ere rts tint mene rT rere 0 28 0 33 mm 0 011 013 in error Module Fastener TOROUB s estque minium ta cituiesti un pte 6 2 N m 55 in Ib into new holes or 4 0 N m 35 in Ib into used holes Lifter Feed Chamber Cover Bardo DCECM ge Loree si came neem rere
9. Install New Piston Rings To install new piston rings proceed as follows NOTE Rings must be installed correctly Ring installation instructions are usually included with new ring sets Follow instructions carefully Use a piston ring expander to install rings see Figure 9 11 Install the bottom oil control ring first and the top compression ring last Refer to Figure 9 12 Piston Ring Piston Ring Expander Figure 9 11 Installing Piston Rings Piston Ring End Gap Identification Mark gt J ZA Top Compression A Ring Center m Compression Ring PoE Expander Oil Control Ring Three piece Figure 9 12 Piston Ring Installation 1 Oil Control Ring Bottom Groove Install the expander and then the rails Make sure the ends of the expander are not overlapped 2 Middle Compression Ring Center Groove Install the center ring using a piston ring installation tool Make sure the identification mark is up or the dykem stripe if contained is to the left of the end gap 3 Top Compression Ring Top Groove Install the top ring using a piston ring expander Make sure the identification mark is up or the dykem stripe if contained is to the left of the end gap Connecting Rods Offset stepped cap connecting rods are used in these engines Inspection and Service Check the bearing area big end for excessive wear score marks running and side clearances refer to Sect
10. Internal damage may occur if installed incorrectly 4 Attach the new fuel pump using the hex flange screws Torque the screws to 2 3 N m 20 in Ib 5 Reconnect the fuel lines to the inlet and outlet fittings and secure with the clamps Carburetor General Engines in this series are equipped with a Keihin BK two barrel side draft carburetor with fixed main jets on a matching intake manifold The carburetor features a self relieving choke serviceable slow jets main jets and a fuel shutdown solenoid See Figure 5 9 Low Idle Fuel Adjustments With Limiters Self Relieving Choke Slow Jets 44 Fuel Shut Off Solenoid 1339 Bowl Drain Screw Figure 5 3 Keihin 2 Barrel Carburetor A warnine Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent 5 3 Section 5 Fuel System and Governor Troubleshooting Checklist e Make sure the air cleaner base and carburetor are When the engine starts hard runs roughly or stalls securely fastened to the engine using gaskets in at low idle speed check the following areas before good conditi
11. L ITITIII F3 t weit A massi Governor Lever Governor i Spring F Governed Idle Spring Figure 5 36 Governor Linkage Air Cleaner Removed for Clarity e As the flyweights move outward they cause the regulating pin to move outward e The regulating pin contacts the tab on the cross shaft causing the shaft to rotate e One end of the cross shaft protrudes through the crankcase The rotating action of the cross shaft is transmitted to the throttle lever of the carburetor through the external throttle linkage See Figure 5 36 e When the engine is at rest and the throttle is in the fast position the tension of the governor spring holds the throttle plate open When the engine is operating the governor gear assembly is rotating The force applied by the regulating pin against the cross shaft tends to close the throttle plate The governor spring tension and the force applied by the regulating pin balance each other during operation to maintain engine speed Section 5 Fuel System and Governor e When load is applied and the engine speed and governor gear speed decreases the governor spring tension moves the governor arm to open the throttle plate wider This allows more fuel into the engine increasing the engine speed As the speed reaches the governed setting the governor spring tension and the force applied by the regulating pin will again offset each other to hold a steady engine speed
12. ON Bevo CM GN SS HO 193NNOO SEIH ALIYV 10d Figure 7 13 Wiring Diagram 15 20 25 Amp Regulated Battery Charging System with DSAI Ignition and Five Pin Connector 7 12 Stator The stator is mounted on the crankcase behind the flywheel Follow the procedures in Section 8 Disassembly and Section 10 Reassembly if stator replacement is necessary Rectifier Regulator The rectifier regulator is mounted on the backing shroud assembly See Figure 7 14 To replace it remove the two mounting screws then disconnect the plug and ground lead NOTE When installing the rectifier regulator take note of the terminal positions and install the plug correctly Rectifier Regulator Connector Plug L Figure 7 14 Rectifier Regulator Testing of the rectifier regulator may be performed as follows using the appropriate Rectifier Regulator Tester see Section 2 To Test NOTE Disconnect all electrical connections attached to the rectifier regulator Testing may be performed with the rectifier regulator mounted or loose The figures show the part removed from the engine for clarity Repeat the applicable test procedure two or three times to determine the condition of the part 20 25 Amp Rectifier Regulators 1 Connect the single lead adapter in between the B center terminal of rectifier regulator being tested and the squared single end of the tandem adapter lead See Figure 7 15 Section 7 Elec
13. connecting rod and piston for reassembly Do not mix end caps and Remove Connecting Rods with Pistons connecting rods and Rings 1 Remove the two hex flange screws securing the closest connecting rod end cap Remove the end cap See Figures 8 54 and 8 55 8 13 Section 8 Disassembly 2 Carefully remove the connecting rod and piston 1 Remove the locking tab thrust washer and note assembly from the cylinder bore See Figure 8 56 orientation 2 Using a screwdriver carefully pry up to unseat governor gear assembly from the governor gear shaft Remove the regulating pin and governor gear assembly See Figure 8 58 Governor Gear Figure 8 56 Removing Piston Connecting Rod Assemblies 3 Repeat the above procedures for the other connecting rod and piston assembly Figure 8 58 Removing Governor Gear Remove Crankshaft 1 Carefully pull the crankshaft from the crankcase 3 Inspect the governor gear shaft for wear or See Figure 8 57 Note thrust washers and shims if damage Remove the shaft only if replacement is used needed Remove Governor Yoke Cross Shaft and Cil Seal 1 Remove the two mounting screws securing the yoke to the governor cross shaft See Figure 8 59 Figure 8 57 Removing Crankshaft Removal of Governor Gear Assembly The governor gear is held onto the shaft by small molded tabs in the gear When the gear is removed from the shaft these tabs are destroyed and the gear Figure
14. disconnect one spark plug lead Connect the spark plug lead to post terminal of spark tester Kohler Part No 25 455 01 5 and attach tester clip to a good engine ground NOTE Iftwo testers are available testing can be performed simultaneously for both cylinders However if only one tester is available two individual tests must be performed The side not being tested must have the spark plug lead connected or grounded Do not crank the engine or perform tests with one spark plug lead disconnected and not grounded or permanent system damage may occur T T Section 7 Electrical System and Components 2 Crank the engine over establishing a minimum of 550 600 RPM and observe tester s for spark 3 Repeat the spark test on the opposite cylinder if cylinders are being tested individually a Ifboth cylinders have good spark but the engine runs poorly or existing plug condition or appearance is questionable install new spark plugs gapped at 0 76 mm 0 030 in and retest engine performance If problem persists go to Test 3 b If one cylinder had good spark but the other cylinder had no spark or intermittent spark go to Test 4 c Ifthere was spark on both cylinders but power is suspect go to Test 3 Test 3 Check for Timing Advance 1 Makea line near the edge of the flywheel screen with a marking pen chalk or narrow tape See Figure 7 7 2 Connect an automotive timing light to cylinder that had good spa
15. yellow zone planning for overhaul or replacement Gauge reading in high red zone esess 3 4 Rings or cylinder worn Tm Defective exhaust valve improper seating Defective intake valve improper seating Piston rings and cylinder in good condition ree Engine is still usable but there is some wear present Customer should start Rings and or cylinder have considerable wear Engine should be reconditioned or replaced Section 4 Air Cleaner and Air Intake System Air Cleaners General These engines utilize a Heavy Duty style air cleaner as shown in Figure 4 1 consisting of a cylindrical housing attached to the carburetor and intake manifold The air cleaner housing contains a paper element and inner element designed for longer service intervals The system is CARB EPA certified and the components should not be altered or modified in any way Heavy Duty Style Air Cleaner Figure 4 1 Heavy Duty Style Air Cleaner Service Weekly and every 150 hours Check filter minder if equipped unhook the two retaining clips on each end and remove the end caps Perform inspection of the paper element and inlet screen area Seasonally or every 300 hours of operation more often under extremely dusty or dirty conditions replace the paper element and check the inner element Follow these steps 1 Unhook the two retaining clips on e
16. 7 N m 95 in 1b Figure 9 16 O Ring I installed in oi Pump Housing All Reinstallations 6 7 N m 60 in 1b 5 Lightly lubricate the I D of the inlet seal with oil and carefully insert the end of the pickup through the seal into the oil pump housing 6 Install the oil pump housing with the pickup tube over the oil pump boss and gears Position the relief valve baffle on screws 2 and 3 Align the three screw hole locations Baffle Mounting 4 P Coverin Screws ANNS Relief Figure 9 18 Oil Pump Screws Teraus Sequence 8 Install and torque the pickup mounting screw to 10 7 N m 95 in Ib into a new hole or 7 3 N m 65 in Ib into a used hole See Figure 9 17 Figure 9 17 Installing Oil Pump and Pickup 9 13 9 14 Section 10 Reassembly General NOTE Make sure the engine is assembled using all specified torque values tightening sequences and clearances Failure to observe specifications could cause severe engine wear or damage Always use new gaskets Apply a small amount of oil to the threads of critical fasteners before assembly unless a Sealant or Loctite is specified or preapplied Make sure all traces of any cleaner are removed before the engine is assembled and placed into operation Even small amounts of these cleaners can quickly break down the lubricating properties of engine oil Check the oil pan crankcase cylinder heads and valve covers to be certain that
17. 9 Section 9 Inspection and Reconditioning Replacement pistons are available in STD bore size and in 0 25 mm 0 010 in and 0 50 mm 0 020 in oversize Replacement pistons include new piston ring sets and new piston pins Replacement ring sets are also available separately for STD 0 25 mm 0 010 in and 0 50 mm 0 020 in oversize pistons Always use new piston rings when installing pistons Never use old rings Some important points to remember when servicing piston rings 1 Thecylinder bore must be deglazed before service ring sets are used 2 Ifthe cylinder bore does not need reboring and if the old piston is within wear limits and free of score or scuff marks the old piston may be reused 3 Remove the old rings and clean up the grooves Never reuse old rings 4 Before installing the new rings on the piston place the top two rings each in turn in its running area in the cylinder bore and check the end gap See Figure 9 9 Compare the ring gap to the specifications listed in Section 1 F i k d M P a dd h Figure 9 9 Measuring Piston Ring End Gap 5 After installing the new compression top and middle rings on the piston check the piston to ring side clearance Compare the clearance to specifications listed in Section 1 If the side clearance is greater than specified a new piston must be used Refer to Figure 9 10 9 10 Figure 9 10 Measuring Piston Ring Side Clearance
18. Crankshaft 10 19 Section 10 Reassembly Figure 10 78 Installing and Torquing Flywheel Fastener Install Ignition Modules 1 Rotate the flywheel to position the magnet away from the ignition module bosses 2 Connect the ground lead to the single kill tab and install the modules onto the crankcase bosses so the tab is away from you in The spark plug lead should be towards you out Mount the wiring harness clamp with the loop up on the starter No 1 side inner module screw and route the harness through it Attach the rectifier regulator ground lead to the outer screw See Figure 10 79 Figure 10 77 Installed Flywheel Key NOTE Make sure the flywheel key is installed properly in the keyway The flywheel can become cracked or damaged if the key is not properly installed 1 Install the woodruft key into the keyway of the crankshaft Make sure that the key is properly seated and parallel with the shaft taper 2 Install the flywheel onto the crankshaft being careful not to shift the woodruff key 3 Install the hex flange screw and washer Figure 10 79 Ignition Module Mounting Details 4 Usea flywheel strap wrench or holding tool to hold the flywheel Torque the hex flange screw 3 Slide the modules up as far away from the securing the flywheel to the crankshaft to flywheel as possible and snug the screws to hold 67 8 N m 50 ft Ib See Figure 10 78 them in that position 4 Rotate the flywheel
19. D 70 F BS n 44 030 44 037 mm 1 7334 1 7337 in Dla WA Cait a RR EO 0 070 mm 0 0028 in Connecting Rod to Crankpin Running Clearance s RR RRRNRE ea 0 030 0 055 mm 0 0012 0 0022 in Dass Wie ait E UE setae anaceee tcaeecansccoeecssessiecaucasuaceceavosaensatenocetsadecsan anc ccaseasenees 0 070 mm 0 0028 in Connecting Rod 10 C rank pin Side Ceara nee sca cscanssensencanseaasgonvonsvssbentoauss 0 30 59 mm 0 0118 0 0232 in Connecting Rod to Piston Pin Running Clearance 0 015 0 028 mm 0 0006 0 0011 in Piston Pin End I D 70 F LI m T 19 015 19 023 mm 0 7486 0 7489 in Toss ODE TERRE eso fedet eeEe E SERVIS IUS ERU NA ANC 19 036 mm 0 7494 in Crankcase Governor Cross Shaft Bore I D 8 025 8 050 mm 0 3159 0 3169 in M x Wear Linii ouo etre de podia pecca E ERES ad UE 8 088 mm 0 3184 in Breather Cover Fastener VON UN S snae i roii edes distorted AE RUE 5 7 N m 51 in Ib CIL DESIDIERIS TOG o o enr O Daun etn Id Mondo UI 21 4 N m 15 7 ft Ib Oil Pan ET SECC TORQUO aaa A 24 4 N m 216 in Ib Crankshaft PAETI dnm T rr 0 30 1 50 mm 0 011 0 059 in Crankshaft Bore In Crankcase New MarDeUr Main Bearing osito idea tre rr eeer ener err reernr erect 50 00 50 025 mm 1 9685 1 969 in yd Maim Dearing Inst
20. Install a new carburetor gasket onto the intake manifold with the tab up Make sure all holes align and are open Section 10 Reassembly 2 Attach the throttle and choke linkages to the carburetor if disconnected previously Install the carburetor with the linkages attached as an assembly See Figure 10 90 Gasket Tab Up FE Figure 10 90 Installing Carburetor onto Manifold Install Governor Lever 1 Install the governor lever onto the governor shaft and connect the throttle linkage with the black clip Do not tighten the governor lever at this time l Governor lever T ELE Governor Cross Shaft alm E m2 A S Figure 10 91 Installing Governor Lever 10 23 Section 10 Reassembly Install Control Bracket and Air Cleaner Assembly 1 Position the control bracket assembly onto the three intake manifold bosses aligning the mounting holes See Figure 10 92 Control S io A A NM a Bracket ex P n EN a F A TA We S 1 Mounting ME TeTer li o ats Figure 10 92 Installing Control Bracket 2 Install a new air cleaner elbow gasket onto the mounting studs 3 Slide the air cleaner assembly onto the four carburetor mounting studs attach the ground lead with star washer if used and finger tighten the hex flange nuts Align the two forward mounting holes in the base with the mounting holes bosses of the intake manifold and control bracket then start the two hex flan
21. Numerical Designation B Spec No CV940 0001 CV960 0001 CV980 0001 CV1000 0001 Complete Spec Number Incorporating Model No with Variation No of Basic Spec C Serial No 3705810334 Year Manufactured Code __ C Factory Code Code__Year 3 2007 38 2008 39 2009 Figure 1 2 Explanation of Engine Identification Numbers 1 3 Section 1 Safety and General Information Oil Recommendations Using the proper type weight and a consistent brand of oil in the crankcase is extremely important So is checking oil daily and changing oil regularly Failure to use the correct oil or using dirty oil causes premature engine wear and failure Cil Type Use high quality detergent oil of API American Petroleum Institute Service Class SJ or higher Select the viscosity based on the air temperature at the time of operation as shown in the following table RECOMMENDED SAE VISCOSITY GRADES NEM QEPEME NENNEN 10W 30 L3 Kohler 10W 30 SS NENNEN NN L TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE Use of synthetic oil having 5W 20 or 5W 30 rating is acceptable up to 4 C 40 F Synthetic oils will provide better starting in extreme cold below 23 C 10 F NOTE Using other than service class SJ or higher oil or extending oil change intervals longer than recommended can cause engine damage NOTE Synthetic oils meeting the listed classifications may be used with oil changes pe
22. This system uses a digital microprocessor which is located in the ignition modules The ignition timing varies depending upon the engine speed with this system BLUE IGNITION STARTER D MODULE WHITE CIGNITION CONNECTOR MALE y WHI FLYWHEEL x IGNITION KILL STATOR TO B ASS Y SPARK PLUG 2 CYLINDER SPARK PLUG 1 CYLINDER SS LET I ARSINO m REGULATOR ORANGE ORANGE RECTIFIER SOLENOID SHIFT Mehl STARTER ASS Y OPTIONAL REGULATOR M CONNECTOR BLOCK WHITE AC CHARGING Molex Plug LEADS Some Models SWITCH OPTIONAL Figure 7 3 Electronic CD Fixed Ignition Timing System Operation of CD Ignition Systems Operation As the flywheel rotates the magnet grouping passes the input coil L1 The corresponding Fixed Timing System magnetic field induces energy into the input coil L1 This system Figure 7 3 consists of the following The resultant pulse is rectified by D1 and charges components capacitor C1 As the magnet assembly completes its pass it activates the triggering device L2 which e Amagnet assembly which is permanently affixed causes the semiconductor switch SCS to turn on to the flywheel With the device switch ON the charging capacitor C1 is directly connected across the primary P of the e Two electronic capacitive discharge ignition output transformer T1 As the capacitor discharges modules which mount on the engine crankcase the current initiates a fast risi
23. a ot Figure 8 25 Removing Nipple b Remove the oil filter cup and spring from housing See Figure 8 26 F Kill Lead nd Disconnecting Ignition Figure 8 28 Removing a Housing Modules Figure 8 26 Disassembled Cup and Spring 8 7 Section 8 Disassembly Remove Grass Screen and Cooling Fan 1 Remove the screws attaching hardware and hex studs securing the grass screen stiffeners and cooling fan to the flywheel See Figures 8 29 and 8 30 Fasteners Figure 8 31 Removing Flywheel Fastener Using Holding Tool 2 Remove the hex flange screw and washer 3 Usea puller to remove the flywheel from the crankshaft See Figure 8 32 NOTE Always use a flywheel puller to remove the flywheel from the crankshaft Do not strike the crankshaft or flywheel as these parts could become cracked or damaged Figure 8 30 Removing Cooling Fan and Hex Studs Remove Flywheel 1 Usea flywheel strap wrench or holding tool see Section 2 to hold the flywheel and loosen the Figure 8 32 Removing Flywheel with a Puller hex flange screw securing the flywheel to the crankshaft See Figure 8 31 4 Remove the woodruff key from the crankshaft NOTE Always use a flywheel strap wrench or Remove Stator Rectifier Regulator and holding tool to hold the flywheel when loosening or tightening the flywheel screw Do not use any type of bar or wedge to hold the flywheel Use of such tools could cause the fly
24. adjusting screws This mixture is then mixed with the main body of air and delivered to the engine As the throttle plate opening increases greater amounts of air fuel mixture are drawn in through the fixed and metered idle progression holes As the throttle plate opens further the vacuum signal becomes great enough so the main circuit begins to work Main High Speed Circuit At high speeds loads the engine operates on the main circuit As a metered amount of air is drawn through the four air jets fuel is drawn through the main jets The air and fuel are mixed in the main nozzles and then enter the main body of airflow where further mixing of the fuel and air occurs This mixture is then delivered to the combustion chamber The carburetor has a fixed main circuit no adjustment is possible 5 5 Section 5 Fuel System and Governor Carburetor Adjustments Adjustment NOTE Carburetor adjustments should be made only after the engine has warmed up The carburetor is designed to deliver the correct fuel to air mixture to the engine under all operating conditions The main fuel jet is calibrated at the factory and is not adjustable The idle fuel adjusting needle is also set at the factory and normally does not need adjustment NOTE Engines operating at altitudes above approximately 1500 m 5000 ft may require a special high altitude main jet Refer to High Altitude Operation later in this section If however the
25. cylinder 1 or cylinder 2 Install the hydraulic lifters into their appropriate location in the crankcase Do not use a magnet See Figure 10 39 Section 10 Reassembly NOTE Hydraulic lifters should always be installed in the same position as before tu Lj Valve Zw Seals disassembly The exhaust lifters are located on the output shaft side of the engine while the intake lifters are located on the fan side of the engine The cylinder numbers are embossed on the top of the crankcase and each cylinder head See Figure 10 40 Figure 10 41 Valve Stem Seals Assemble Cylinder Heads Prior to installation lubricate all components with engine oil paying particular attention to the lip of the valve stem seal valve stems and valve guides Install the following items in the order listed below using a valve spring compressor See Figures 10 42 and 10 43 Intake and exhaust valves Valve spring retainers Valve springs Valve spring keepers Valve Stem Seals Guide Plate Pivot Studs Guide Plate Studs gt Figure 10 40 Match Numbers on Cylinder Barrel e and Head 4t i Keepers Valve Stem Seals Figure 10 42 Valve Components These engines use valve stem seals on the intake and exhaust valves Always use new seals whenever valves are removed or if the seal is deteriorated or damaged in any way Never reuse an old seal Figure 10 41 10 11 Section 10 Reassembly Figure 10 43 Installing Valve
26. engine is hard starting or does not operate properly it may be necessary to adjust or service the carburetor Low Idle Speed RPM Adjustment 1 Low Idle Speed RPM Setting Place the throttle control in the idle or slow position Set the low idle speed approximately 300 RPM less than the intended or specified Governed Idle Speed by turning the low idle speed adjusting screw in or out Check the speed using a tachometer IMPORTANT The Governed Idle Speed Adjustment must follow any resetting of the Low Idle Speed NOTE The actual low idle speed depends on the application Refer to the equipment manufacturer s recommendations The low idle speed for basic engines is 1200 RPM To ensure best results when setting the low idle fuel needle the low idle speed should be 1200 RPM 75 RPM Low Idle Fuel Adjustments With Limiters Low Idle Speed RPM Adjustment 5 6 Low Idle Fuel Adjustment NOTE Engines will have fixed low idle or limiter caps on the two idle fuel adjusting needles Step 3 can only be performed within the limits allowed by the cap Do not attempt to remove the limiter caps 1 Start the engine and run at half throttle for 5 to 10 minutes to warm up The engine must be warm before doing steps 2 3 and 4 2 Place the throttle control into the idle or slow position Adjust the low idle speed to 1200 RPM Follow the Adjusting the Low Idle Speed RPM procedure 3 Low Idl
27. engine to check and or replace the float Use a float kit to replace the float pin float valve clip and screw 1 Perform the removal procedures for the appropriate air cleaner and the carburetor outlined in Section 8 Disassembly 2 Clean the exterior surfaces of dirt or foreign material before disassembling the carburetor Remove the four mounting screws and carefully 5 8 separate the fuel bowl from the carburetor Do not damage the inner or bowl O Ring Transfer any remaining fuel into an approved container Save all parts Fuel can also be drained prior to bowl removal by loosening removal of the bowl drain screw See Figure 5 12 Fuel Bowl Bowl Drain Screw Figure 5 12 Fuel Bowl Removed From Carburetor 3 Remove the float pin screw and lift out the old float pin and inlet needle See Figure 5 13 Discard all of the parts The seat for the inlet needle is not serviceable and should not be removed Needle ati m n Figure 5 13 Removing Float and Inlet Needle 4 Clean the carburetor bowl and inlet seat areas as required before installing the new parts 5 Attach the inlet needle to the plastic tang of the float with the wire clip The formed 90 lip should point up with the needle valve hanging down See Figure 5 14 Inlet Needle Figure 5 14 Float and Inlet Needle Details 6 7 Install the float and inlet needle down into the seat and carburetor body Install the new pi
28. felt through the spark plug hole b Keyway of crankshaft will be aligned with 1 cylinder c Norocker arm push rod movement if crankshatt is rotated slightly back and forth If they are moving rotate the crankshaft one full revolution 3 Pre bled Lifters Apply downward pressure to the push rod side of rocker arm to compress the lifter and bottom the internal plunger Several manual compressions may be necessary Hold in this position for Step 4 Non bled Lifters Follow the valve clearance adjustment procedure Non Bled Lifters When Cylinder Heads and Lifters are Not Removed It takes two hands to make the lash adjustment A clamping device or an assistant to hold the lifter compressed while making the adjustment will make this noticeably easier NOTE 4 Insert a 0 127 mm 0 005 in feeler gauge between the end of one valve and the rocker arm Turn the adjuster until a slight drag is felt Hold the adjuster in this position and tighten the locking setscrew Torque the setscrew to 7 3 N m 65 in Ib After tightening recheck the adjustment Proper valve clearance is 0 101 0 152 mm 0 004 0 006 in See Figure 10 52 ics Plunger A Figure 10 52 Adjusting Valve Clearance 5 Repeat the procedure for the other valve on this side 10 14 6 Viewed from the PTO end rotate the crankshaft 270 3 4 turn counterclockwise and align the crankshaft keyway with the 2 cylinder which now puts that cylind
29. keep dirt grass clippings etc out of the engine 3 Remove the oil fill cap dipstick wipe oil off Reinsert the dipstick into the tube and rest the oil fill cap on the tube Do not thread the cap onto the tube See Figure 6 2 Oil Fill Cap Dipstick um Pj a Figure 6 2 Oil Fill Cap Dipstick 4 Remove dipstick and check oil level The level should be between the F and L marks If low remove the cap from the oil fill tube and add oil of the proper type up to the F mark Reinstall oil fill cap and dipstick Refer to Oil Type on page 6 1 Always check the level with the dipstick before adding more oil Operating Range Figure 6 3 Oil Level Marks on Dipstick 6 2 NOTE To prevent extensive engine wear or damage always maintain the proper oil level in the crankcase Never operate the engine with the oil level below the L mark or above the F mark on the dipstick Changing Oil and Oil Filter Changing Oil Change oil seasonally or every 150 hours of operation more frequently under severe conditions Refill with service class SJ or higher oil as specified in the Viscosity Grades table on page 6 1 Change the oil while the engine is still warm The oil will flow more freely and carry away more impurities Make sure the engine is level when filling or checking oil Change the oil as follows 1 Clean the areas around one of the drain plugs oil fill cap dipsti
30. on the sealing surfaces as it could cause damage resulting in leaks Note the assembly and orientation of parts See Figures 8 48 and 8 49 iBreather 1 A 5E B pu bU a FEE m et Figure 8 48 Removing Breather Assembly 8 12 Figure 8 49 Removing Breather Filter Remove Oil Pan Assembly 1 Remove the fourteen hex flange screws securing the oil pan to the crankcase See Figure 8 50 Figure 8 50 Removing Oil Pan Screws 2 Locate the two protruding tabs on the oil pan Carefully tap to break the gasket seal Do not pry on the sealing surfaces as this could cause leaks Separate the oil pan from the crankcase See Figures 8 51 and 8 52 Remove the old gasket Figure 8 51 Location of Protruding Tabs Section 8 Disassembly Figure 8 52 Removing Oil Pan Figure 8 54 Removing Connecting Rod Screws Oil Pump Assembly NOTE Ifa carbon ridge is present at the top The oil pump is mounted to the inside of the oil pan of either cylinder bore use a ridge If service is required refer to the service procedures reamer tool to remove the ridge before under Oil Pump Assembly in Section 9 attempting to remove the piston Remove Camshaft 1 Remove the camshaft and shim if used See Figure 8 53 de mat Dur a 4 my i J Figure 8 55 Remove Connecting Rod Caps NOTE The cylinders are numbered on the crankcase Use the numbers to mark Figure 8 53 Removing Camshaft each end cap
31. or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent 1 Disconnect the fuel shut off solenoid lead 2 Remove the fuel inlet hose from the carburetor Properly contain any remaining fuel 3 Remove the carburetor and linkages as an assembly See Figure 8 17 Section 8 Disassembly 4 Remove the carburetor gasket 5 The carburetor and linkages can be separated as necessary Remove Oil Sentry If Equipped 1 Disconnect the lead from the Oil Sentry switch 2 Remove the Oil Sentry switch from the oil pan See Figure 8 18 Pressure Switch Figure 8 18 Oil Sentry Switch Location in Oil Pan Remove Baffles and Intake Manifold 1 Remove the screws securing the valley baffles to the cylinder heads and backing shroud assembly 8 5 Section 8 Disassembly ETT Baffle hg Figure 8 19 Removing Valley Baffles 2 Remove the four screws securing each of the outer cylinder baffles in place See Figure 8 20 Figure 8 20 Removing Outer Cylinder Baffles 3 Remove the four hex flange screws securing the intake manifold to the cylinder heads Cut any wire ties securing wiring 4 Remove the intake manifold and gaskets See Figure 8 21 Mounting Mounting Locations Locations amp ee a Figure 8 21 Removing Intake Manifold 8 6 Remove Oil Cooler 1 Remove the two oil cooler mounting screws Do not lose an
32. this position Check the RPM using a tachometer Turn the high speed screw to obtain the intended high speed no load RPM The governed idle speed must be set before making this adjustment See Figure 5 11 5 7 Section 5 Fuel System and Governor Movejand ji Eeverjin Rull y F dud uc r2 r J o P x a Wa T r A F ue f HighSpeed RPM S Adjustment Screw l D a c zs W tiie Figure 5 11 Setting High Speed RPM Air Cleaner Removed for Clarity Carburetor Servicing The following section covers the disassembly various servicing procedures and reassembly of the carburetor For each procedure carefully inspect all components and replace those that are worn or damaged The following should also be noted as affiliated servicing is performed e Inspect the carburetor body for cracks holes and other wear or damage e Inspect the float for cracks holes and missing or damaged float tabs Check the float hinge and shaft for wear or damage e Inspect the fuel inlet needle and seat for wear or damage e The choke plate is spring loaded Check to make sure it moves freely on the shaft NOTE The main and slow jets are fixed and side specific and can be removed if required Fixed jets for high altitudes are available Float Replacement If symptoms described in the carburetor troubleshooting guide indicate float level problems remove the carburetor from the
33. tightened securely Use appropriate torque values and sequences when necessary Piston blow by or leaky valves confirm by Recondition piston rings cylinder bore valves and valve inspecting components guides Restricted exhaust Repair replace restricted muffler exhaust system 3 3 Section 3 Troubleshooting Compression Test A compression test is best performed on a warm engine Clean any dirt or debris away from the base of the spark plugs before removing them Be sure the choke is off and the throttle is wide open during the test Compression should be at least 160 psi and should not vary more than 15 between cylinders Cylinder Leakdown Test A cylinder leakdown test can be a valuable alternative to a compression test By pressurizing the combustion chamber from an external air source you can determine if the valves or rings are leaking and how badly The Cylinder Leakdown Tester is a relatively simple inexpensive leakdown tester for small engines The tester includes a quick disconnect for attaching the adapter hose and a holding tool Leakdown Test Instructions 1 Run the engine for 3 5 minutes to warm it up 2 Remove the spark plug s and the air filter from engine 3 Rotate the crankshaft until the piston of cylinder being tested is at top dead center of the compression stroke Hold the engine in this position while testing The holding tool supplied with the tester can be used if the PTO end of the
34. troubles occur be sure to check the simple causes which at first may seem too obvious to be considered For example a starting problem could be caused by an empty fuel tank Some general common causes of engine troubles are listed below Use these to locate the causing factors Refer to the specific section s within this service manual for more detailed information Engine Cranks But Will Not Start Empty fuel tank Fuel shut off valve closed Poor fuel dirt or water in the fuel system Clogged fuel line Spark plug lead s disconnected Kill switch in off position Faulty spark plugs Faulty ignition module s Carburetor solenoid malfunction Vacuum fuel pump malfunction or oil in vacuum hose 11 Vacuum hose to fuel pump leaking cracked 12 Battery connected backwards 13 Safety interlock system engaged P cro tS ole SS Engine Starts But Does Not Keep Running 1 Restricted fuel tank cap vent 2 Poor fuel dirt or water in the fuel system 3 Faulty or misadjusted choke or throttle controls 4 Loose wires or connections that short the kill terminal of ignition module to ground 5 Faulty cylinder head gasket 6 Faulty carburetor 7 Vacuum fuel pump malfunction or oil in vacuum hose 8 Leaking cracked vacuum hose to fuel pump 9 Intake system leak Engine Starts Hard 1 PTO drive is engaged Dirt or water in the fuel system Clogged fuel line Loose or faulty wires or connections F
35. will turn then torque the hex nut to 7 3 N m 65 in Ib See Figure 10 101 5 Iw eur AVELL ES Carburetor 9 o Lift Rotate Vey re Clockwise Figure 10 101 Adjusting Governor 4 Ensure that the correct colored springs are used Connect the governor spring with long looped end to the inner hole on the governor lever and control bracket Connect the governed idle spring to the outer governor lever hole and control bracket The long end of each spring must be toward the governor lever Check that the springs do not contact the valley baffle See Figure 10 102 10 26 Cova N SA Taa n et de Figure 10 102 Governor Springs Installed Governor Spring RPM Chart Governor Idle Spring High Speed RPM Color 1200 1550 RPM 1551 1800 RPM Color Red 3101 3300RPM Figure 10 103 Governor Spring RPM Chart Install Oil Sentry If Equipped 1 Apply pipe sealant with Teflon Loctite No 59241 or equivalent to the threads of the Oil Sentry switch and install it into the 1 8 port in the oil pan See Figure 10 104 Torque to 10 1 N m 90 in Ib Pressure Switch Figure 10 104 Oil Sentry Pressure Switch Location 2 Connect the green wire lead to the Oil Sentry terminal Install Blower Housing and Cylinder Shrouds 1 Install the dipstick tube with a new lower O Ring into the crankcase Secure with the lower mounting screw Torque the screw to 4 0 N m 35 in I
36. wires or components while the engine is running They can be sources of electrical shock amp WARNING Explosive Gas can cause fires and severe acid burns Charge battery only in a well ventilated area Keep sources of ignition away Explosive Gas Batteries produce explosive hydrogen gas while being charged To prevent a fire or explosion charge batteries only in well ventilated areas Keep sparks open flames and other sources of ignition away from the battery at all times Keep batteries out of the reach of children Remove all jewelry when servicing batteries Before disconnecting the negative ground cable make sure all switches are OFF If ON a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or gasoline vapors are present Section 1 Safety and General Information Engine Identification Numbers When ordering parts or in any communication involving an engine always give the Model Specification and Serial Numbers including letter suffixes if there are any Identification Decal The engine identification numbers appear on a decal or decals affixed to the engine shrouding See Figure 1 1 An explanation of these numbers is shown in Figure 1 2 r Figure 1 1 Engine Identification Decal Location A Model No CV 9805S C d Engine PO ommand Engine mni Version Code Vertical Crankshaft S Electric Start
37. 0 hours of operation Always use a genuine Kohler oil filter 5 Apply a thin film of clean oil to the rubber gasket on the new filter Partial prefilling of the oil filter is recommended 6 Install the replacement oil filter to the filter adapter or oil cooler Turn the oil filter clockwise until the rubber gasket contacts the oil filter housing not inner cup then tighten the filter an additional 3 4 1 turn Oil Filter 7 Fill the crankcase with new oil of the proper type to the F mark on the dipstick Oil Filter e 8 Start the engine and check for oil leaks Correct Housing any leaks before placing the engine into service Check oil level to be sure it is up to but not over Figure 6 7 Engine Mounted Oil Filter the F mark 6 3 Section 6 Lubrication System Service Oil Cooler These engines are equipped with an oil cooler mounted under the No 2 side cylinder shroud separate from the oil filter See Figure 6 9 Oil Cooler Figure 6 9 Oil Cooler Inspect and clean the oil cooler every 150 hours of operation more frequently under severe conditions In order to be effective the oil cooler must be kept free of debris To service the oil cooler clean the outside of fins with a brush vacuum or compressed air If required remove the two screws holding the cooler unit to the backing shroud assembly Carefully lift the cooler and clean the underside of the cooler After cleaning reinstall
38. 051 in Isunpimns ICANGE ooo E SIUE S Nc NEU EE ire 0 025 0 063 mm 0 0010 0 0025 in Bore I D S AAEE E EENS A EE 20 000 20 025 mm 0 7874 0 7884 in Too VOIE L e etc an eat vs tun ast cO MPeD Sra UE U NEQU PN ENS EDS 20 038 mm 0 7889 in Camshaft Bearing Surface O D I EN E UU T TT 19 962 19 975 mm 0 7859 0 7864 in Noks Noar DU DH ee E ne piae biu M EN UEM MERE MEE 19 959 mm 0 7858 in Cam Lobe Profile Minimum Dimension Measured From Base Circle To Top Of Lobe lib dini T 35 mm 1 3779 in loci E rae 35 mm 1 3779 in Values are in Metric units Values in parentheses are English equivalents Lubricate threads with engine oil prior to assembly 1 7 Section 1 Safety and General Information Carburetor Intake Manifold and Air Cleaner Intake Manifold Mounting Fastener Torque Torque Using Sequence m TWO SIA CS pssi Sen a UR TRHEMIMIEN NS first to 16 9 N m 150 in Ib finally to 22 6 N m 200 in Ib Carburetor Air Cleaner Mounting Nut TOEQUG eine tior tator t EP eto tin 7 9 N m 70 in Ib Air Cleaner Mounting Screw Torque Into Intake Manifold 9 9 N m 88 in Ib Control Bracket Mounting Screw Into Intake Manifold from Air Cleaner Torque 9 9 N m 88 in Ib Connecting Rod Cap Fastener Torque torque TOLTHOEOETIeTIOS oes udii een toe tera tUa SERE RS aU 11 3 N m 100 in Ib Crankpin End I
39. 20 25 Amp Regulated Charging System Section 7 HOLIMS 3unss3aHd 110 A SSV YALYVLS LJIHS GION310S ONO o ON e LCE BE BH3O0NI AO 2 sayan Y 9N ld AWS BONES ONIOHVHO OV 7 H3l1HVIS SEMEN 490718 4 S YOLOSNNOD i Goh dat Nes JOLV4n93U anis J AS GION310S i H31HVvl1S Uk a34 o A SSV CTIIM NOILINOI Dm Hr YOLVLS SLIHM d33HMA 14 3 1INGOW NOILINOI QION3 10S guvoa KO auva z l l ONnONO T wos Q a34 Q IO3INVA 3AMYLNI H3JONI TAO T Li 9N1d MMVdS SOd uei X p a4 Hc a34 ZNN 3LI HM AEN CON S 8IH ALINVJOd HO LO3NNOO Figure 7 11 Wiring Diagram 15 20 25 Amp Regulated Battery Charging System with CD Ignition and Four Pin Connector 7 10 Section 7 Electrical System and Components 1VNOI LdO HOLIMS 3unsS3Hd IO w f i Ha Tl iif iu EN NOI LVN9IS3O0 Qv3 3 INGOW n N33H9 Q NS 440 1nHS 0 3LIRM ac MM OJH 3HIM N3dH9 QNnOH9 SQv31 9NI9HVHO OVI O d I ON370S x2v g 3L1HM ASSY H31HVl1S H31HV15 a LJlHS QION3 OS beer AVNH3LX3 d3oN0342 ze H L N I 9HYYHI E 9nd MHvdS 13701A E ET H QV eo SAS SS Qv33 9n d uvas SS yacna i HO L93NNO9 yoly Inoy QION310S ge nov Ja SS i H3lHVlS a Q annoxs lO use H3l JI 1938 a iiii ONTLNNOW HO1V INS 34 NOI LdO 9N HOJ ONnOHO 341100
40. 28 Locking Tab Washer Details 5 Orient the flat of the oil pump gear to match the position of the flat on the camshaft Then install the closure plate to the crankcase Carefully seat the camshaft and the crankshaft into their mating bearings Rotate the crankshatt slightly to help the oil pump and governor gears mesh See Figure 10 29 10 8 a E p Tx E Figure 10 29 Installing Oil Pan 6 Install the fourteen hex flange screws securing the oil pan to the crankcase Torque the fasteners in the sequence shown in Figure 10 31 to 24 4 N m 216 in Ib Figure 10 31 Oil Pan Fastener Torque Sequence Section 10 Reassembly Check Crankshaft End play Install Breather 1 Set the engine as shown and use a dial indicator 1 Make sure the sealing surfaces of the crankcase to check the crankshaft end play against the and breather cover are clean and free of any specification listed in Section 1 nicks or burrs Do not scrape the surfaces as this could result in leakage 2 Install the breather chamber gasket as shown See Figure 10 33 Assemble and install breather assembly components as illustrated in Figure 10 34 Make sure the filter does not extend above the top surface and all parts are properly aligned Figure 10 32 Checking Crankshaft End play eL Breather Hose Flange Nuts 4 ums E T Sn gt ai ee lt _ Gasket Studs 4 Crankcase Figure 10 3
41. 4 Breather Assembly Details 10 9 Section 10 Reassembly 3 Install the four hex flange screws and torque using the sequence shown in Figure 10 35 to 5 7 N m 51 in Ib Figure 10 35 Breather Assembly Fastener Torque Sequence 4 Lightly lubricate the lower end of the breather hose with oil and install into the hole in breather assembly The cover should be situated between the two raised rings of the hose Install Hydraulic Lifters 1 Bleed the hydraulic lifters of internal oil so the plunger in the lifter can be depressed by hand Use an old cutoff push rod mounted in a drill press arbor press or vice and slowly apply pressure two or three times to bleed the lifters See Figure 10 36 If a vice is used in bleeding the lifters be sure to install protective coverings over the jaws to avoid damage to the base of the lifter Figure 10 36 Push Rod Tool 10 10 NOTE Another tool for bleeding may be made from an old tappet and ball bearing welded together See Figure 10 37 Figure 10 37 Tappet and Ball Bearing Welded Together 2 Apply camshaft lubricant see Section 2 to the bottom surface of each lifter See Figure 10 38 Lubricate the hydraulic lifters and the lifter bores in the crankcase with engine oil Do not prime the lifters Figure 10 38 Applying Camshaft Lubricant to Bottom of Lifters 3 Note the mark or tag identifying the hydraulic lifters as either intake or exhaust and
42. 5 mm 3 540 in 0 033 0 72 mm 0 0013 0 0028 in s 5 6 9 0 N m 49 79 in Ib M 15 3 N m 135 in Ib n 2 5 3 3 N m 22 29 in Ib 4 0 6 0 N m 35 53 in Ib ee 8 0 11 0 N m 71 97 in lb 6 2 N m 55 in Ib 9 9 N m 88 in Ib Inu 7 9 N m 70 in Ib 0 012 0 050 mm 0 0004 0 0019 in 0 038 0 076 mm 0 0015 0 0030 in 0 050 0 088 mm 0 0020 0 0035 in 7 038 7 058 mm 0 2771 0 2779 in T 7 135 mm 0 2809 in T 7 038 7 058 mm 0 2771 0 2779 in eae 7 159 mm 0 2819 in Measure 11 mm 0 433 in above the bottom of the piston skirt at right angles to the piston pin Section 1 Safety and General Information Valve Guide Reamer Size E ie EN TEE T C DO OO CT T 7 048 mm 0 2775 in 125 TOTHU lee codices oed m Ere mnt ae Crear rer RUPEM MM pM d MEINE 7 298 mm 0 2873 in Nominal Valve ICCAT IE NENNT 45 General Torque Values Metric Fastener Torque Recommendations for Standard Applications Tightening Torque N m in Ib or 10 Property Class Noncritical Fasteners 12 11 1 7 15 2 9 26 4 1 36 5 0 44 2 0 18 2 5 22 3 2 28 5 8 51 8 1 72 9 7 86 4 0 35 4 3 38 5 7 50 9 9 88 14 0 124 16 5 146 6 8 60 10 5 93 13 6 120 24 4 216 33 9 300 40 7 360 17 0 150 Tightening Torque N m ft Ib or 10 Property Class Noncritical Fasteners Into Aluminum M10 J 217 16 27 1 20 47 5 35
43. 8 Choke Repair 1 Remove the carburetor from the engine Discard the old mounting gaskets for the air cleaner and carburetor Clean the areas around the choke shaft and the self relieving choke mechanism thoroughly Remove and discard the plastic cap from the end of the choke lever shaft assembly Note the position of the spring legs and the choke plate for correct reassembly later See Figure 5 29 Remove the two screws attaching the choke plate to the choke shaft Pull the shaft out of the carburetor body note the preload of spring and discard the removed parts Figure 5 29 Choke Details Use a screw extractor easy out and remove the original choke shaft bushing with the old choke lever from the carburetor housing Save the bushing to use as a driver for installing the new Section 5 Fuel System and Governor Install the new return spring onto the new choke shaft so the outboard leg of the spring is behind the formed stop on the end of the choke shaft See Figure 5 32 bushing Discard the old lever NOTE Make sure it stays in this location during 6 Clean the I D of both choke shaft bores as the following step required 7 Insert the new bushing through the new choke lever from the outside and start the bushing in the outer shaft bore Position the choke lever so the protruding boss on the carburetor housing is between the two stops formed in the choke lever See Figure 5 30 Choke Sh
44. 8 59 Removing Cross Shaft Yoke Screws must be replaced Therefore remove the gear only if absolutely necessary If the governor cross shaft 2 Pull the governor cross shaft out of crankcase and yoke or gear condition does not require removal remove seal the governor gear may be left in place If removal is necessary perform as follows 8 14 Section 8 Disassembly Remove Lifter Feed Chamber Cover and Removal of Main Bearings Gaskets NOTE Flywheel and PTO side main bearings 1 Remove the three screws securing the lifter feed should only be removed if replacement chamber cover and gaskets Carefully separate is required due to wear If removal is the parts from the crankcase See Figure 8 60 performed use a press and support the adjacent cast surface around the bearing flange when performing Do not press against or support by the gasket outer perimeter surface See Figure 8 62 Figure 8 60 Removing Lifter Feed Chamber Cover Components Support This Surface Remove Flywheel and PTO End Oil Seals 1 Remove the oil seals from the crankcase and oil pan using a seal puller See Figure 8 61 Figure 8 62 Support Surface Details Figure 8 61 Removing Oil Seals 8 15 8 16 Section 9 Inspection and Reconditioning This section covers the operation inspection and repair reconditioning of major internal engine components The following components are not covered in this section They are cove
45. ARGING sis REGULATOR LEADS CONNECTOR BLOCK OIL PRESSURE SWITCH A OPTION Figure 7 6 Digital Spark Advance Ignition DSAI System Operation of DSAI Ignition Systems Operation The system provides more consistent energy to the DSAI Ignition System Explanation spark plugs at all engine speeds by using the 12 volt A digital spark advance ignition system DSAI is battery as its source of power Engine speed and top used on some models The DSAI ignition system is an dead center TDC location reference information advanced 12 volt version of the fixed timing ignition is provided by the flywheel magnet group as it system used on other models Two inductive style passes the ignition module System triggering and ignition modules control the ignition timing based on engine timing is performed by a digitally controlled engine RPM A typical DSAI application Figure 7 6 microprocessor This digital control provides consists of the following components repeatable and consistent engine cylinder spark e Amagnet assembly which is permanently affixed timing Each DSAI module performs its function to the flywheel independently for each engine cylinder e Two inductive 12 volt ignition modules which mount on the engine crankcase Figure 7 6 e A12 volt battery which supplies current to the ignition modules e Akill switch or key switch which grounds the spark advance module to stop the engine e Two spark plugs 7 6 Troubles
46. Crankcase Inspection and Service Check all gasket surfaces to make sure they are free of gasket fragments Gasket surfaces must also be free of deep scratches or nicks Inspect the main bearing if so equipped for wear or damage refer to Section 1 Specifications Tolerances and Special Torque Values Replace the bearing or crankcase using a miniblock or short block as required Check the cylinder bore for scoring In severe cases unburned fuel can cause scuffing and scoring of the cylinder wall It washes the necessary lubricating oils off the piston and cylinder wall As raw fuel seeps down the cylinder wall the piston rings make metal to metal contact with the wall Scoring of the cylinder wall can also be caused by localized hot spots resulting from blocked cooling fins or from inadequate or contaminated lubrication If the cylinder bore is badly scored excessively worn tapered or out of round resizing is necessary Use an inside micrometer to determine the amount of wear refer to the Specifications Tolerances and Special Torque Values in Section 1 then select the nearest suitable oversize of either 0 25 mm 0 010 in or 0 50 mm 0 020 in Resizing to one of these oversizes will allow usage of the available oversize piston and ring assemblies Initially resize using a boring bar then use the following procedures for honing the cylinder Honing While most commercially available cylinder hones can be used
47. DOO cocos eniti tener meen Sener ovp rere 45 040 45 145 mm 1 7732 1 7773 in Maxs Wear Lii ues cosomta tutore dee tdeo docui pides etus Hao a aea UeNS CRX ET DUE SUR SORGE 45 158 mm 1 7778 in Crankshaft to Sleeve Bearing Crankcase Rinne ISdPaHceed NEW eed ouem debemus ierit omi eno MIU 0 040 0 167 mm 0 0015 0 0065 in Crankshaft Bore In Oil Pan New without Bearing 50 025 50 00 mm 1 9694 1 9685 in 1 8 Section 1 Safety and General Information Crankshatt to Sleeve Bearing In Oil Pan R nnine Clearance NB auediesandgpiqueas cm un BEN Gage eiiiai 0 040 0 167 mm 0 0015 0 0065 in Flywheel End Main Bearing Journal EH TEE 44 978 45 00 mm 1 770 4 771 in D Max Wear L NET m 44 90 mm 1 767 in haie Ea pP ere E E Rr here eer ere ere Te 0 022 mm 0 0009 in Max COBESOP Round dpsecseonease eazescretcaznaciyenngritanatSpsonnnineiacthesesthaedeteceeeeessinnons 0 025 mm 0 0010 in Closure Plate End Main Bearing Journal BUSES 44 978 45 00 mm 1 770 4 771 in OU eI Wear DID et iuit daentmianpEs UNE I cs Ii UNE 44 90 mm 1 767 in Eb MI To zn 0 022 mm 0 0009 in Max OO ROUMO aenqunasnte uana gpcetnaeatnnac ae wane a SEAE 0 025 mm 0 0010 in Connecting Rod Journal BD ga TV sees 43 982 44 000 mm 1 731 1 732 in LI Ve ottime Durus I
48. Hours Yearly or Every 500 Hours e Have crankshaft splines lubricated o ery oo Hue Teraina leeren aso Every 600 Hours 1Perform these maintenance procedures more frequently under extremely dusty dirty conditions Have a Kohler Engine Service Dealer perform this service Storage Fill the fuel tank with clean fresh gasoline Run If the engine will be out of service for 30 days or more the engine for 2 to 3 minutes to get stabilized use the following storage procedure fuel into the rest of the system Close the fuel shut off valve when the unit is being stored or 1 Clean the exterior surfaces of the engine Avoid transported spraying water at the wiring harness or any of the electrical components To empty the system run the engine until the tank and the system are empty 2 Change the oil and oil filter while the engine is still warm from operation See Change Oil and 4 Remove the spark plugs and add one tablespoon Oil Filter in Section 6 The fuel system must be completely emptied or the gasoline must be treated with a stabilizer to prevent deterioration If you choose to use a stabilizer follow the manufacturer s recommendations and add the correct amount for the capacity of the fuel system of engine oil into each spark plug hole Install the spark plugs but do not connect the plug leads Crank the engine two or three revolutions Disconnect the battery or use a battery minder to keep the batter
49. N HOLIMS 9N d 3ONVHO a34 YOLY1S T33HMA14 3LIHM E 7 T 93N S 33nG0N IO NOILIN9I i AH311V8 Q3H l a SOd J M E EEE E me J YSONITAD 1 i Ond xuvds f EI a I ON3TOS i m duvo2 D i E a l E aNnouo AO REN ms OD ONIINQON 8HV2 SNO x N33H9 AO n T SS a34 EI JN JLIHM ZAV OS HO 193NNO2 S 8IH ALIYWIOd N Figure 7 12 Wiring Diagram 15 20 25 Amp Regulated Battery Charging System with DSAI Ignition and Four Pin Connector 7 11 Section 7 Electrical System and Components 1VNOI LdO HOLIMS 3unSS38d MON e r ue N33H9 ii pec jd Nee 7 Q NS NOI LVN9IS3Q A QV3 3 INGOW r m M X ol M M X om iim as My 330 LAHS SjLIHM 8 Q3H N33H9 SQv3 9NIOHVHOD JV 3LIHM A 9N I 9HYYH LAIIOIA QNNOWD 42V 18 Q ONY L Pad QION310S ASSY H3lHVlS H3lHVl1S l3JIHS GQION310S H3O0NI34A2 2 i 9N1d wuvds N QV3l 9N1d MHVdSl 420 1g HO O3NNO2 Z yOLVANOSY e f QGION3308 A MOV Ig YSALYVLS il N N33H9 d ONnOHO M D oo H31 JI LO3H HH GNTINCIOR j HOLY 1938 3 I Y3O0N ii a34 en ETE TSSHMA 14 3LIHM S 3 I1300N NOI LINOI Q38y H3OUNI IAD SN Id MYVdS guva2 NOI LdO N HOJ ANNOY HOLIMS ON dl i J NYYO Q3 ee 1 KT oe ee ar eet ae 2 I Q1ON370S p e e IIl ais Q 9NI IN
50. Oil to Crankcase 1 Install the oil drain plugs See Figure 10 109 Torque the plugs to 21 4 N m 15 7 ft Ib NOTE Make sure that both oil drain plugs are installed and torqued to the above specifications to prevent oil leakage Figure 10 111 Reinstall the Dipstick in Tube Connect Spark Plug Leads 1 Connect the leads to the spark plugs See Figure 10 112 Drain Plug Starter Side Shown Figure 10 109 Reinstall Oil Drain Plugs 2 Install a new oil filter following the instructions in Section 6 3 Apply a thin film of clean engine oil to the rubber gasket on the oil filter and thread the filter onto the adapter nipple See Figure 10 110 4 Hand tighten the filter until the rubber gasket contacts the adapter then tighten the filter an dditi 3 4 1 turn See Fi 10 110 RUMOR eatin at ane Figure 10 112 Connect Spark Plug Leads Prepare the Engine for Operation The engine is now completely reassembled Before starting or operating the engine be sure to do the following 1 Make sure all hardware is tightened securely 2 Make sure the oil drain plugs Oil Sentry pressure switch and a new oil filter are installed 3 Fill the crankcase with the correct amount weight and type of oil Refer to oil recommendations and procedures in the Safety Figure 10 110 Installing and Tightening Oil Filter and General Information and Lubrication System sections 5 Add oil to bring the level
51. SERVICE MANUAL KOHLER COMMAND PRO CV940 CV1000 VERTICAL CRANKSHAFT KOHLER ENGINES Section 1 Section 2 Section 3 Section 4 Section 5 Section 6 Section 7 Section 8 Section 9 Contents Safety and General Information 1Leeeeeeeeee ee eeeee eene enne nnn MOONS lt r NS arses cosets ween Troubleshooting PCR ETE EE Air Cleaner and Air Intake System Fuel System and Governor Lubrication System Electrical System and Components Disassembly Inspection and Reconditioning Section 10 REASSEMDIY ccccccceeseeeeeseecenseecnseeseaseecenseneaseeseseeeanseseaseseaasesoanseooaseseensesonsessess Section 1 Safety and General Information Safety Precautions To ensure safe operation please read the following statements and understand their meaning Also refer to your equipment manufacturer s manual for other important safety information This manual contains safety precautions which are explained below Please read carefully A WARNING Warning is used to indicate the presence of a hazard that can cause severe personal injury death or substantial property damage if the warning is ignored A CAUTION Caution is used to indicate the presence of a hazard that will or can cause minor personal injury or property damage if the caution is ignored NOTE Note is u
52. UUD 43 97 mm 1 731 in hoop M 0 018 mm 0 0007 in Max Out of Round asssieseiveipi tont ena oU URN IU DI nEapeU iU tur UNMR UNUM UMS 0 025 mm 0 0010 in b BIS do NENNT 53 00 53 09 mm 2 0866 2 0901 in Crankshaft T I R LEO ea VN ca ears cea cs dumb aD TE EM A UM 0 279 mm 0 0110 in Entire Crank in V DloCKS cuite riti unie inpar o portum Fas ved PE de Pars Raten 0 10 mm 0 0039 in Cylinder Bore Cylinder Bore LD Dino P 90 000 90 025 mm 3 543 8 544 in IVfax WV CO TAMA Ke cies satceteean vaste tense qe ttes ecas quise bou E AEA VEU RUNE 90 075 mm 3 546 in Mox OUO ROUIC eum ENIM eer ene en eR en MU 0 013 mm 0 00051 in INIA E REM 0 013 mm 0 00051 in Main Bearing I D Crankcase Oil Pan I VF Mis CG me C E N 45 040 45 145 mm 1 773 1 777 in Moc WV COT bM 45 158 mm Cylinder Head Cylinder Head Fastener Torque Head Bolt Torg ein Iwo Stages meuren ienna first to 22 6 N m 200 in Ib finally to 45 2 N m 400 in Ib IM aec Outo eed al DISSE ect op en Oe eee eee RN Indem Eni EN 0 076 mm 0 003 in Pipe Pus 9 d FORCED cosa pooxtueten dead E Ronee ener rr Perec dude 28 25 N m 250 in Ib locker rni big AVT TO gE entero i gU ea Us 11 3 N m 100 in Ib pelsesew AV tO locking orrera ttd tig tgdetirinpns n CP Ert E 7 3 N m 65 in Ib Fan Flywheel Paid abener TOPOUE uas onbres bet situa utut Nb dar DE 9 9 N m 88 in Ib
53. ach end and remove the end caps from the air cleaner housing 2 Check and clean the screen area on the inlet side Pull the air cleaner element out of the housing on opposite side See Figures 4 2 and 4 3 Inlet Screen Figure 4 2 Accessing Inlet Screen Paper Element Inner Element Figure 4 3 Removing Elements 3 After the paper element is removed check the condition of the inner element It should be replaced whenever it appears dirty typically every other time the paper element is replaced or every 600 hours Clean the area around the base of the inner element before removing it so dirt does not get into the engine 4 1 Section 4 Air Cleaner and Air Intake System 4 Do not wash the paper element and inner element or use compressed air this will damage the elements Replace dirty bent or damaged elements with new genuine Kohler elements as required Handle the new elements carefully do not use if the sealing surfaces are bent or damaged 5 Check all parts for wear cracks or damage and that ejector area is clean See Figure 4 4 Replace any damaged components Wd NUT Figure 4 4 Ejector Area 6 Install the new inner element followed by the paper element Slide each fully into place in the air cleaner housing 7 Reinstall the end caps and secure with the retaining clips See Figure 4 1 Air Cleaner Components Whenever the air cleaner cover is removed or the paper element or inner
54. aft Spring Ends Figure 5 32 Choke Shaft and Spring Details 10 Slide the choke shaft and spring into the carburetor Pivot preload the shaft 4 turn counterclockwise with the inner leg of the spring against the formed stop within the choke lever as originally assembled See Figures 5 29 and 5 33 The outer leg of the spring must still be behind the formed stop of the choke shaft Figure 5 30 Assembling Choke Lever 8 Turn the old bushing upside down and use it as a driver to carefully press or tap the new bushing into the carburetor body until it bottoms Check that the choke lever pivots freely without restriction or binding See Figure 5 31 Figure 5 33 Installing Choke Assembly Components 11 Place a drop of Loctite on the threads of each new screw Position and install the new choke plate to the flat side of the choke shaft Start the two screws Close the choke and check the plate alignment within the carburetor throat then tighten the screws securely Do not overtighten See Figure 5 34 Figure 5 31 Installing Bushing 5 13 Section 5 Fuel System and Governor Float Kit Bowl Kit Fuel Solenoid Kit Carburetor Overhaul Kit 12 Check for proper operation and free movement of the parts Install the new cap Always use new gaskets when servicing or reinstalling carburetors Repair kits are available which include new gaskets and other components Service repair kits available for Kei
55. aintenance is necessary to prolong battery life A WARNING Explosive Gas Batteries produce explosive hydrogen gas while being charged To prevent a fire or explosion charge batteries only in well ventilated areas Keep sources of ignition away from the battery at all times Keep batteries out of the reach of children Remove all jewelry when servicing batteries Before disconnecting the negative ground cable make sure all switches are OFF If ON a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or gasoline vapors are present Figure 7 2 Battery Voltage Test Battery 1 Regularly check the level of electrolyte Add distilled water as necessary to maintain the recommended level NOTE Do not overfill the battery Poor performance or early failure due to loss of electrolyte will result 7 3 Section 7 Electrical System and Components Electronic Ignition Systems There are two different types of ignition systems used on theseengines All systems use an ignition module which energizes the spark plug The difference in the system is in the way the ignition timing is triggered The Fixed Ignition System utilizes a Capacitive Discharge CD coil See Figure 7 3 This is a basic ignition system that uses a fixed ignition module where the ignition timing and spark remains constant regardless of the engine speed The Digital Spark Advance Ignition DSAI System See Figure 7 6
56. all of the old gasket material has been removed Use gasket remover lacquer thinner or paint remover to remove any remaining traces Clean the surfaces with isopropyl alcohol acetone lacquer thinner or electrical contact cleaner Typical Reassembly Sequence The following sequence is suggested for complete engine reassembly This procedure assumes that all components are new or have been reconditioned and all component subassembly work has been completed The sequence may vary to accommodate options or special equipment Detailed procedures follow Install flywheel end oil seal Install lifter feed chamber gaskets and cover Install flywheel end main bearing Install governor shafts seal and governor gear Install crankshaft Install connecting rods with pistons and rings Install camshaft Install oil pan seal and main bearing 9 Install oil pan assembly 10 Check crankshaft endplay 11 Install breather assembly 12 Install hydraulic lifters 13 Assemble and install cylinder heads 14 Install push rods and rocker arms 15 Install valve covers ot qoe 16 Install spark plugs 17 Install oil filter housing 18 Install intake manifold 19 Install backing shroud assembly 20 Install stator wiring harness and rectifier regulator 21 Install flywheel 22 Install ignition module 23 Install outer cylinder baffles 24 Install oil cooler 25 Install cooling fan and grass screen 26 Install electric st
57. an the parts as required NOTE Do not soak the armature or use solvent when cleaning Wipe clean using a soft cloth or use compressed air Drive pce End Cap gt 04 Aia Commutator End Plate Screw ie Bolt Figure 7 32 Delco Remy Starter 7 19 Section 7 Electrical System and Components Inspection Drive Pinion Check and inspect the following areas a The pinion teeth for abnormal wear or damage b The surface between the pinion and the clutch mechanism for nicks or irregularities which could cause seal damage c Check the drive clutch by holding the clutch housing and rotating the pinion The pinion should rotate in one direction only Brushes and Springs Inspect both the springs and brushes for wear fatigue or damage Measure the length of each brush The minimum length for each brush is 7 6 mm 0 300 in See Figure 7 33 Replace the brushes if they are worn undersize or their condition is questionable Wear Limit Length 7 6 mm 0 300 in Figure 7 33 Checking Brushes Armature 1 Clean and inspect the commutator outer surface The mica insulation must be lower than the commutator bars undercut to ensure proper operation of the commutator See Figure 7 34 7 20 Commutator O D Mica Insulation Figure 7 34 Commutator Mica Inspection 2 Usean ohmmeter set to the Rx1 scale Touch the probes between two different segments of the commutator and check for continuity S
58. arefully slide the flywheel end of the crankshaft through the main bearing in the crankcase See Figure 10 16 Figure 10 16 Installing Crankshaft Install Connecting Rods with Pistons and Rings NOTE The cylinders are numbered on the crankcase Make sure to install the piston connecting rod and end cap into its appropriate cylinder bore as previously marked at disassembly Do not mix the end caps and connecting rods NOTE Proper orientation of the piston connecting rod assemblies inside the engine is extremely important Improper orientation can cause extensive wear or damage Be certain the pistons and connecting rods are assembled exactly as shown in Figure 10 17 1 Stagger the piston rings in the grooves until the end gaps are 120 apart The oil ring rails should also be staggered No 1 Side Y No 2 Side Figure 10 17 Proper Piston and Connecting Rod Orientation 2 Lubricate the cylinder bore piston and piston rings with engine oil Compress the rings of the 1 piston using a piston ring compressor 3 Lubricate the crankshaft journals and connecting rod bearing surfaces with engine oil 4 Make sure the Fly stamping on the piston is facing toward the flywheel side of the engine See Figure 10 18 Use a hammer with a rubber grip and gently tap the piston into the cylinder as shown in Figure 10 19 Be careful that the oil ring rails do not spring free between the bottom of the ring compressor an
59. arter 27 Install valley baffles 28 Install carburetor 29 Install governor lever 30 Install control bracket and air cleaner assembly 31 Install throttle and choke linkages 32 Install fuel pump 33 Install Oil Sentryswitch if equipped 34 Install blower housing and cylinder shroud 35 Install muffler 36 Install oil filter and add oil to crankcase 37 Connect spark plug leads Install Flywheel End Oil Seal 1 Make sure that the seal bore of the crankcase is clean and free of any nicks or burrs See Figure 10 1 Figure 10 1 Seal Bore of Crankcase 10 1 Section 10 Reassembly 2 Applya light coat of clean engine oil to the outside diameter of the oil seal 3 Install the oil seal into the crankcase using a seal driver Make sure the oil seal is installed straight and true in the bore and that the tool bottoms against the crankcase See Figures 10 2 and 10 3 be 5 Figure 10 3 Installed Flywheel Side Oil Seal _ Install Lifter Feed Chamber Gaskets and Cover 1 Install the lifter feed chamber gasket followed by the lifter feed cover over the lifter feed chamber 2 Install the three screws Make sure all the parts are properly aligned Torque the screws to 6 2 N m 55 in Ib into new holes or 4 0 N m 35 in Ib into used holes See Figure 10 4 10 2 Mounting Screws Lifter Feed Chamber Figure 10 4 Lifter Feed Chamber Assembly Details Install Fl
60. ate the problem can usually be found somewhere in the charging system or with the battery Section 7 Electrical System and Components NOTE Always zero ohmmeter on each scale before testing to ensure accurate readings Voltage tests should be made with the engine running at 3600 RPM no load The battery must be good and fully charged No Charge to Battery Battery Continuously Charges at High Rate 1 Trace B lead from rectifier regulator to key switch or other accessible connection Disconnect it from switch or connection Connect an ammeter from loose end of B lead to positive terminal of battery Connect DC voltmeter from loose end of B lead to negative terminal of battery With engine running at 3600 RPM read voltage on voltmeter If voltage is 13 8 volts or more place a minimum load of 5 amps on battery to reduce voltage Observe ammeter Remove connector from rectifier regulator With engine running at 3600 RPM measure AC voltage across stator leads using an AC voltmeter With engine stopped measure the resistance across stator leads using an ohmmeter With the engine stopped measure the resistance from each stator lead to ground using an ohmmeter Perform same test as step 1 above 1 If voltage is 13 8 14 7 and charge rate increases when load is applied the charging system is OK and battery was fully charged If voltage is less than 13 8 or charge rate does not increase when load
61. aulty or misadjusted choke or throttle controls Faulty spark plugs QUOTE Low compression Weak spark Fuel pump malfunction causing lack of fuel Engine overheated cooling air circulation restricted Quality of fuel Flywheel key sheared Intake system leak Engine Will Not Crank 1 ey Ol ge o9 Iw PTO drive is engaged Battery is discharged Safety interlock switch is engaged Loose or faulty wires or connections Faulty key switch or ignition switch Faulty electric starter or solenoid Seized internal engine components Engine Runs But Misses 1 ot pe cem p p p Dirt or water in the fuel system Spark plug lead disconnected Poor quality of fuel Faulty spark plug s Loose wires or connections that intermittently ground the ignition kill circuit Engine overheated Faulty ignition module or incorrect air gap Carburetor adjusted incorrectly Engine Will Not Idle 1 pe e c T e Du Dirt or water in the fuel system Stale fuel and or gum in carburetor Faulty spark plugs Fuel supply inadequate Idle fuel adjusting needles improperly set Idle speed adjusting screw improperly set Low compression Restricted fuel tank cap vent Engine overheated cooling system air circulation problem 3 1 Section 3 Troubleshooting Engine Overheats 1 Airintake grass screen cooling fins or cooling shrouds clogged Excessive engine load Low crankcase oil level High crankcase oi
62. b See Figure 10 105 2 Attach the lift bracket if used onto crankcase with the two mounting screws Torque the screws to 9 9 N m 88 in Ib See Figure 10 105 Cil Fill Mounting C Rudi 5 Oil Fill Tube and and Lift Bracket Figure 10 10 3 Align and install the blower housing Secure with the four shoulder screws Torque the screws to 4 0 N m 35 in Ib for inital installations or 2 0 N m 17 7 in lb anytime thereafter See Figure 10 106 X Lak i a Figure 10 106 Installing Blower Housing 4 Install the two cylinder shrouds and secure with the shoulder screws Torque the screws to 4 0 N m 35 in Ib for initial installations or 2 0 N m 17 7 in Ib anytime thereafter See Figure 10 107 Section 10 Reassembly Mounting Screws 9 ae a IO p ph rre 3 oh m a d r L Cylinder Shrouds zs nr d AT Pay AE LII LII i Figure 10 107 Installing Cylinder Shrouds Install Muffler 1 Install the port liners if equipped Attach the muffler and secure with the four hex flange nuts onto the exhaust studs Torque the hex flange nuts to 24 4 N m 216 in Ib 2 Install any attaching hardware and brackets Torque M6 screws to 9 9 N m 88 in Ib and M8 screws to 24 4 N m 216 in Ib F E E zt t kuan Underside View Figure 10 108 Muffler Installation 3 Install the spark arrestor if used 10 27 Section 10 Reassembly Install Oil Filter and Add
63. bly The governor gear must be replaced once it is removed from the crankcase NOTE The governor gear is held onto the shaft by small molded tabs in the gear When the gear is removed from the shaft these tabs are destroyed and the gear must be replaced Therefore remove the gear only if absolutely necessary 9 11 Section 9 Inspection and Reconditioning Oil Pan Assembly Inspection Inspect the oil seal in the oil pan and remove it if it is worn or damaged Refer to Install Oil Pan Oil Seal in Section 10 for new oil seal installation Inspect the main bearing surface for wear or damage refer to Section 1 Specifications Tolerances and Special Torque Values Replace the bearing or oil pan assembly if required Oil Pump Assembly Disassembly 1 Remove the three hex flange screws securing the oil pump housing including the relief valve baffle and the single screw for the pickup See Figure 9 13 2 Remove the oil pump housing and pickup from the oil pan 3 Remove the oil pump gerotor gears from the oil pan recess 4 Remove the oil pickup by pulling it free from the oil pump body 5 The relief valve is a one piece style staked to the oil pump housing removal should not be attempted nor is internal servicing possible If a problem with the relief valve is encountered the oil pump should be replaced See Figure 9 15 Mounting Screws 9 12 Inspection Inspect the oil pump housing Gerotor gea
64. ck 2 Remove one of the oil drain plugs oil fill cap dipstick Be sure to allow ample time for complete drainage Oil Drain Plug Figure 6 5 Drain Plug No 2 Side Section 6 Lubrication System 3 Reinstall the drain plug and torque to 21 4 N m 15 7 ft Ib 4 Fill the crankcase with new oil of the proper type to the F mark on the dipstick Refer to Oil Type on page 6 1 Always check the level with the dipstick before adding more oil 5 Reinstall the oil fill cap dipstick and tighten securely Figure 6 8 Optional Remote Mounted Oil Filter Replace the oil filter as follows 1 Before removing the oil filter clean the area around the oil filter and housing to keep dirt and debris out of the engine Remove the old filter On crankcase mounted oil filter housings a spring loaded inner cup allows automatic oil drainback into the crankcase as the oil filter is removed Wipe off the surface where the oil filter mounts Figure 6 6 Reinstalling Oil Fill Cap Dipstick 2 Drain the oil from the engine crankcase Changing Oil Filter 3 Allow ample time for the oil to drain from the The oil filter on most engines is located on top of the crankcase crankcase between the cylinders Some models use a remote mounted oil filter See Figures 6 7 and 6 8 4 Reinstall the drain plug and torque to 21 4 N m Replace the oil filter seasonally 150 hours or at least 15 7 ft Ib every other oil change every 30
65. conditioning NOTE If the crankpin is reground visually check to ensure that the fillet blends smoothly with the crankpin surface See Figure 9 1 High Point from Fillet Intersections The Fillet Must Blend Smoothly with the Bearing 45 Journal Surface Minimum Must Be Completely Smooth Figure 9 1 Crankpin Fillets The connecting rod journal can be ground one size under When grinding a crankshaft grinding stone deposits can get caught in the oil passages which could cause severe engine damage Removing the crankpin plug when the crankshaft is ground provides easy access for removing any grinding deposits that may collect in the oil passages Use the following procedure to remove and replace the plug Procedure to Remove Crankshaft Plug 1 Drill a 346 hole through the plug in the crankshaft 2 Thread a 3A or 1 long self tapping screw with a flat washer into the drilled hole The flat washer must be large enough to seat against the shoulder of the plug bore See Figure 9 2 3 Tighten the self tapping screw until it draws the plug out of the crankshaft Procedure to Install New Plug 1 Usea single cylinder camshaft pin Kohler Part No 47 380 09 S as a driver and tap the plug into the plug bore until it seats at the bottom of the bore Make sure the plug is tapped in evenly to prevent leakage 9 2 Self Tapping Screw Flat Washer LT Plug Crankshaft T Figure 9 2 Removing Crankpin Plug
66. crankshaft is accessible Lock the holding tool onto the crankshaft Install a 3 8 breaker bar into the hole slot of the holding tool so it is perpendicular to both the holding tool and crankshaft PTO If the flywheel end is more accessible use a breaker bar and socket on the flywheel nut screw to hold it in position An assistant may be needed to hold the breaker bar during testing If the engine is mounted in a piece of equipment it may be possible to hold it by clamping or wedging a driven component Just be certain that the engine cannot rotate off of TDC in either direction Install the adapter into the spark plug hole but do not attach it to the tester at this time Connect an air source of at least 50 psi to the tester Turn the regulator knob in the increase direction clockwise until the gauge needle is in the yellow set area at the low end of the scale Connect the tester quick disconnect to the adapter hose while firmly holding the engine at TDC Note the gauge reading and listen for escaping air at the carburetor intake exhaust outlet and crankcase breather Check the test results against the following table Leakciown Test Results Air escaping from crankcase breather scsciswessacsoemavceernesseannes Air escaping from exhaust system essct gue studet Air escaping form Carburetor s bt ObH TRIS FIRE HEIEPIEMDU EAM IUPN Gauge reading in low green Zone a secos DURER Gauge reading in moderate
67. d top of the cylinder Section 10 Reassembly Figure 10 18 Fly Mark on Piston Figure 10 19 Installing Piston Assembly Using Ring Compressor Tool 5 Install the inner rod cap to the connecting rod using the two hex flange screws Torque the screws in increments to 11 3 N m 100 in Ib Illustrated instructions are provided in the service rod package See Figure 10 20 NOTE Align the chamfer of the connecting rod with the chamfer of its mating end cap When installed the flat faces of the connecting rods should face each other The faces with the raised rib should be toward the outside 10 5 Section 10 Reassembly Screws 6 Repeat the above procedure for the other connecting rod and piston assembly Install Camshaft 1 Liberally apply camshaft lubricant Kohler Part No 25 357 14 S to each of the cam lobes Lubricate the camshaft bearing surfaces of the crankcase and the camshaft with engine oil See Figure 10 21 Lubricant Applied Figure 10 21 Camshaft Lubricant Applied to Cam Lobes 2 Position the timing mark of the crankshaft gear at the 12 o clock position 3 Slide the camshaft into the bearing surface of the crankcase positioning the timing mark of the camshaft gear at the 6 O clock position Make sure that the camshaft gear and crankshaft gear mesh with both timing marks aligned See Figure 10 22 10 6 0 Timing Marks ey Figure 10 22 Aligning Cran
68. e engine is hot or running Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent WARNING Cleaning Solvents can cause severe injury or death Use only in well ventilated areas away from ignition sources Flammable Solvents Carburetor cleaners and solvents are extremely flammable Keep sparks flames and other sources of ignition away from the area Follow the cleaner manufacturer s warnings and instructions on its proper and safe use Never use gasoline as a cleaning agent 1 2 Carbon Monoxide can cause severe nausea fainting or death Avoid inhaling exhaust fumes and never run the engine in a closed building or confined area Lethal Exhaust Gases Engine exhaust gases contain poisonous carbon monoxide Carbon monoxide is odorless colorless and can cause death if inhaled Avoid inhaling exhaust fumes and never run the engine in a closed building or confined area A CAUTION Electrical Shock can cause injury Do not touch wires while engine is running Electrical Shock Never touch electrical
69. e Figure 8 13 8 4 2 Disconnect the throttle linkage and dampening spring from the governor lever at the small bushing See Figure 8 13 P i Eu on 3 7 Governor z Springs Linkage a Throttle V Linkage m Figure 8 13 Disconnect Linkages and Governor Springs 3 Carefully pry off the pal nut remove the two washers note assembly order and disconnect the choke linkage from the pivot lever Do not lose any parts Secure the remaining pivot parts with tape to avoid losing them Always use a new pal nut during reassembly 4 Ifthe fuel pump is being removed with the bracket disconnect the pulse vacuum hose and outlet fuel hose from the pulse pump Properly contain any remaining fuel See Figure 8 14 Figure 8 14 Disconnecting Pulse Hose 5 Remove the lower mounting screw going into the intake manifold and remove the main control bracket See Figure 8 15 Figure 8 15 Removing Control Bracket 6 Loosen the hex flange nut and remove the governor lever from cross shaft See Figure 8 16 Figure 8 16 Removing Governor Lever Remove Carburetor A WARNING Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite if it comes in contact with hot parts
70. e Fuel Needle s Setting Place the throttle into the idle or slow position a Turn one of the low idle fuel adjusting needles out counterclockwise from the preliminary setting until the engine speed decreases rich Note the position of the needle Now turn the adjusting needle in clockwise The engine speed may increase then it will decrease as the needle is turned in lean Note the position of the needle Set the adjusting needle midway between the rich and lean settings See Figure 5 6 b Repeat the procedure on the other low idle adjustment needle 4 Recheck adjust the Low Idle Speed RPM to the specified setting Adjust to Midpoint Adjust to Midpoint Left Side Figure 5 6 Optimum Low Idle Fuel Settings Governed Idle System A governed idle control system is used to maintain a desired idle speed regardless of ambient conditions temperature parasitic load etc that may change An outer secondary spring connected between the governor lever and the governed idle adjuster on the main bracket establishes the governed idle speed See Figure 5 7 Governed Idle Spring mM ul j Figure 5 7 Governor Springs Installed Governed Idle Speed Adjustment 1 Make sure the governed idle spring is in the outer hole in the governor lever and the hole in the governed idle outer adjuster See Figure 5 7 2 Make sure the governor spring is in the inner slot of the governor lever and the
71. e covers on the same sides as originally installed 3 Install a new grommet on each valve cover mounting screw Start each screw 4 Check the position of each cover and gasket then torque each screw to 7 9 N m 70 in Ib See 10 Figure 10 56 Figure 10 56 Torquing Valve Cover Screw 10 15 Section 10 Reassembly Install Spark Plugs 1 Use new Champion XC10YC or equivalent spark plugs 2 Set the gap at 0 76 mm 0 030 in 3 Install new plugs and torque to 24 4 29 8 N m 18 22 ft Ib See Figure 10 57 Figure 10 57 Installing Spark Plugs Install Oil Filter Housing Assembly Reassemble the oil filter housing if disassembled previously See Figures 10 58 through 10 63 Figure 10 60 Installing Spring into Housing c Insert the oil filter cup aligning the cutout with the corresponding section in the housing See Figure 10 61 2a A h e n i aan d Install and tighten the nipple in the housing Use a 5 16 Allen wrench bit and torque to 18 0 N m va 160 in Ib See Figures 10 62 and 10 63 Oil Filter Valve Spring im Vi EN Figure 10 58 Oil Filter Housing Components a Install the small spring onto the rubber valve and insert the small end through the corresponding hole in the cup until properly seated See Figure 10 59 b Install the larger spring into the filter housing See Figure 10 60 Figure 10 61 Installing Cup 10 16 Section 10 Reassembly 2 Install
72. e develops sufficient speed to disengage the starter but does not keep running a false start the engine rotation must be allowed to come to a complete stop before attempting to restart the engine If the starter is engaged while the flywheel is rotating the starter pinion and flywheel ring gear may clash resulting in damage to the starter If the starter does not crank the engine shut off the starter immediately Do not make further attempts to start the engine until the condition is corrected Do not drop the starter or strike the starter frame Doing so can damage the starter Rectifier Regulator Flywheel Stator Ammeter Operation Solenoid Shift Starter When power is applied to the starter the electric solenoid moves the drive pinion out onto the drive shaft and into mesh with the flywheel ring gear When the pinion reaches the end of the drive shaft it rotates the flywheel and cranks the engine When the engine starts and the start switch is released the starter solenoid is deactivated the drive lever moves back and the drive pinion moves out of mesh with the ring gear into the retracted position Starter Removal and Installation Refer to the Disassembly and Reassembly Sections for starter removal and installation procedures Troubleshooting Guide Starting Difficulties Section 7 Electrical System and Components 1 Check the specific gravity of the battery If low recharge or Batte
73. ect each valve for defects such as a warped head excessive corrosion or a worn stem end Replace valves found to be in bad condition A normal valve and valves in bad condition are shown in the accompanying illustrations 9 5 Section 9 Inspection and Reconditioning Normal Even after long hours of operation a valve Leakage A poor grind on face or seat of valve will can be reconditioned and reused if the face and allow leakage resulting in a burned valve on one side margin are in good shape If a valve is worn to where only the margin is less than 1 82 do not reuse it The valve shown was in operation for almost 1000 hours under controlled test conditions Bad Condition The valve depicted here should be Coking Coking is normal on intake valves and is not replaced Note the warped head margin damaged harmful If the seat is good the valve could be reused and too narrow These conditions could be attributed after cleaning to excessive hours or a combination of poor operating conditions 9 6 Excessive Combustion Temperatures The white deposits seen here indicate very high combustion temperatures usually due to a lean fuel mixture Gum Gum deposits usually result from using stale gasoline Gum is a prevalent cause of valve sticking The cure is to ream the valve guides and clean or replace the valves depending on their condition Section 9 Inspection and Reconditioning Stem Corrosion Moisture in fu
74. ectric spark but the spark must be discharged or damage to the system can result Do not crank or run an engine with a spark plug lead disconnected Always provide a path for the spark to discharge to ground Reported ignition problems are most often due to poor connections Before beginning the test procedure check all external wiring Be certain all ignition related wires are connected including the spark plug leads Be certain all terminal connections fit snugly Make sure the ignition switch is in the run position NOTE The CD ignition systems are sensitive to excessive load on the kill lead If a customer complains of hard starting low power or misfire under load it may be due to excessive draw on the kill circuit Perform the appropriate test procedure Test Procedure for Standard Fixed Timing CD Ignition System Isolate and verify the trouble is within the engine ignition system 1 Locate the plug connectors where the wiring harnesses from the engine and equipment are joined Separate the connectors and remove the white kill lead from the engine connector Rejoin the connectors and position or insulate the kill lead terminal so it cannot touch ground Try to start the engine to verify whether the reported problem is still present NOTE If the engine starts or runs during any of the testing you may need to ground the kill lead to shut it down Because you have interrupted the kill circuit it may not stop usin
75. ee Figure 7 35 Test all the segments Continuity must exist between all or the armature is bad Insulation Check Armature Coil Figure 7 35 Checking Armature 3 Check for continuity between the armature coil segments and the commutator segments See Figure 7 35 There should be no continuity If continuity exists between any two the armature is bad 4 Check the armature windings insulation for shorting Shift Fork Check that the shift fork is complete and the pivot and contact areas are not excessively worn cracked or broken Brush Replacement The brushes and springs are serviced as a set 4 Use a new Kohler Brush and Spring Kit if replacement is necessary 1 Perform steps 1 5 in Starter Disassembly 2 Remove the two screws securing the brush holder assembly to the end cap plate Note the orientation for reassembly later See Figure 7 36 Discard the old brush holder assembly Figure 7 36 Removing Brush Holder 3 Clean the component parts as required 4 The new brushes and springs come preassembled in a brush holder with a protective sleeve that will also serve as an installation tool See Figure 7 37 Figure 7 37 Service Brush Kit yy 5 Perform Steps 10 13 in the Starter Reassembly sequence Installation must be done after the armature drive lever and frame are installed if the starter has been disassembled Section 7 Electrical System and Components Starter S
76. el could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent Fuel System Components The typical carbureted fuel system and related components include the following Fuel Tank and Valve Fuel Lines In line Fuel Filter Fuel Pump Carburetor Operation The fuel from the tank is moved through the in line filter and fuel lines by the fuel pump On engines not equipped with a fuel pump the fuel tank outlet is located above the carburetor inlet allowing gravity to feed fuel to the carburetor Fuel then enters the carburetor float bowl and is drawn into the carburetor body There the fuel is mixed with air This fuel air mixture is then burned in the engine combustion chamber Fuel Recommendations General Recommendations Purchase gasoline in small quantities that can be used within 30 days and store only in clean approved containers Do not use gasoline left over from the previous season unless treated with a fuel stabilizer see Storage in Section 1 to minimize gum deposits and ensure easy starting Do not use gasoline containing Methanol or 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 fuel rating method it should be 90 octane
77. el or from condensation are the most common causes of valve stem corrosion Condensation occurs from improper preservation during storage and when engine is repeatedly stopped before it has a chance to reach normal operating temperatures Replace corroded valves Overheating An exhaust valve subject to overheating will have a dark discoloration in the area above the valve guide Worn guides and faulty valve springs may cause this condition Also check for clogged air intake and blocked fins when this condition is noted 9 7 Section 9 Inspection and Reconditioning Valve Guides If a valve guide is worn beyond specifications it will not guide the valve in a straight line This may result in burnt valve faces or seats loss of compression and excessive oil consumption To check valve guide to valve stem clearance thoroughly clean the valve guide and using a split ball gauge measure the inside diameter of the guide Then using an outside micrometer measure the diameter of the valve stem at several points on the stem where it moves in the valve guide Use the largest stem diameter to calculate the clearance by subtracting the stem diameter from the guide diameter If the intake clearance exceeds 0 038 0 076 mm 0 0015 0 0030 in or the exhaust clearance exceeds 0 050 0 088 mm 0 0020 0 0035 in determine whether the valve stem or guide is responsible for the excessive clearance The maximum LD wear on the intake
78. element are serviced check the following Air Cleaner Housing Make sure the housing is not damaged or broken and properly secured Air Cleaner Inlet Make sure the air cleaner inlet is secured tightly to the carburetor and not cracked or damaged Breather Tube Make sure the tube is attached to the air cleaner base and the breather cover NOTE Damaged worn or loose air cleaner components can allow unfiltered air into the engine causing premature wear and failure Tighten or replace all loose or damaged components 4 2 Air Intake Cooling System To ensure proper cooling make sure the grass screen cooling fan fins and external surfaces of the engine are kept clean at all times Seasonally or every 150 hours of operation more often under extremely dusty or dirty conditions remove the cylinder shrouds and blower housing Clean the cooling fins and external surfaces as necessary Make sure all shrouds are reinstalled Cylinder Shroud 4 Section 5 Fuel System and Governor Description This section covers the carbureted fuel system used on these engines The governor system is covered at the end of this section A WARNING Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the engine is hot or running since spilled fu
79. emoved for Clarity 5 16 Section 6 Lubrication System General This engine uses a full pressure lubrication system This system delivers oil under pressure to the crankshaft camshaft and connecting rod bearing surfaces In addition to lubricating the bearing surfaces the lubrication system supplies oil to the hydraulic valve lifters A high efficiency gerotor pump is located in the oil pan The oil pump maintains high oil flow and oil pressure even at low speeds and high operating temperatures A pressure relief valve limits the maximum pressure of the system Service The oil pan must be removed to service the oil pickup the pressure relief valve and the oil pump Refer to the appropriate procedures in Sections 8 9 and 10 Oil Recommendations Using the proper type weight and a consistent brand of oil in the crankcase is extremely important 5o is checking oil daily and changing oil regularly Failure to use the correct oil or using dirty oil causes premature engine wear and failure Use high quality detergent oil of API American Petroleum Institute service class SJ or higher Select the viscosity based on the air temperature at the time of operation as shown in the following table To SAE VISCOSITY GRADES a RR ae NUEN 10W 30 mu eee ONSITE ISDN F IE rri m 2 NA o r E a do 2 To oO 1 422 4 TEMPERATURE RANGE EXPECTED aera NEXT i mice Use of synthetic oil having 5W 20 or 5W 30 rating is acce
80. er at TDC on the compression stroke 7 Repeat steps 3 5 for setting the valve clearance on the 2 side 8 Rotate the crankshaft to check for free operation of the valve train Check for clearance between the valve spring coils at full lift or bending of push rod s can occur Minimum allowable clearance is 0 25 mm 0 010 in Check Assembly Important Rotate the crankshaft a minimum of two revolutions to check assembly and overall proper operation Adjust Valve Clearance Non Bled Lifters When Cylinder Heads and Lifters are Not Removed 1 Turn the adjusters in the rocker arms down clockwise only enough to capture the push rods in the recesses See Figure 10 50 2 Rotate the crankshaft to establish Top Dead Center TDC on the Compression Stroke for the 1 cylinder Check for a Compression will be felt through the spark plug hole b Keyway of crankshaft will be aligned with 1 cylinder c No rocker arm push rod movement if crankshatt is rotated slightly back and forth If they are moving rotate the crankshaft one full revolution 3 Turn one of the 71 side rocker arm adjusting nuts down until push rod is snug but can be rotated with drag This is 0 lash See Figure 10 53 sN y fand Feel for 2 Drag d Figure 10 53 Establishing the 0 Lash Point 4 Mark or note the setting of the adjustment nut then turn tighten the adjuster nut four 4 complete revolutions clockwise p
81. ervice Clean the drive lever and armature shaft Apply Kohler electric starter drive lubricant see Section 2 Versilube G322L or Mobil Temp SHC 32 to the lever and shaft Clean and check the other starter parts for wear or damage as required Starter Reassembly 1 Apply drive lubricant see Section 2 to the armature shaft splines Install the drive pinion onto the armature shaft 2 Install and assemble the stop collar retainer assembly a Install the stop collar down onto the armature shaft with the counter bore recess up b Install a new retainer in the larger rear eroove of the armature shaft Squeeze with a pliers to compress it in the groove c Slide the stop collar up and lock it into place so the recess surrounds the retainer in the groove If necessary rotate the pinion outward on the armature splines against the retainer to help seat the collar around the retainer Figure 7 38 Installing Stop Collar and Retainer NOTE Always use a new retainer Do not reuse old retainers which have been removed 7 21 Section 7 Electrical System and Components 3 Install the offset thrust stop washer so the smaller offset of the washer faces the retainer collar See Figure 7 39 Thrust Washer Figure 7 39 Installing Thrust Washer 4 Apply a small amount of oil to the bearing in the drive end cap and install the armature with the drive pinion 5 Lubricate the fork end and center pivot
82. es or 7 3 N m 65 in Ib for used holes Cylinder h a Baffle BW Mounting Screws j mle v 2 Mounting Screws Figure 10 83 Installing Cylinder Baffle Am Screws 10 21 Section 10 Reassembly Install Oil Cooler 1 Connect the two oil cooler hoses between the oil filter adapter and the oil cooler Secure with new clamps See Figure 10 84 2 Align the oil cooler with the bosses in the backing shroud assembly Secure with the two screws and washers See Figure 10 85 Lu Rl uim LT ETT Mounting rj bai fee ee ff L4 Ibo A iia N a Ba iL aj T f E is 3 A j y P om p Figure 10 85 Installing Oil Cooler Install Cooling Fan and Grass Screen A CAUTION Failure to utilize or re assemble the grass screen as designed could result in grass screen failure and serious personal injury 1 Position the cooling fan onto the flywheel aligning the mounting locations Apply a small amount of Loctite No 243 to the threads and install the three long mounting screws Torque the screws to 9 9 N m 88 in Ib See Figure 10 86 2 Apply a small amount of Loctite No 243 to the external threaded section unless new parts with 10 22 pre applied locking compound are being used Thread the four hex grass screen studs into the mounting holes in the flywheel Torque each stud to 9 9 N m 88 in Ib See Figure 10 86 3 Install the stiffener followed by the meta
83. for overfilled crankcase and or oil in pulse line If none of the checks reveal the cause of the problem replace the pump 5 2 Fuel Pump General These engines use either a pulse style fuel pump or optional remote mounted electric fuel pump assembly See Figures 5 1 and 5 2 The pumping action of pulse style pumps is created by the oscillation of positive and negative pressures within the crankcase This pressure is transmitted to the pulse pump through the rubber hose connected between the pump and crankcase The pumping action causes the diaphragm on the inside of the pump to pull fuel in on its downward stroke and to push it into the carburetor on its upward stroke Two check valves prevent fuel from going backward through the pump an s Fuel Pump Figure 5 2 Optional Electric Fuel Pump Fuel Pump Replacement Replacing the Pulse Style Fuel Pump Replacement pumps are available through your source of supply To replace the pulse pump follow these steps Note orientation of pump before removing 5ee Figure 5 1 Section 5 Fuel System and Governor 1 Disconnect the fuel lines from the inlet outlet and pulse fittings on fuel pump 2 Remove the two mounting screws and take off the pump 3 Connect the pulse line to the new fuel pump and make sure opposite end is properly connected to oil filter housing fitting NOTE Make sure the orientation of the new pump is consistent with the removed pump
84. from the recess in the housing See Figures 7 23 and 7 24 NOTE Test procedure for checking starter solenoid is on pages 7 25 and 7 26 7 17 Section 7 Electrical System and Components Figure 7 24 Removing Plunger 4 Remove the two thru larger bolts See Figure 7 18 Figure 7 25 Removing Thru Bolts 7 25 Remove the commutator end plate assembly containing the brush holder brushes springs and locking caps Remove the thrust washer from inside the commutator end See Figure 7 26 Figure 7 26 Removing Commutator End Plate Assembly 6 Remove the frame from the armature and drive end cap See Figure 7 27 Figure 7 27 Starter Frame Removed 7 Remove the drive lever pivot bushing and backing plate from the end cap See Figure 7 28 Figure 7 28 Removing Backing Plate and Pivot Bushing 8 Take out the drive lever and pull the armature out of the drive end cap See Figure 7 29 9 Remove the thrust washer from the armature shaft See Figure 7 29 Figure 7 29 Armature and Lever Removed 10 Push the stop collar down to expose the retaining ring See Figure 7 30 Figure 7 30 Retaining Ring Detail Section 7 Electrical System and Components 11 Remove the retainer from the armature shaft Save the stop collar NOTE Do not reuse the old retainer Figure 7 31 Removing Retaining Ring 12 Remove the drive pinion assembly from the armature 13 Cle
85. g the switch 7 5 Section 7 Electrical System and Components a Ifthe problem is gone the electrical system Crank the engine and observe the tester spark on the unit is suspect Check the key switch gap Repeat the procedure on the other cylinder wires connections safety interlocks etc Remember to reconnect the first spark plug lead b Ifthe problem persists the condition is a If one side is not firing check all wiring associated with the ignition or electrical connections and terminals on that side If system of the engine Leave the kill lead wiring is okay replace ignition module and isolated until all testing is completed retest for spark 2 Test for spark on both cylinders with Kohler b Ifthe tester shows spark but the engine ignition tester Kohler Part No 24 455 02 5 misses or won t run on that cylinder try a Disconnect one spark plug lead and connect it to new spark plug the post terminal of the tester Connect the clip to a good ground not to the spark plug c Ifneither side is firing recheck position of ignition switch and check for shorted kill lead CONNECTOR ee n SCREW SPARK PLUG CARBURETOR 1 CYLINDER SOLENOID VIDLETZ IGNITION ORANGE MODULE ORANGE RED VO NAA SOLENOID SHIFT STARTER ASS Y COPTIONAL mid FLYWHEEL Molex Plug E mn STATOR Some Models NS S BH SJ ASS Y IGNITION MODULE SPARK PLUG r AC CH
86. ge screws Check positions of all parts then torque the four hex flange nuts to 7 9 N m 70 in Ib in the sequence illustrated and the two hex flange screws to 9 9 N m 88 in Ib See Figures 10 93 10 94 and 10 95 E Breather Hose Port DAP ET Kole Tare Mead Vent Hose location m nm c ha 5 u s F a gt vo 8 Mounting f Nuts L ww a 10 24 Figure 10 94 Torque Sequence for Air Cleaner Mounting Nuts Mounting lt SS MEM TAM Figure 10 95 Installing Alr Cleaner Mounting Screws 4 Connect the breather hose to the fitting on the outlet of the air cleaner and connect the fuel solenoid lead 5 Connect the formed vent hose to the air cleaner housing and the vent port on the carburetor 6 Connect the choke link to the control pivot pin Reinstall the washer and secure with a new push on pal nut See Figure 10 96 Push on Nut p Choke Linkage wf Figure 10 96 Installing Choke Link and Push On Nut Install Throttle and Choke Linkages If the individual throttle choke control linkages were disconnected during disassembly reconnect them based on the operating direction of the control cables to be used On Control Levers Hole A is used for Outer Pull control cable actuation Hole B is used for Inner Pull control cable actuation See Figures 10 97 and 10 98 1 Connect the choke linkage to the appropriate hole in the choke lever and secure with the small cli
87. ghtly lubricate the inside diameter of the bearing with oil XEtn m Bearing d Jh Figure 10 24 Installed Main Bearing In Oil Pan Oil Seal 1 Check to make sure that there are no nicks or burrs in the crankshaft seal bore of the oil pan 2 Apply a light coat of engine oil to the outside diameter of the oil seal 3 Install the oil seal into the oil pan using a seal driver Make sure the oil seal is installed straight and true in the bore to the depth shown in Figure 10 26 Section 10 Reassembly E Oil Seal 3mm 0 118 in Figure 10 26 Oil Seal Depth in Oil Pan 4 Apply a light coat of clean engine oil to the inside diameter of the main bearing Oil Pump Assembly The oil pump is mounted inside the oil pan If service was required and the oil pump was removed refer to the assembly procedures under Oil Pump Assembly in Section 9 10 7 Section 10 Reassembly Install Oil Pan Assembly 1 Make sure the sealing surfaces of the oil pan and crankcase are clean dry and free of any nicks or burrs Install a new O Ring in the oil pan See Figure 10 27 Figure 10 27 O Ring Installed 2 Install a new oil pan gasket onto the crankcase 3 Make sure the oil pump and oil pick up are installed in the oil pan 4 Ensure the end of the locking tab washer on the governor gear is positioned outward in the 6 o clock position inside the crankcase See Figure 10 28 Figure 10
88. gs valves and carburetor Normal and fouled plugs are shown in the following photos 7 1 Section 7 Electrical System and Components Normal A plug taken from an engine operating under normal conditions will have light tan or gray colored deposits If the center electrode is not worn a plug in this condition could be set to the proper gap and reused Carbon Fouled Soft sooty black deposits indicate incomplete combustion caused by a restricted air cleaner over rich carburetion weak ignition or poor compression Worn On a worn plug the center electrode will be rounded and the gap will be greater than the specified gap Replace a worn spark plug immediately 7 2 Wet Fouled A wet plug is caused by excess fuel or oil in the combustion chamber Excess fuel could be caused by a restricted air cleaner a carburetor problem or operating the engine with too much choke Oil in the combustion chamber is usually caused by a restricted air cleaner a breather problem worn piston rings or valve guides Overheated Chalky white deposits indicate very high combustion temperatures This condition is usually accompanied by excessive gap erosion Lean carburetor settings an intake air leak or incorrect spark timing are normal causes for high combustion temperatures Section 7 Electrical System and Components Battery 2 Keep the cables terminals and external surfaces of the battery clean A build up of cor
89. he carburetor Remove the four mounting screws and separate the fuel bowl from the carburetor Transfer any remaining fuel into an approved container Remove and discard the old O Rings Fuel can also be drained prior to bowl removal by loosening removal of the bowl drain screw See Figure 5 18 5 9 Section 5 Fuel System and Governor Fuel Bowl L Li z Main Nozzles i Bowl Drain Screw Main Jets 9 Figure 5 18 Fuel Bowl Removed From Carburetor Figure 5 20 Main Jets and Nozzles Removed NOTE Further disassembly of the fuel bowl 4 Remove the screw securing the flat washer and is not necessary unless the Fuel ground lead if equipped from the top of the Solenoid Kit or Fuel Bowl Kit obtained carburetor then carefully pull lift out the two separately will also be installed slow jets The slow jets may be sized side specific mark or tag for proper reassembly Note the small 2 Remove the float pin screw and lift out the old O Ring on the bottom of each jet See Figure 5 21 float pin and inlet needle See Figure 5 19 and 5 22 Save parts for cleaning and reuse unless Discard all the old parts The seat for the inlet a Jet Kit is also being installed Clean the slow needle is not serviceable and should not be jets using compressed air Do not use wire or removed carburetor cleaner Inlet Needle 3 Use an appropriate size flat screwdriver and carefully remove the two main jets from the carbu
90. he engine is equipped with the following spark plugs Type The standard spark plug is a Champion XC10YC Kohler Part No 62 132 04 S Equivalent alternate brand plugs can also be used Gap 0 76 mm 0 030 in Thread Size 14mm Reach 19 1 mm 3 4 in Hex Size 15 9 mm 5 8 in Spark Plug Service Every 200 hours of operation remove each spark plug Check its condition and either reset the gap or replace with a new plug as necessary Replace spark plugs every 600 hours To service the plugs perform the following steps 1 Before removing each spark plug clean the area around the base of the plug to keep dirt and debris out of the engine 2 Remove the plug and check its condition See Inspection following this procedure Replace the plug if necessary NOTE Do not clean spark plug in a machine using abrasive grit Some grit could remain in the spark plug and enter the engine causing extensive wear and damage 3 Check the gap using a wire feeler gauge Adjust the gap to 0 76 mm 0 030 in by carefully bending the ground electrode See Figure 7 1 Ground Electrode Figure 7 1 Servicing Spark Plug 0 76 mm 0 030 in Gap 4 Reinstall the spark plug into the cylinder head and torque to 24 4 29 8 N m 18 22 ft Ib Inspection Inspect each spark plug as it is removed from the cylinder head The deposits on the tip are an indication of the general condition of the piston rin
91. hin BK two barrel carburetors and affiliated components are High Altitude Kit 1525 3048 m 5 000 10 000 ft High Altitude Kit Over 3048 m 10 000 ft 1 Carburetor Body Subassembly 12 2 Idle Speed Screw 13 3 Idle Speed Spring 14 4 Screw Ib 5 Ground Lead 16 6 Retaining Washer 17 7 Slow Jet RH Side 18 8 Slow Jet LH Side 19 9 O Ring Slow Jet 2 20 10 Fuel Bowl 21 11 O Ring Fuel Bowl Upper 22 O Ring Fuel Bowl Lower Drain Screw Bowl Screw 4 Fuel Solenoid Sealing Washer Float Pin Screw Float Clip Float Valve Inlet Needle Main Nozzle Right Side Figure 5 35 Keihin BK Two Barrel Carburetor Exploded View 5 14 2 9 24 2 26 2 28 29 30 31 92 Main Nozzle Left Side Main Jet Right Side Main Jet Left Side Choke Dust Cap Choke Shaft Spring Bushing Choke Lever Choke Plate Choke Plate Screw 2 Governor General The governor is designed to hold the engine speed constant under changing load conditions Most engines are equipped with a centrifugal flyweight mechanical governor The governor gear flyweight mechanism of the mechanical governor is mounted inside the crankcase and is driven off the gear on the camshaft This governor design works as follows e Centrifugal force acting on the rotating governor gear assembly causes the flyweights to move outward as speed increases Governor spring tension moves them inward as speed decreases
92. holder assembly down into place around the commutator install the positive brush lead grommet in the cutout of the frame See Figure 7 47 1 Y e LI Figure 7 47 Installing Brush Holder Assembly using Tool with Extension 11 Install the end cap onto the armature and frame aligning the thin raised rib in the end cap with the corresponding slot in the grommet of the positive brush lead 12 Install the two thru bolts and the two brush holder mounting screws Torque the thru bolts to 5 6 9 0 N m 49 79 in Ib Torque the brush holder mounting screws to 2 5 3 3 N m 22 29 in Ib See Figures 7 48 and 7 49 Figure 7 48 Torquing Thru Bolts 7 24 Figure 7 49 Torquing Brush Holder Screws 13 Hook the plunger behind the upper end of the drive lever and install the spring into the solenoid Insert the three mounting screws through the holes in the drive end cap Use these to hold the solenoid gasket in position then mount the solenoid Torque the screws to 4 0 6 0 N m 35 53 in Ib 14 Connect the positive brush lead bracket to the solenoid and secure with the hex nut Torque the nut to 8 11 N m 71 97 in Ib Do not overtighten See Figure 7 50 Positive Brush Lead Figure 7 50 Positive Brush Lead Connection Solenoid Test Procedure Solenoid Shift Style Starters Disconnect all leads from the solenoid including the positive brush lead attached to the lower stud ter
93. hole in the high speed inner adjuster See Figure 5 7 Pull the governor lever away from carburetor to the limit of its travel and check that the governor spring is loose and not under any tension See Figure 5 7 Turn the high speed RPM adjustment screw counter clockwise if required until spring is loose See Figure 5 8 Pivot Hold Lever Away Figure 5 8 Holding Governor Lever and Checking Spring Looseness Section 5 Fuel System and Governor 3 Hold the governor lever away from the carburetor so the throttle lever is against the idle speed RPM adjustment screw of the carburetor Start the engine and allow it to warm up then adjust the screw to set approximately 1200 RPM Check using a tachometer Turn the adjustment screw inner clockwise in to increase or counterclockwise out to decrease speed 4 Release the governor lever and check that the throttle lever is in the idle centered position See Figure 5 9 Turn the governed idle outer adjuster screw to obtain the equipment manufacturer s recommended idle speed 1500 1800 RPM The governed idle speed RPM is typically 300 RPM approximate higher than the low idle speed See Figure 5 10 Figure 5 9 Throttle Lever in Idle Position Air Cleaner Removed for Clarity Governed Idle Speed Adjustment Screw Fr Figure 5 10 Setting Governed Idle Speed RPM 5 Move the throttle lever to the wide open full throttle position and hold in
94. hooting DSAI Ignition Systems The DSAI ignition system is designed to be trouble free for the life of the engine Other than periodically checking replacing the spark plugs no maintenance timing or module adjustments are necessary or possible Mechanical systems do occasionally fail or break down however so the following troubleshooting information is provided to help you get to the root of a problem Reported ignition problems are most often due to poor connections Before beginning the test procedure check all external wiring Be certain all ignition related wires are connected including the spark plug leads Be certain all terminal connections fit snugly Make sure the ignition switch is in the RUN position Test Procedure for DSAI Ignition Systems The following procedures are provided for troubleshooting ignition problems on DSAI equipped engines They will allow you to isolate and pinpoint the failed component s Special Tools Required e Hand Tachometer e Ignition Tester Kohler Part No 25 455 01 S e Automotive Timing Light e Multi meter Digital Specifications Required e Spark plug gap 0 76 mm 0 030 in NOTE Ignition tester Kohler Part No 25 455 01 5 must be used to test ignition on these engines Use of any other tester can result in inaccurate findings The battery on the unit must be fully charged and properly connected before making any of these tests a battery that is hooked up or charged backward wi
95. igher operating temperatures and overheating e Check for obvious fuel and oil leaks and damaged components Excessive oil leakage can indicate a clogged or improperly assembled breather worn damaged seals and gaskets or loose or improperly torqued fasteners e Check the air cleaner cover and base for damage or indications of improper fit and seal e Check the air cleaner element Look for holes tears cracked or damaged sealing surfaces or other damage that could allow unfiltered air into the engine Also note if the element is dirty or clogged These could indicate that the engine has been under serviced e Check the carburetor throat for dirt Dirt in the throat is further indication that the air cleaner is not functioning properly e Check the oil level Note if the oil level is within the operating range on the dipstick or if itis low or overfilled e Check the condition of the oil Drain the oil into a container the oil should flow freely Check for metal chips and other foreign particles Sludge is a natural by product of combustion a small accumulation is normal Excessive sludge formation could indicate overrich carburetion weak ignition overextended oil change intervals or wrong weight or type of oil was used to name a few NOTE Itis good practice to drain oil at a location away from the workbench Be sure to allow ample time for complete drainage Cleaning the Engine After inspecting the external co
96. imum of 10 2 cm 4 in above the level in the open side Section 3 Troubleshooting If the level in the engine side is less than specified low no vacuum or the level in the engine side is lower than the level in the open side pressure check for the conditions in the table below Close the shut off clamp before stopping the engine To test the crankcase vacuum with the Vacuum Pressure Gauge Kit see Section 2 1 Pa Remove the dipstick or oil fill plug cap Install the adapter into the oil fill dipstick tube opening Push the barbed fitting on the gauge solidly into the hole in the adapter Start the engine and bring it up to operating speed 3200 3600 RPM Check the reading on the gauge If the reading is to the left of 0 on the gauge vacuum or negative pressure is indicated If the reading is to the right of 0 on the gauge positive pressure is present Crankcase vacuum should be a mimimum of 4 inches of water If the reading is below the specification or if pressure is present check the table below for possible causes and remedies esee tener tt Crankcase Vacuum Pressure in Crankcase Possible PossibeCaus and recheck pressure Crankcase breather clogged or inoperative Disassemble breather clean parts thoroughly reassemble Seals and or gaskets leaking Loose or improperly torqued fasteners Replace all worn or damaged seals and gaskets Make sure all fasteners are
97. ion 1 Specifications Tolerances and Special Torque Values Replace the rod and cap if scored or excessively worn Section 9 Inspection and Reconditioning Service replacement connecting rods are available in STD crankpin size and 0 25 mm 0 010 in undersize Always refer to the appropriate parts information to ensure that correct replacements are used Hydraulic Lifters Inspection Check the base surface of the hydraulic lifters for wear or damage If the lifters need to be replaced apply a liberal coating of Kohler lubricant 25 357 14 S to the base of each new lifter before it is installed Bleeding the Lifters To prevent a possible bent push rod or broken rocker arm it is important to bleed any excess oil out of the lifters before they are installed 1 Cuta 50 75 mm 2 3 in piece from the end of an old push rod and chuck it in a drill press 2 Lay a rag or shop towel on the table of the drill press and place the lifter open end up on the towel 3 Lower the chucked push rod until it contacts the plunger in the lifter Slowly pump the plunger two or three times to force the oil out of the feed hole in the side of the lifter Governor Gear Assembly Inspection The governor gear is located within the crankcase Inspect the governor gear teeth Replace the gear if it is worn chipped or if any teeth are missing Inspect the governor weights They should move freely in the governor gear Disassem
98. ions of washers and the spacer See Figure 8 40 8 10 Section 8 Disassembly Figure 8 45 Removing Valves with Valve Spring Compressor 3 Once the valve spring is compressed remove the following items See Figures 8 46 and 8 47 Valve spring keepers Valve spring retainers Valve springs Valve spring caps Intake and exhaust valves mark position Valve stem seals La s D L TF T MS a Figure 8 43 Match Numbers on Cylinder Barrel and Heads Disassemble Cylinder Heads 1 Remove the two adjusters rocker arm pivots and rocker arms from the cylinder head Remove the pivot studs and guide plate as required See Figure 8 44 Figure 8 46 Valve Train Components c5 PER Figure 8 44 Removing Rocker Arms 2 Compress the valve springs using a valve spring compressor See Figure 8 45 8 11 Section 8 Disassembly oR Valve Siem Seals Figure 8 47 Valve Stem Seals NOTE These engines use valve stem seals on the intake and exhaust valves Use a new seal whenever valves are removed or if the seal is deteriorated in any way Never reuse an old seal 4 Repeat the above procedure for the other cylinder head Do not interchange parts from one cylinder head to the other Remove Breather Assembly 1 Remove the four hex flange screws securing the breather assembly and gasket to the crankcase 2 Carefully break the gasket seal and remove the breather and filter Do not pry
99. is applied test stator Tests 2 and 3 If voltage is 28 volts or more stator is OK Rectifier regulator is faulty Replace the rectifier regulator If voltage is less than 28 volts stator is probably faulty and should be replaced Test stator further using an ohmmeter Test 3 If resistance is 0 064 0 2 ohms the stator is OK If the resistance is infinity ohms stator is open Replace stator If the resistance is infinity ohms no continuity the stator is OK not shorted to ground If resistance or continuity is measured the stator leads are shorted to ground Replace stator If the voltage is 14 7 volts or less the charging system is OK The battery is unable to hold a charge Service battery or replace as necessary If voltage is more than 14 7 volts the rectifier regulator is faulty Replace rectifier regulator 7 15 Section 7 Electrical System and Components DC Voltmeter x Figure 7 20 Connections for Testing Charging System Electric Starting Motors These engines use solenoid shift starters for electric starting A Delco Remy solenoid shift starter is typically used Starting Motor Precautions NOTE NOTE NOTE NOTE 7 16 Do not crank the engine continuously for more than 10 seconds at a time If the engine does not start allow a 60 second cool down period between starting attempts Failure to follow these guidelines can burn out the starter motor If the engin
100. kshaft and Camshaft Timing Marks Determining Camshaft End Play 1 Place anew oil pan gasket into position on the crankcase 2 Position the camshaft endplay checking tool over camshaft Use a feeler gauge to check the endplay between the camshaft and endplay checking tool Camshaft endplay should be between 0 3 1 3 mm 0 011 0 051 in See Figure 10 23 y y a Figure 10 23 Checking Camshaft End Play 3 No shim is typically used from the factory However if the camshaft end play is not within the specified range remove the checking tool and shim as necessary Several color coded shims are available White 0 69215 0 73025 mm 0 02725 0 02875 in Blue 0 74295 0 78105 mm 0 02925 0 03075 in Red 0 79375 0 83185 mm 0 03125 0 03275 in Yellow 0 84455 0 88265 mm 0 03325 0 03475 in Green 0 89535 0 99345 mm 0 03525 0 03675 in Gray 0 94615 0 98425 mm 0 03725 0 03875 in Black 0 99695 1 03505 mm 0 03925 0 04075 in 5 Reinstall the end play checking tool and recheck the end play Install Oil Pan Seal and Main Bearing Main Bearing If the oil pan main bearing was removed for servicing a new bearing should be installed at this time 1 Make sure the oil pan bore for the main bearing is clean dry and free of nicks or burrs 2 Install a new bearing with the notch in the 12 o clock position using a press and driver Make sure the bearing is fully seated against the flange See Figure 10 24 3 Li
101. l grass screen onto the four hex studs Secure with the four special washers and mounting screws using Loctite No 243 on the threads Torque the screws to 9 9 N m 88 in Ib See Figure 10 86 Screws ac Special D S Washers 4 Mounting Studs L Fan Screws Figure 10 86 Cooling Fan and Grass Screen Assembly Details Install Electric Starter 1 Install the electric starter motor using the two hex flange screws See Figure 10 87 2 Torque the two hex flange screws to 15 3 N m 135 in Ib Mounting Screws Figure 10 87 Installing Electric Starter Motor 3 Connect the leads to the solenoid See Figure 10 88 Figure 10 88 Connecting Leads to Starting Motor Install Valley Baffles 1 Install the two valley baffles and secure with the mounting screws The lower section should fit under the outer baffle Torque the M6 screws going into the cylinder head to 10 7 N m 95 in Ib for new holes or 7 3 N m 65 in Ib for used holes Torque the M6 screw going into the lower blower housing mounting clip to 3 9 N m 35 in Ib See Figure 10 89 Valley Baffles M Screw E SHE i 2 Figure 10 89 Installing Valley Baffles Install Carburetor A WARNING Explosive Fuel Gasoline may be present in the carburetor and fuel system Gasoline is extremely flammable and its vapors can explode if ignited Keep sparks and other sources of ignition away from the engine 1
102. l level Faulty carburetor Lean fuel mixture DUI Sy Engine Knocks 1 Excessive engine load Low crankcase oil level Old or improper fuel Internal wear or damage Hydraulic lifter malfunction Quality of fuel Incorrect grade of oil QUII SS D Engine Loses Power 1 Low crankcase oil level High crankcase oil level Dirty air cleaner element Dirt or water in the fuel system Excessive engine load Engine overheated Faulty spark plugs Low compression Exhaust restriction Low battery Incorrect governor setting Lo 29 De tS II Gc Tu mM e Engine Uses Excessive Amount of Oil 1 Incorrect oil viscosity type 2 Clogged broken or inoperative crankcase breather Worn or broken piston rings Worn cylinder bore Worn valve stems valve guides Crankcase overfilled Blown head gasket overheated Ao OE N Oil Leaks from Oil Seals Gaskets 1 Clogged broken or inoperative crankcase breather 2 Loose or improperly torqued fasteners 3 Piston blowby or leaky valves 4 Restricted exhaust External Engine Inspection Before cleaning or disassembling the engine make a thorough inspection of its external appearance and condition This inspection can give clues to what might be found inside the engine and the cause when it is disassembled 3 2 e Check for buildup of dirt and debris on the crankcase cooling fins grass screen and other external surfaces Dirt or debris on these areas are causes of h
103. ll crank the engine but it won t have spark Be certain the drive is in neutral and all external loads are disconnected Section 7 Electrical System and Components Test 1 Isolate and Verify the Trouble is Within the Engine Ignition System 1 Locate the connectors where the wiring harnesses from the engine and equipment are joined Separate the connectors and remove the white kill lead from the engine connector Rejoin the connectors and position or insulate the kill lead terminal so it cannot touch ground Try to start the engine to verify whether the reported problem is still present NOTE Ifthe engine starts or runs during any of the testing you may need to ground the kill lead to shut it down Because you have interrupted the kill circuit it may not stop using the switch a If the problem goes away the electrical system on the equipment is suspect Check the key switch wires connections safety interlocks etc b Ifthe problem persists the condition is associated with the ignition or electrical system of the engine Leave the kill lead isolated until all testing is completed c Identify the white kill lead of the engine wiring harness connector Establish a connection to a known good ground location The engine should kill completely If not or only one cylinder is affected go to Test 4 but also check the white kill lead connection for the affected DSAI module Test 2 Test for Spark 1 With the engine stopped
104. locked flange to flange and tighten each of the studs until bottomed tight Install Backing Shroud Assembly 1 To aid assembly install the lower oil cooler hose onto the oil filter housing prior to installing the backing shroud assembly Secure with a clamp positioned as shown See Figure 10 69 NOTE New hose clamps are recommended for reassembly or if clamps have been loosened expanded several times to avoid leakage 10 18 A 10 69 Lower oi Cooler Hose Details ps Install the backing shroud assembly and secure to the crankcase with the four M6 screws Torque the four screws going into the crankcase to 10 7 N m 99 in Ib into new holes or 7 3 N m 65 in Ib into used holes See Figure 10 70 Figure 10 70 Installing Backing Shroud Assembly Install Stator Wiring Harness and Rectifier Regulator 1 Apply pipe sealant with Teflon Loctite No 59241 or equivalent to the stator mounting holes Position the stator aligning the mounting holes so the leads are at the bottom and toward the rectifier regulator mount on the No 1 side Install and torque the two hex flange screws to 6 2 N m 55 in Ib See Figure 10 71 Route the stator wires under the two molded clips in backing shroud assembly See Figure 10 71 Mounting Screws i e E Figure 10 71 Installing Stator 5 Check the terminal on the end of the fused B charging lead to be sure the locking tang is angled upward if remo
105. lus one flat of nut 1 6 turn or a total of 4 1 6 turns Turn 4 1 6 Revolutions From 0 Lashi ee Wey i on Bled Lifters Figure 10 54 Setting Valve Lash N 5 Hold the adjuster nut in this position and tighten the locking setscrew Torque the setscrew to 7 3 N m 65 in Ib 6 Repeat the procedure for the other valve on the this side 7 Viewed from the PTO end rotate the crankshaft 270 3 4 turn counterclockwise and align the crankshaft keyway with the 2 cylinder which now puts that cylinder at TDC on the compression stroke 8 Repeat steps 3 6 for setting the valve clearance on the 2 side 9 Rotate the crankshaft to check for free operation of the valve train Check the clearance between the valve spring coils at full lift Minimum allowable clearance is 0 25 mm 0 010 in Section 10 Reassembly Check Assembly Important Check if engine can be turned over completely and compression is noted If it cannot locks up at some point return the piston to TDC between the intake and exhaust strokes first for one cylinder and then the other waiting ten minutes to allow lifters to bleed down then check for compression again Install Valve Covers 1 Make sure the sealing surfaces are clean and free of any nicks or burrs 2 Install and properly seat the seal onto each of the valve covers See Figure 10 55 Figure 10 55 Installing Seal on Valve Cover 2 Install the valv
106. minal Remove the mounting hardware and separate the solenoid from the starter for testing Test 1 Solenoid Pull In Coil Plunger Actuation Test Use a 12 volt power supply and two test leads Connect one lead to the flat spade S start terminal on the solenoid Momentarily connect the other lead to the lower large post terminal See Figure 7 51 When the connection is made the solenoid should energize audible click and the plunger retract Repeat the test several times If the solenoid fails to activate it should be replaced NOTE DO NOT leave the 12 volt test leads connected to the solenoid for any time over what is necessary for performing each of the individual tests Internal damage to the solenoid may otherwise occur 12 volt Test Leads Momentary Connection Only Figure 7 51 Testing Pull In Coil Plunger Actuation Test 2 Solenoid Pull In Coil Contact Continuity Test Use an ohmmeter set to the audible or Rx2K scale and connect the two ohmmeter leads to the two large post terminals Perform the preceding test 1 and check for continuity See Figure 7 52 The ohmmeter should indicate continuity if no continuity is indicated the solenoid should be replaced Repeat test several times to confirm condition Section 7 Electrical System and Components 12 volt Test Leads Momentary r Connection Only Figure 7 52 Testing Pull In Coil Solenoid Contact Continuity Test 3 Solenoid Hold In Coil F
107. minimum Unleaded gasoline is recommended as it leaves less combustion chamber deposits and reduces harmful exhaust emissions Leaded gasoline is not recommended Gasoline Alcohol blends Gasohol up to 10 ethyl alcohol 90 unleaded gasoline by volume is approved as a fuel for Kohler engines Other gasoline alcohol blends including E20 and E85 are not to be used and not approved Any failures resulting from use of these fuels will not be warranted Gasoline Ether blends Methyl Tertiary Butyl Ether MTBE and unleaded gasoline blends up to a maximum of 15 MTBE by volume are approved as a fuel for Kohler engines Other gasoline ether blends are not approved Fuel Filter Most engines are equipped with an in line fuel filter Periodically inspect the filter and replace with a genuine Kohler filter seasonally or every 150 operating hours Fuel Line These engines use Low Permeation SAE 30 R7 rated fuel line certified to meet emission requirements Standard fuel line may not be used Order replacement hose by part number through a Kohler Engine Service Dealer 5 1 Section 5 Fuel System and Governor Fuel System Tests When the engine starts hard or turns over but will not start it is possible that the problem is in the fuel system To find out if the fuel system is causing the problem perform the following test Troubleshooting Fuel System Related Causes 1 Check the following a Make sure the fuel tank con
108. n oversizing a a good level of suds If the suds break down during cylinder it should be machined exactly cleaning discard the dirty water and start again 0 25 mm 0 010 in or 0 50 mm 0 020 in with more hot water and detergent Following the over the new diameter Section 1 The scrubbing rinse the cylinder with very hot clear corresponding oversize Kohler replacement water dry it completely and apply a light coating of piston will then fit correctly engine oil to prevent rusting the desired size remove the coarse stones and Before installing the piston into the cylinder bore it replace them with burnishing stones Continue is necessary that the clearance be accurately checked with the burnishing stones until the bore is This step is often overlooked and if the clearances are within 0 013 mm 0 0005 in of the desired size not within specifications engine failure will usually and then use finish stones 220 280 grit and result polish the bore to its final size A crosshatch should be observed if honing is done correctly The crosshatch should intersect at approximately 23 33 off the horizontal Too flat an angle could cause the rings to skip and wear excessively and too steep an angle will result in high oil Use the following procedure to accurately measure consumption 5ee Figure 9 3 9 NOTE Do not use a feeler gauge to measure piston to bore clearance it will yield inaccurate measurements Always use a micromete
109. ndition of the engine clean the engine thoroughly before disassembling it Also clean individual components as the engine is disassembled Only clean parts can be accurately inspected and gauged for wear or damage There are many commercially available cleaners that will quickly remove grease oil and grime from engine parts When such a cleaner is used follow the manufacturer s instructions and safety precautions carefully Make sure all traces of the cleaner are removed before the engine is reassembled and placed into operation Even small amounts of these cleaners can quickly break down the lubricating properties of engine oil Basic Engine Tests Crankcase Vacuum Test A partial vacuum should be present in the crankcase when the engine is operating Pressure in the crankcase normally caused by a clogged or improperly assembled breather can cause oil to be forced out at oil seals gaskets or other available spots Crankcase vacuum is best measured with either a water manometer or a vacuum gauge see Section 2 Complete instructions are provided in the kits To test the crankcase vacuum with the manometer 1 Insert the stopper hose into the oil fill hole Leave the other tube of manometer open to atmosphere Make sure the shut off clamp is closed 2 Start the engine and run at no load high speed 3200 to 3750 RPM 3 Open the clamp and note the water level in the tube The level in the engine side should be a min
110. ng flux field in the Figure 7 4 transformer core A high voltage pulse is generated from this action into the secondary winding of the e A kill switch or key switch which grounds the transformer This pulse is delivered to the spark plug modules to stop the engine gap Ionization of the gap occurs resulting in an arc at the plug electrodes This spark ignites the fuel air Two spark plugs mixture in the combustion chamber 7 4 Kill Switch or Off Position of Key Switch r DUE l L Section 7 Electrical System and Components Ignition Modules pa ON 4 Spark Plug Nu Magnet 0 28 0 33 mm 0 011 0 013 in Air Gap Flywheel Figure 7 4 Capacitive Discharge Fixed Timing Ignition System The timing of the spark is controlled by the location of the flywheel magnet group as referenced to engine top dead center Y Spark Plug amp Figure 7 5 Capacitive Discharge CD Ignition Module Schematic Troubleshooting CD Ignition Systems The CD ignition systems are designed to be trouble free for the life of the engine Other than periodically checking replacing the spark plugs no maintenance or timing adjustments are necessary or possible Mechanical systems do occasionally fail or break down however so the following troubleshooting information is provided to help you get to the root of a reported problem A CAUTION High Energy Electric Spark The CD ignition systems produce a high energy el
111. ng with the fuel High oil consumption can also occur when the piston ring end gap is incorrect because the ring cannot properly conform to the cylinder wall under this condition Oil control is also lost when ring gaps are not staggered during installation When cylinder temperatures get too high lacquer and varnish collect on pistons causing rings to stick which results in rapid wear A worn ring usually takes on a shiny or bright appearance Scratches on rings and pistons are caused by abrasive material such as carbon dirt or pieces of hard metal Overheated or Deteriorated Oil Figure 9 8 Common Types of Piston Damage Section 9 Inspection and Reconditioning Detonation damage occurs when a portion of the fuel charge ignites spontaneously from heat and pressure shortly after ignition This creates two flame fronts which meet and explode to create extreme hammering pressures on a specific area of the piston Detonation generally occurs from using low octane fuels Preignition or ignition of the fuel charge before the timed spark can cause damage similar to detonation Preignition damage is often more severe than detonation damage Preignition is caused by a hot spot in the combustion chamber from sources such as glowing carbon deposits blocked cooling fins an improperly seated valve or wrong spark plug s See Figure 9 8 for some common types of piston and ring damage MA Scored Piston and Rings 9
112. ntries using the Research method it should be 90 octane minimum Unleaded gasoline is recommended as it leaves less combustion chamber deposits and reduces harmful exhaust emissions Leaded gasoline is not recommended and must not be used on EFI engines or on other models where exhaust emissions are regulated Gasoline Alcohol blends Gasohol up to 10 ethyl alcohol 90 unleaded gasoline by volume is approved as a fuel for Kohler engines Other gasoline Alcohol blends including E20 and E85 are not to be used and not approved Any failures resulting from use of these fuels will not be warranted Gasoline Ether blends Methyl Tertiary Butyl Ether MTBE and unleaded gasoline blends up to a maximum of 15 MTBE by volume are approved as a fuel for Kohler engines Other gasoline ether blends are not approved Section 1 Safety and General Information Periodic Maintenance Instructions A WARNING Accidental Starts Disabling engine Accidental starting can cause severe injury or death Before working on the engine or equipment EH disable the engine as follows 1 Disconnect the spark plug lead s 2 Disconnect negative battery cable from battery Maintenance Schedule These required maintenance procedures should be performed at the frequency stated in the table They should also be included as part of any seasonal tune up Starting Engine Every 150 Hours More frequently under severe operating conditions e Every 300
113. of the drive lever with drive lubricant see Section 2 Position the fork end into the space between the captured washer and the rear of the pinion 6 Slide the armature into the drive end cap and at the same time seat the drive lever into the housing NOTE Correctly installed the center pivot section of the drive lever will be flush or below the machined surface of the housing which receives the backup washer See Figure 7 40 Figure 7 40 Installing Armature and Pivot Lever 7 22 Figure 7 41 Installing Backup Washer and Install the backup washer followed by the rubber grommet into the matching recess of the drive end cap The molded recesses in the grommet should be out matching and aligned with those in the end cap See Figure 7 41 LE r Grommet 8 Install the frame with the small notch forward onto the armature and drive end cap Align the notch with the corresponding section in the rubber grommet Install the drain tube in the rear cutout if it was removed previously See Figure 7 42 Figure 7 42 Installing Frame and Drain Tube 9 Install the flat thrust washer onto the commutator end of the armature shaft See Figure 7 43 Thrust Washer Figure 7 43 Installing Thrust Washer 10 Starter reassembly when replacing the Brushes Brush Holder Assembly a Hold the starter assembly vertically on the end housing and carefully position the assembled brush holder assembly wi
114. on adjusting or disassembling the carburetor e Make sure the air cleaner element including e Make sure the fuel tank is filled with clean fresh precleaner if equipped is clean and all air cleaner gasoline components are fastened securely e Make sure the fuel tank cap vent is not blocked e Make sure the ignition system governor system and that it is operating properly exhaust system and throttle and choke controls are operating properly If the engine is hard e Make sure fuel is reaching the carburetor This starting runs roughly or stalls at low idle speed includes checking the fuel shut off valve fuel it may be necessary to adjust or service the tank filter screen in line fuel filter fuel lines and carburetor fuel pump for restrictions or faulty components as necessary Troubleshooting Carburetor Related Causes Possible Cause Probable Remedy 1 Engine starts hard runs roughly Low idle fuel mixture some models speed improperly or stalls at idle speed adjusted Adjust the low idle speed tab then adjust the low idle fuel needle Engine runs rich indicated by Clogged air cleaner Clean or replace black sooty exhaust smoke Choke partially closed during operation Check the choke lever misfiring loss of speed and power linkage to ensure choke is operating properly governor hunting or excessive Low idle fuel mixture is improperly adjusted Adjust low idle throttle opening fuel needle some models
115. on 1 for minimum lift and or dimensional specifications Inspect the cam gear for badly worn chipped or missing teeth Replacement of the camshaft will be necessary if any of these conditions exist Crankshaft Inspection and Service Inspect the gear teeth of the crankshaft If the teeth are badly worn chipped or some are missing replacement of the crankshaft will be necessary Inspect the crankshaft bearing surfaces for scoring grooving etc Replaceable bearings are used in the crankshaft bore of the oil pan and or crankcase Do not replace the bearings unless they show signs of damage or are out of running clearance specifications If the crankshaft turns easily without noise and there is no evidence of scoring grooving etc on the races or bearing surfaces the bearings can be reused Inspect the crankshaft keyways If they are worn or chipped replacement of the crankshaft will be necessary Inspect the crankpin for score marks or metallic pickup Slight score marks can be cleaned with crocus cloth soaked in oil If the wear limits as stated in Specifications and Tolerances are exceeded it will be necessary to either replace the crankshaft or regrind the crankpin to 0 25 mm 0 010 in undersize If reground a 0 25 mm 0 010 in undersize connecting rod big end must then be used to achieve proper running clearance Measure the crankpin for size taper and out of round 9 1 Section 9 Inspection and Re
116. or Tester 120 volt current Kohler 25 761 20 S Rectifier Regulator Tester 240 volt current Kohler 25 761 41 S Used to test rectifier regulators Individual Components Available Design Technology Inc CS PRO Regulator Test Harness DTI 031 Special Regulator Test Harness with Diode DTI 033 Spark Advance Module SAM Tester To test the SAM ASAM and DSAM on engines with SMART SPARK Kohler 25 761 40 S Starter Retaining Ring Tool Inertia Drive To remove and reinstall drive retaining rings excluding FASCO starters Kohler 25 761 18 S Starter Servicing Kit All Starters SE Tools KL R 82411 To remove and reinstall drive retaining rings and brushes Individual Component Available SE Tools KLR 82416 Starter Brush Holding Tool Solenoid Shift rs D Tachometer Digital Inductive Design Technology Inc For checking operating speed RPM of an engine DTI 110 Vacuum Pressure Tester Kohler 25 761 22 5 Alternative to a water manometer 2 2 Section 2 Tools amp Aids Bids Dielectric Grease Fel Pro Electric Starter Drive Lubricant Inertia Drive Electric Starter Drive Lubricant Solenoid Shift RTV Silicone Sealant Kohler 25 597 07 S Loctite 5900 Heavy Body in 4 oz aerosol dispenser Only oxime based oil resistant RTV sealants such as those listed are approved for use Loctite Nos 5900 or 5910 are recommended for best sealing characteristics Loctite 5910 Loctite Ultra Black 598 Loctite Ultra Blue 587 Locti
117. p Throttle Control Clamp Location Choke Control a A A Links Connected Here Figure 10 97 Throttle Choke Linkage Details for Outer Pull Actuation 2 Connect the throttle linkage to the appropriate hole in the throttle lever and secure with the small clip Section 10 Reassembly Control Cable Clamp Locations I g A N Links Connected Here Figure 10 98 Throttle Choke Linkage Details for Inner Pull Actuation Install Fuel Pump 1 Install the fuel pump with hoses to the control bracket if removed earlier Torque the mounting screws to 4 0 N m 35 in Ib 2 Connect the outlet fuel line to the carburetor inlet and secure with a clamp 3 Install the pulse hose and inlet hoses in their proper locations See Figure 10 99 Outlet Hose Fuel Pump amp f E Figure 10 99 Fuel Pump Mounting and Hose Details 10 25 Section 10 Reassembly Adjusting Governor 1 Position the governor lever so the clamping area is inboard but completely on the knurled area of governor cross shaft See Figure 10 100 Lever 4 MG 5 overnor Brushed Knurled Area d Figure 10 100 Brushed Knurled Area 2 Move the governor lever toward the carburetor as far as it will go wide open throttle and hold in position See Figure 10 101 3 Insert a long thin rod or tool into the hole on the cross shaft and rotate the shaft clockwise viewed from the end as far as it
118. poor or slow governor response To compensate for the effects of high altitude special high altitude jet kits are available The kits include new main jets slow jets where applicable necessary gaskets and O Rings Refer to the parts manual for the correct kit number Fuel Shut off Solenoid Most carburetors are equipped with a fuel shut off solenoid The solenoid is attached to the fuel bowl See Figure 5 4 The solenoid has a spring loaded pin that retracts when 12 volts is applied to the lead allowing fuel flow to the main jets When current is removed the pin extends blocking the fuel flow Fuel Shut Off Solenoid Figure 5 4 Fuel Shut off Solenoid Below is a simple test made with the engine off that can determine if the solenoid is functioning properly 1 Shut off fuel and remove the solenoid from the carburetor When the solenoid is loosened and removed gas will leak out of the carburetor Have a container ready to catch the fuel 2 Wipe the tip of the solenoid with a shop towel or blow it off with compressed air to remove any remaining fuel Take the solenoid to a location with good ventilation and no fuel vapors present You will also need a 12 volt power source that can be switched on and off 3 Besure the power source is switched off Connect the positive power source lead to the red lead of the solenoid Connect the negative power source lead to the solenoid body Section 5 Fuel System and Governo
119. ptable up to 4 C 40 F Synthetic oils will provide better starting in extreme cold below 23 C 10 F NOTE Using other than service class SJ or higher oil or extending oil change intervals longer than recommended can cause engine damage NOTE Synthetic oils meeting the listed classifications may be used with oil changes performed at the recommended intervals However to allow piston rings to properly seat anew or rebuilt engine should be operated for at least 50 hours using standard petroleum based oil before switching to 6 synthetic oil A logo or symbol on oil containers identifies the API service class and SAE viscosity grade See Figure 6 1 Figure 6 1 Oil Container Logo The top portion of the symbol shows service class such as API SERVICE CLASS SJ The symbol may show additional categories such as SH SG CC or CD The center portion shows the viscosity grade such as SAE 10W 30 If the bottom portion shows Energy Conserving it means that oil is intended to improve fuel economy in passenger car engines 6 1 Section 6 Lubrication System Checking Oil Level The importance of checking and maintaining the proper oil level in the crankcase cannot be overemphasized Check oil BEFORE EACH USE as follows 1 Make sure the engine is stopped level and is cool so the oil has had time to drain into the sump 2 Clean the area around the oil fill cap dipstick before removing it This will help to
120. r the piston to bore clearance 1 Usea micrometer and measure the diameter of the piston 11 mm 0 433 in above the bottom of the piston skirt and perpendicular to the piston pin 5ee Figure 9 4 Measure 11 mm above the Bottom of Piston Skirt at Right Angles to Piston Pin Figure 9 3 Cylinder Bore Crosshatch after Honing 4 After resizing check the bore for roundness taper and size Use an inside micrometer telescoping gauge or bore gauge to take measurements The measurements should be Figure 9 4 Measuring Piston Diameter 9 3 Section 9 Inspection and Reconditioning 2 Useaninside micrometer telescoping gauge or bore gauge and measure the cylinder bore Take the measurement approximately 63 5 mm 2 5 in below the top of the bore and perpendicular to the piston pin 3 Piston to bore clearance is the difference between the bore diameter and the piston diameter step 2 minus step 1 Flywheel Inspection Inspect the flywheel for cracks and the flywheel keyway for damage Replace the flywheel if it is cracked Replace the flywheel the crankshaft and the key if flywheel key is sheared or the keyway is damaged Inspect the ring gear for cracks or damage Kohler does not provide the ring gear as a serviceable part Replace the flywheel if the ring gear is damaged 9 4 Cylinder Head and Valves Inspection and Service After cleaning check the flatness of the cylinder head and the cor
121. r 4 Turn the power source on and observe the pin in the center of the solenoid The pin should retract with the power on and return to its original position with the power off Test several times to verify operation Carburetor Details The Keihin BK two barrel carburetor is a side draft design The circuits within the carburetor function as described following Float Circuit The fuel level in the bowl is maintained by the float and fuel inlet needle The buoyant force of the float stops fuel flow when the engine is at rest When fuel is being consumed the float will drop and fuel pressure will push the inlet needle away from the seat allowing more fuel to enter the bowl When demand ceases the buoyant force of the float will again overcome the fuel pressure rising to the predetermined setting and stop the flow Slow amp Mid Range Circuit At low speeds the engine operates only on the slow circuit As a metered amount of air is drawn through the slow air bleed jets fuel is drawn through the two main jets and further metered through the slow jets Air and fuel are mixed in the body of the slow jet and exit to the transfer port From the transfer port the air fuel mixture is delivered to the idle progression chamber From the idle progression chamber the air fuel mixture is metered through the idle port passages At low idle when the vacuum signal is weak the air fuel mixture is controlled by the setting of the idle fuel
122. re MaxX osecensten umdoeru eve tix t abeo im ev me remp aT RE Piston Thrust Face O D Piston Thrust Face to Cylinder Bore Running Clearance DN A Starter Assembly Thru Bolt Torque Delcoskemi Solenoid SMIN Jorion Monine rew OPC serseri O Usu Sae Brush Holder Mounting Screw Torque Delco ANGI ITOT RUN Solenoid Starter Mounting Hardware Torque Deco quen v O e ian ere ere MINI Nut Positive Brush Lead Torque DCT ORG IO o iarci CN Stator Mounting Screw TOV GG sesenta um pU IN et MESA os e Uds Throttle Choke Control Bracket Fasien r JORQUB raon eade binP iu E MIENNE INN Valve Cover Valve Cover Fastener TORQUE es tertiae e vtbat eias Valves and Valve Lifters Hydraulic Valve Lifter to Crankcase Running Clearance Intake Valve Stem to Valve Guide Running Clearance Exhaust Valve Stem to Valve Guide Running Clearance Intake Valve Guide I D PIO us en re re a E I L M ee DVT Wear EE Eaeorasesseniste st sdr cem sea vins d ipo PIG PESE EsE EE SIR DUO SEEN EOS RUSddE Exhaust Valve Guide I D INI teste riot es oes sce see E M D M I UM Nax Wear DHT D o sseeseneste stunde tesis E Section 1 Safety and General Information 0 04 0 08 mm 0 0015 0 0031 in 0 04 0 08 mm 0 0015 0 0031 in eterne 0 03 0 19 mm 0 0011 0 0074 in 0 30 0 55 mm 0 011 0 021 in 0 94 mm 0 037 in eee 89 953 89 967 mm 3 5414 8 5420 in 89 92
123. red in sections of their own Air Cleaner Section 4 Carburetor amp External Governor Section 5 Ignition Charging amp Electric Starter Section 7 Clean all parts thoroughly Only clean parts can be accurately inspected and gauged for wear or damage There are many commercially available cleaners that will quickly remove grease oil and grime from engine parts When such a cleaner is used follow the manufacturer s instructions and safety precautions carefully Make sure all traces of the cleaner are removed before the engine is reassembled and placed into operation Even small amounts of these cleaners can quickly break down the lubricating properties of engine oil Use an aerosol gasket remover paint stripper or lacquer thinner to remove any old gasket material Apply the solvent allow time for it to work and then brush the surface with a brass wire brush After all old material is removed clean the surface with isopropyl alcohol lacquer thinner or aerosol electrical contact cleaner Do not scrape the surfaces as any scratches nicks or burrs can result in leaks See Service Bulletin 252 for further information Refer to A Guide to Engine Rebuilding TP 2150 A for additional information Measurement Guide IP 2159 B and Engine Inspection Data Record TP 2435 are also available use these to record inspection results Camshaft Inspection and Service Check the lobes of the camshaft for wear or damage See Secti
124. responding top surface of the crankcase using a surface plate or piece of glass and feeler gauge as shown in Figure 9 5 The maximum allowable out of flatness is 0 076 mm 0 003 in Figure 9 5 Checking Cylinder Head Flatness Carefully inspect the valve mechanism parts Inspect the valve springs and related hardware for excessive wear or distortion Check the valves and valve seat area or inserts for evidence of deep pitting cracks or distortion Check clearance of the valve stems in the guides See Figure 9 6 for valve details and specifications EXHAUST VALVE O 3 DQ KSN Eq a ASU how 4 Section 9 Inspection and Reconditioning INTAKE VALVE Lh 4 A SetAnge 89 8 B SeatTaper eo 8 D Guide LD 7 038 7 058 mm 0 2771 0 2779 in 7 038 7 058 mm 0 2771 0 2779 in E Valve Head Diameter 38 625 38 685 mm 1 5206 1 5230 in _ 1 625 31 825 mm 1 2450 1 2549 in _ F ValveFace Angle 45 o 45 o G Valve Margin Min 1 0mm 0 0393 in 10mm 0039in H Valve Stem Diameter 6 982 7000 mm 0 2749 0 2756 in 6 970 6 988 mm 0 2744 0 2751 in Figure 9 6 Valve Details Hard starting or loss of power accompanied by high fuel consumption may be symptoms of faulty valves Although these symptoms could also be attributed to worn rings remove and check the valves first After removal clean the valve heads faces and stems with a power wire brush Then carefully insp
125. retor Note and mark the jets by location for proper installation The main jets may be size side specific After the main jets are removed the main nozzles can be removed out through the bottom of the main towers Note the orientation direction of the nozzles The end with the two raised shoulders should be out down adjacent to the main jets Save the parts for cleaning and reuse See Figure 5 20 E L Figure 5 22 Slow Jets and O Ring Detail 5 10 Section 5 Fuel System and Governor 5 Remove the idle speed RPM adjustment screw 9 Make sure the O Ring near the bottom of each and spring from the carburetor Discard the parts slow jet is new or in good condition Align and insert the two slow jets into the top of the NOTE The carburetor is now disassembled for carburetor See Figure 5 22 appropriate cleaning and installation of the parts in the overhaul kit Further 10 Install the large flat retaining washer and secure disassembly is not necessary The with the mounting screw attaching the ground throttle shaft assembly fuel inlet seat lead if originally secured by the screw idle fuel adjustment screws with limiter and carburetor body are non serviceable 11 Install the new idle speed RPM adjustment items and should not be removed The screw and spring onto the carburetor Thread choke shaft assembly is serviceable in until 3 or 4 threads are exposed as an initial however it should not be removed adjustment See Fig
126. retor body Install the new pivot pin through the float hinge and secure with the new retaining screw See Figure 5 26 Figure 5 23 Installing Main Nozzles and Main Jets 5 11 Section 5 Fuel System and Governor 14 15 5 12 Figure 5 27 Checking Float Height a Figure 5 26 Installing Float Assembly Hold the carburetor body so the float assembly hangs vertically and rests lightly against the fuel inlet needle The inlet needle should be fully seated but the center pin of the needle on retainer clip end should not be depressed Check the float height adjustment NOTE The inlet needle center pin is spring loaded Make sure the float rests against the fuel inlet needle without depressing the center pin The correct float height setting is 17 mm 0 669 in 1 5 mm 0 059 in measured from the float bottom to the body of the carburetor See Figure 5 27 Replace the float if the height is different than specified Do not attempt to adjust by bending the float tab NOTE Be sure to measure from the casting surface not the rubber gasket if still attached 16 i B bo ln am me 5 D lt um 1 ee ee Figure 5 28 Installing Fuel Bowl When the proper float height is obtained carefully reinstall the fuel bowl using new O Rings onto the carburetor Secure with the four original screws Torque the screws to 2 5 0 3 N m 23 2 6 in Ib See Figure 5 2
127. rformed at the recommended intervals However to allow piston rings to properly seat a new or rebuilt engine should be operated for at least 50 hours using standard petroleum based oil before switching to synthetic oil A logo or symbol on oil containers identifies the API service class and SAE viscosity grade See Figure 1 3 Figure 1 3 Oil Container Logo 1 4 Refer to Section 6 Lubrication System for detailed procedures on checking the oil changing the oil and changing the oil filter Fuel Recommendations A WARNING Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Before servicing the fuel system make sure there are no sparks open flames or other sources of ignition nearby as these can ignite gasoline vapors Disconnect and ground the spark plug leads to prevent the possibility of sparks from the ignition system General Recommendations Purchase gasoline in small quantities that can be used within 30 days and store in only clean approved containers Do not use gasoline left over from the previous season unless treated with a fuel stabilizer see Storage to minimize gum deposits and ensure easy starting Do not use gasoline containing Methanol or 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 cou
128. ring each valve cover 2 Remove the valve cover and gasket from each cylinder head Note the locations of individual valve covers if they are different See Figure 8 38 ie ioe Figure 8 40 Removing Cylinder Head Fasteners 3 Mark the position of the push rods as either intake or exhaust and cylinder 1 or 2 Push rods should always be reinstalled in the same positions 4 Carefully remove the push rods cylinder head and head gaskets See Figure 8 41 5 Repeat the procedure for the other cylinder head Remove Cylinder Heads and Hydraulic Lifters 1 Loosen the inner set screws and back off the rocker arm adjusting nuts 2 Remove the pipe plug from the cylinder head to access the screw in the center location See Figure 8 39 Figure 8 41 Removing Cylinder Head Assembly 6 Remove the lifters from the lifter bores Use a Hydraulic Lifter Tool Do not use a magnet to remove lifters Mark the lifters by location as either intake or exhaust and cylinder 1 or 2 Hydraulic lifters should always be reinstalled in the same position See Figures 8 42 and 8 43 Figure 8 39 Removing Pipe Plug NOTE The exhaust lifters are located on the output shaft side of the engine while the intake lifters are located on the fan side of the engine The cylinder head number is embossed on the outside of each cylinder head See Figure 8 43 3 Remove the five hex flange screws securing each cylinder head Note the locat
129. rk N wy W Ww Qo JP Pw heel Screen Mark Figure 7 7 Mark For Timing Advance 3 Run the engine at idle and use the timing light beam to locate the line on the screen Draw a line on the blower housing next to the line on the screen Accelerate to full throttle and watch for movement of the line on the screen relative to the line on the blower housing If both cylinders had good spark repeat the test on the other cylinder See Figure 7 8 7 8 a Iftheline on the screen moved away from the line on the blower housing during acceleration the DSAI ignition module for the cylinder being tested is working properly If it didn t move away go to Test 4 b Ifyou were able to check timing on both cylinders the lines you made on the blower housing should be 90 apart If not go to Test 4 Test 4 Test the Ignition Modules and Connections 1 Remove the blower housing from the engine Inspect the wiring for any damage cuts bad crimps loose terminals or broken wires Check that connections are oriented properly on terminals of modules 2 Disconnect the leads from the ignition module s and clean all of the terminals male and female with aerosol electrical contact cleaner to remove any old dielectric compound dark residue dirt or contamination Disconnect the spark plug leads from the spark plugs 3 Using a multi meter check that a proper ground is established between the ground black lead of the DSAI mod
130. rosive acid General or grime on the external surfaces can cause the A 12 volt battery with 400 cold cranking amps cca is battery to self discharge Self discharge occurs generally recommended for starting in all conditions rapidly when moisture is present A smaller capacity battery is often sufficient if an application is started only in warmer temperatures 3 Wash the cables terminals and external surfaces Refer to the following table for minimum capacities with a mild baking soda and water solution based on anticipated ambient temperatures The Rinse thoroughly with clear water actual cold cranking requirement depends on engine size application and starting temperatures The NOTE Do not allow the baking soda solution cranking requirements increase as temperatures to enter the cells as this will destroy the decrease and battery capacity shrinks Refer also to the electrolyte operating instructions of the equipment this engine powers for specific battery requirements Battery Test To test the battery you will need a DC voltmeter Battery Size Recommendations Perform the following steps See Figure 7 2 1 Connect the voltmeter across the battery terminals Above 22 0 2 Crank the engine If the battery drops below 9 volts while cranking the battery is too small discharged or faulty TOF 23 C or below If the battery charge is insufficient to turn over the engine recharge the battery Battery Maintenance Regular m
131. rs and oil pan recess for nicks burrs wear or any visible damage Inspect the inlet seal for the pickup in the housing If any parts are worn or damaged replace the inlet seal oil pump or oil pan as required Reassembly 1 Make sure the recess in the closure plate for the oil pump gerotor gears is clean 2 Lubricate the oil pump Gerotor gears with grease Lubriplate 100 Pre Kote 45 or equivalent and install into the recess See Figure 9 14 Figure 9 14 Installing and Lubricating Oil Pump Gerotor Gears 3 Lightly lubricate with oil and install the inlet seal into the oil pump housing until it is fully seated See Figure 9 15 Inlet Seal Relief Valve Figure 9 15 Installing Inlet Seal in Oil Pump Housing Section 9 Inspection and Reconditioning 4 Install the O Ring in the groove of the oil pump 7 Check the alignment of parts and torque the housing Use a small quantity of grease to hold it oil pump housing screws as specified using the in place See Figure 9 16 sequence shown in Figure 9 18 Torque the hex flange screws as follows a Install fastener into location No 1 and lightly tighten to position the pump b Install fastener into location No 2 and fully torque to the recommended value c Install fastener into location No 3 and fully torque to the recommended value d Finish torquing fastener in location No 1 to the recommended value te seas us i a ey WE First Time Installation 10
132. ry replace battery as necessary 1 Clean corroded connections and tighten loose connections Starter Wiring 2 Replace wires in poor condition and with frayed or broken Does Not insulation Energize 1 By pass the switch or solenoid with a jumper wire If starter Starter Switch cranks normally replace the faulty components Remove or Solenoid and perform individual solenoid test procedure See pages 7 25 and 7 26 Batt 1 Check the specific gravity of the battery If low recharge or one replace battery as necessary 1 Check for excessively dirty or worn brushes and commutator Clean using a coarse cloth not emery cloth Starter Energizes 2 Replace brushes if excessively or unevenly worn but Turns 1 Make sure the clutch or transmission is disengaged or Slowly placed in neutral This is especially important on equipment Transmission with hydrostatic drive The transmission must be exactly in or neutral to prevent resistance which could keep the engine Engine from starting 2 Check for seized engine components such as the bearings connecting rod and piston Delco Remy Starters Figure 7 21 Delco Remy Starter Starter Disassembly 1 Remove the hex nut and disconnect the positive brush lead bracket from the solenoid terminal 2 Remove the three Torx head screws securing the solenoid to the starter See Figure 7 22 3 Torx Head Screws Unhook the plunger pin from the drive lever Remove the gasket
133. s with Valve Spring Compressor Install Cylinder Heads 1 Check to make sure there are no nicks or burrs on the sealing surfaces of the cylinder head or the crankcase 2 Check that the dowel pins are in place in the two lower locations and install a new cylinder head gasket with printing up See Figure 10 44 Figure 10 44 Installing New Head Gaskets NOTE Match the numbers embossed on the cylinder heads and crankcase See Figure 10 40 3 Install the cylinder head Make sure the head is flat on the gasket and dowel pins Install a flat washer on the screws in the lower two locations 1 and 3 and the location closest to the exhaust port location 5 See Figures 10 45 and 10 47 Start the five hex flange screws 10 12 Fj Figure 10 45 Washers and Spacer Locations on Cylinder Head Screws 4 Torque the hex flange screws in two stages first to 22 6 N m 200 in Ib finally to 45 2 N m 400 in Ib following the sequence in Figure 10 47 5 Repeat the procedure for the opposite cylinder Figure 10 47 Cylinder Head Fastener Torque Sequence 6 Make sure the threads of the pipe plugs for the cylinder heads are clean and dry Install a plug into each cylinder head above the No 2 screw location and torque to 29 3 N m 260 in Ib 5ee Figure 10 48 NO bs Figure 10 48 Installing Pipe Plug in Cylinder Heads Install Guide Plate Pivot Studs Push Rods and Rocker Arms 1 Install the p
134. sed to notify people of installation operation or maintenance information that is important but not hazard related For Your Safety These precautions should be followed at all times Failure to follow these precautions could result in injury to yourself and others amp WARNING Accidental Starts can cause severe injury or death Disconnect and ground spark plug leads before servicing Accidental Starts Disabling engine Accidental starting can cause severe injury or death Before working on the engine or equipment disable the engine as follows 1 Disconnect the spark plug lead s 2 Disconnect negative battery cable from battery WARNING Rotating Parts can cause severe injury Stay away while engine is in operation Rotating Parts Keep hands feet hair and clothing away from all moving parts to prevent injury Never operate the engine with covers shrouds or guards removed WARNING Psi ESS Hot Parts can cause severe burns Do not touch engine while operating or just after stopping Hot Parts Engine components can get extremely hot from operation To prevent severe burns do not touch these areas while the engine is running or immediately after it is turned off Never operate the engine with heat shields or guards removed 1 1 Section 1 Safety and General Information Explosive Fuel can cause fires and severe burns Do not fill the fuel tank while th
135. sembly Remove Fuel Pump A WARNING Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent NOTE Based on the style of fuel pump used refer to the following Pulse Style Fuel Pump The pulse style fuel pump is mounted to the side of the control bracket It may be removed separately or with the bracket To remove separately 1 Remove the two hex flange mounting screws securing the fuel pump to the control bracket 2 Disconnect the inlet outlet and pulse vacuum hoses and remove the fuel pump See Figure 8 12 Properly contain any remaining fuel wee Outlet Hose s TM A Figure 8 12 Removing Pulse Pump Electric Fuel Pump 1 Removal will be determined based on mounted location and application Disconnect the lead connections fuel line connections and mounting hardware as required Properly contain any remaining fuel Remove Control Bracket Governor Springs and Lever 1 Unhook the governed idle and governor springs from the controls on the main bracket and the governor lever Note the color location and position of each Se
136. t and position so the flat is 2 up See Figure 10 11 Figure 10 7 Installing Governor Cross Shaft Seal Seal depth 1 5 2 0 mm 0 059 0 078 in Governor _ Cross Shaft Crankcase Surface K Oil Seal E v l Figure 10 11 Installing Governor Cross Shaft Figure 10 8 Governor Shaft Seal Depth 10 3 Section 10 Reassembly 4 Attach the governor yoke to the cross shaft so the curved section is up as marked Secure with the two screws If a thread locking compound is not pre applied apply a small amount of Loctite No 266 or equivalent to the screw threads before installing Torque the screws to 2 2 N m 20 in Ib See Figure 10 12 Figure 10 1 2 Installed Governor Shaft Yoke 5 Install the first regulating pin with the head down so it will contact the yoke Install the governor gear with the second regulating pin and the flyweight assembly in down onto the governor shaft until it locks into position Apply a small amount of grease to the locking tab thrust washer and install on top of the governor gear so the tang is facing up in the 6 o clock position See Figures 10 13 10 14 and 10 15 F Second __ Regulating Pin a Governor Gear lien en P Regulating Ein Mes En Figure 10 13 Regulating Pin Details 10 4 4 Governor Gear Assembly n Position Figure 10 15 Installed Locking Tab Washer Install Crankshaft 1 C
137. tains clean fresh proper fuel Make sure the vent in fuel tank cap is open Make sure the fuel valve is open Make sure the fuel lines to fuel pump are secured and in good condition 2 Check for fuel in the combustion chamber If there is fuel at the tip of the spark plug fuel is a Disconnect and ground spark plug leads reaching the combustion chamber b Close the choke on the carburetor c Crank the engine several times If there is no fuel at the tip of the spark plug d Remove the spark plug and check for fuel at check for fuel flow from the fuel tank Test 3 the tip 3 Check for fuel flow from the tank to the fuel pump If fuel does flow from the line check for faulty a Remove the fuel line from the inlet fitting of fuel pump Test 4 the fuel pump b Hold the line below the bottom of the tank If fuel does not flow from the line check the fuel Open the shut off valve if so equipped and tank cap vent fuel pickup screen in line filter observe flow shut off valve and fuel line Correct any observed problem and reconnect the line 4 Check the operation of the fuel pump If fuel does flow from the line check for faulty a Remove the fuel line from the inlet fitting of carburetor Refer to the Carburetor portions of the carburetor this section b Crank the engine several times and observe flow If fuel does not flow from the line check for a clogged fuel line If the fuel line is unobstructed check
138. te Ultra Copper Spline Drive Lubricant Kohler 25 357 12 5 2 3 Section 2 Tools amp Aids Special Tools You Can Make Flywheel Holding Tool A flywheel holding tool can be made out of an old junk flywheel ring gear as shown in Figure 2 1 and used in place of a strap wrench 1 Using an abrasive cut off wheel cut out a six tooth segment of the ring gear as shown 2 Grind off any burrs or sharp edges 3 Invert the segment and place it between the ignition bosses on the crankcase so that the tool bosses will lock the tool and flywheel in position for loosening tightening or removing with a puller Figure 2 1 Flywheel Holding Tool Rocker Arm Crankshaft Tool A spanner wrench to lift the rocker arms or turn the crankshaft may be made out of an old junk connecting rod 1 Find a used connecting rod from a 10 HP or larger engine Remove and discard the rod cap 2 4 Remove the studs of a Posi Lock rod or grind off the aligning steps of a Command rod so the joint surface is flat Find a 1 in long capscrew with the correct thread size to match the threads in the connecting rod Use a flat washer with the correct I D to slip on the capscrew and approximately 1 O D Kohler Part No 12 468 05 S Assemble the capscrew and washer to the joint surface of the rod as shown in Figure 2 2 Figure 2 2 Rocker Arm Crankshaft Tool Section 3 Troubleshooting Troubleshooting Guide When
139. tenie eE e Eaa ar IU UU 6 2 N m 55 in Ib Muffler Muer ketaiming DNE DOPO sass oarcccnsness atau n NONE Ed mista 24 4 N m 216 in Ib Screw intermittent bracket into weld DUE coser htt en dnt n eS ttu sae 13 5 N m 120 in Ib Oil Cooler Mounin Sere we TOPOUB sous busbe erar ista na MN ERN IU 3 9 N m 35 in Ib Cil Filter Gl eric aioe is t m 3 4 1 turn after gasket contact Cil Filter Adapter Housing Mounin Screw TOPRQUE esc ds E MID dussituM spud NIE 24 4 N m 216 in Ib Piston Piston Rings and Piston Pin Piston te Pistom Pin Running Clearance csoeocsasc ti aras etd onis eietudiren sins 0 006 0 018 mm 0 0002 0 0007 in Piston Pin Bore I D NOW iccccsccccccccccsscececsccccccccccssesccscccceceseeeecessaceceesesseeeesnnucecceseseseeessacceceesencens 19 006 17 013 mm 0 7482 0 7485 in DOT Vet MN asec da Esa ep ens on patentee shag detur died DN FUIS oceans 19 025 mm 0 7490 in Piston Pin O D hi 18 995 19 000 mm 0 7478 0 7480 in INV ete SUD a sep eeiceetsectesenact oU udis E dism o HE dIU UM U ESOS 18 994 mm 0 7478 in 1 10 Top Compression Ring to Groove Side Clearance Middle Compression Ring to Groove Side Clearance Oil Control Ring to Groove Side Clearance Top and Center Compression Ring End Gap INO Tce sc acess ean feet MERE III D SEND MEN EE Used Bo
140. tery cable from battery Clean all parts thoroughly as the engine is disassembled Only clean parts can be accurately inspected and gauged for wear or damage There are many commercially available cleaners that will quickly remove grease oil and grime from engine parts When such a cleaner is used follow the manufacturer s instructions and safety precautions carefully Make sure all traces of the cleaner are removed before the engine is reassembled and placed into operation Even small amounts of these cleaners can quickly break down the lubricating properties of engine oil Typical Disassembly Sequence The following sequence is suggested for complete engine disassembly The sequence can be varied to accommodate options or special equipment Disconnect spark plug leads Shut off fuel supply Drain oil from crankcase and remove oil filter Remove muffler Remove cylinder shrouds and blower housing Remove electric starter motor Remove air cleaner assembly Remove fuel pump Remove control bracket governor springs and lever 10 Remove carburetor 11 Remove intake manifold 12 Remove Oil Sentry if equipped 13 Remove baffles and intake manifold 14 Remove oil cooler 15 Remove oil filter housing 16 Remove ignition modules 17 Remove grass screen and cooling fan 18 Remove flywheel 19 Remove stator rectifier regulator and wiring harness 20 Remove backing shroud assembly SF tS See II
141. th Teflon Loctite No 5924 or equivalent to the threads of the switch 2 Install the switch into the tapped hole in oil pan See Figure 6 12 3 Torque the switch to 10 1 N m 90 in Ib Section 6 Lubrication System Testing Compressed air a pressure regulator pressure gauge and a continuity tester are required to test the switch 1 Connect the continuity tester across the blade terminal and the metal case of the switch With 0 psi pressure applied to the switch the tester should indicate continuity switch closed Gradually increase the pressure to the switch As the pressure increases through the range of 7 11 psi the tester should indicate a change to no continuity switch open The switch should remain open as the pressure is increased to 90 psi maximum Gradually decrease the pressure through the range of 7 11 psi The tester should indicate a change to continuity switch closed down to 0 psi Replace the switch if it does not operate as specified 6 5 6 6 Section 7 Electrical System and Components This section covers the operation service and repair of the electrical system components Systems and components covered in this section are e Spark Plugs e Battery and Charging System e Electric Starter e Electronic Ignition Systems CD and DSAT Spark Plugs Engine misfire or starting problems are often caused by a spark plug that has improper gap or is in poor condition T
142. th the supplied protective tube against the end of the commutator armature The mounting screw holes in the metal clips must be up out Slide the brush holder assembly down into place around the commutator and install the positive brush lead grommet in the cutout of the frame See Figure 7 44 The protective tube may be saved and used for future servicing Figure 7 44 Installing Brush Holder Assembly with Supplied Tube Starter reassembly when not replacing the Brushes Brush Holder Assembly a Carefully unhook the retaining caps from over each of the brush assemblies Do not lose the springs See Figure 7 45 Section 7 Electrical System and Components Figure 7 45 Removing Retaining Clips b Position each of the brushes back in their slots so they are flush with the I D of the brush holder assembly Insert the Brush Installation Tool with extension or use the tube described above from a prior brush installation through the brush holder assembly so the holes in the metal mounting clips are up out Install the brush springs and snap on the four retainer caps See Figure 7 46 Figure 7 46 Brush Installation Tool with Extension 7 23 Section 7 Electrical System and Components Extension d Hold the starter assembly vertically on the end housing and carefully place the tool with extension and assembled original brush holder assembly onto the end of the armature shaft Slide the brush
143. the valve on its seat with the grinder Continue grinding until a smooth surface is obtained on the seat and on the valve face Thoroughly clean the cylinder head in soap and hot water to remove all traces of grinding compound After drying the cylinder head apply a light coating of SAE 10 oil to prevent rusting Valve Stem Seals These engines use valve stem seals on the intake and exhaust valves Always use new seals when the valves are removed from the cylinder head The seals should also be replaced if deteriorated or damaged in any way Never reuse an old seal Pistons and Rings Inspection Scuffing and scoring of pistons and cylinder walls occurs when internal engine temperatures approach the welding point of the piston Temperatures high enough to do this are created by friction which is usually attributed to improper lubrication and or overheating of the engine Normally very little wear takes place in the piston boss piston pin area If the original piston and connecting rod can be reused after new rings are installed the original pin can also be reused but new piston pin retainers are required The piston pin is included as part of the piston assembly if the pin boss in the piston or the pin are worn or damaged a new piston assembly is required Ring failure is usually indicated by excessive oil consumption and blue exhaust smoke When rings fail oil is allowed to enter the combustion chamber where it is burned alo
144. the filter housing assembly and secure with the M8 hex head screw Make sure the housing is flat on crankcase and O Ring remains Cup with in position Torque the screw to 24 4 N m Spring and 216 in Ib See Figure 10 65 Valve Nipple VISTOS Em Screw T4 Housing Figure 10 62 Installing Nipple into Cup and Oil Filter Housing Oil Filter Housing Figure 10 65 Torquing Oil Filter Housing 3 The oil filter may be installed now or upon completion of engine assembly as described in Section 6 Install Intake Manifold 1 Install new intake manifold gaskets so the notched section is inward and points toward the flywheel side See Figure 10 66 Figure 10 63 Torquing Nipple into Housing Installation 1 Make sure all sealing surfaces are clean and all three dowel pins are in position Install or check that new O Rings are around all three dowel pins of the oil filter adapter See Figure 10 64 Figure 10 64 O Rings Installed on Crankcase for Cil Filter Housing 10 17 Section 10 Reassembly Mount the intake manifold to the cylinder heads Make sure the gaskets remain in the proper position Torque the four screws in two stages first to 16 9 N m 150 in Ib finally to 22 6 N m 200 in Ib using the sequence shown in Figure 10 68 Figure 10 68 Intake Manifold Torque Sequence 9 Install the carburetor mounting studs into intake manifold if removed earlier Use two hex nuts
145. the oil cooler to the backing shroud with the two mounting screws A d i i 4 Fj Figure 6 10 Cleaning Top of Oil Cooler 6 4 f Oil Cooler Figure 6 11 Cleaning Underside of Oil Cooler Oil Sentry General Some engines are equipped with an optional Oil Sentry M oil pressure monitor switch See Figure 6 12 If the oil pressure drops below an acceptable level the Oil Sentry will either shut off the engine or activate a warning signal depending on the application The pressure switch is designed to break contact as the oil pressure increases above 7 11 psi and make contact as the oil pressure decreases below 7 11 psi On stationary or unattended applications pumps generators etc the pressure switch can be used to ground the ignition module to stop the engine On vehicular applications lawn tractors mowers etc the pressure switch can only be used to activate a low oil warning light or signal NOTE Make sure the oil level is checked before each use and is maintained up to the F mark on the dipstick This includes engines equipped with Oil Sentry Pressure Figure 6 12 Oil Sentry Pressure Switch Installation The Oil Sentry pressure switch is installed in the oil pan pressure port See Figure 6 12 On engines not equipped with Oil Sentry the installation hole is sealed with a 1 8 27 N P T F pipe plug To install the switch follow these steps 1 Apply pipe sealant wi
146. to position the magnet directly under one ignition module 10 20 5 Insert a 0 30 mm 0 012 in flat feeler gauge between the magnet and the ignition module See Figure 10 80 DSAI engines do not require or have an air gap setting Loosen the screws enough to allow the magnet to pull the module down against the feeler gauge Figure 10 80 Setting Ignition Module Air Gap 6 Torque the screws to 6 2 N m 55 in Ib into new holes or 4 0 N m 35 in Ib into used holes 7 Repeatsteps 4 through 6 for the other ignition module 8 Rotate the flywheel back and forth checking for clearance between the magnet and ignition modules Make sure the magnet does not strike the modules Check the gap with a feeler gauge and readjust if necessary Final Air Gap 0 280 0 330 mm 0 011 0 013 in 9 Make sure the leads are under the molded clip on the starter side See Figure 10 81 Figure 10 81 Lead Routing Details Section 10 Reassembly Install Outer Cylinder Baffles 1 Install the outer cylinder baffles Make sure the spark plug lead is routed through the corresponding opening in each baffle Start each of the screws Torque the M6 shoulder screws going through the backing shroud assembly into the extruded holes in the baffles to 4 0 N m 35 in Ib for initial installations or 2 0 N m 17 7 in lb anytime thereafter Torque the M6 screws going into the cylinder head and crankcase to 10 7 N m 95 in Ib for new hol
147. trical System and Components Figure 7 15 Connected Adapter 2 Connect the tester ground lead with spring clamp to the body of the rectifier regulator 3 Connect the red lead and one of the black leads to the pair of terminals on the open end of the tandem adapter lead connections are not location specific 4 Connect the remaining black lead from the tester to one of the outer AC terminals on the rectifier regulator See Figure 7 16 WM ud UM Figure 7 16 Connected Tester 7 13 Section 7 Electrical System and Components 5 Plug the tester into the proper AC outlet power for tester being used Turn on the power switch The POWER light should be illuminated and one of the four status lights may be on as well See Figure 7 17 This does not represent the condition of the part Figure 7 17 Powered Tester 6 Press the TEST button until a click is heard and then release See Figure 7 18 Momentarily one of the four lights will illuminate indicating the partial condition of the part Aa em iL Figure 7 18 Pressing Test Button a Ifthe OK green light comes on disconnect the tester black lead attached to one AC terminal and reconnect it to the other AC terminal Repeat the test If the OK green light comes on again the part is good and may be used b Ifany other light is displayed in either of the tests the rectifier regulator is faulty and should not be used
148. ule closest to spark plug lead and a known good ground location on the engine 4 Turn the key switch to the ON position and check for 12 volts at the center power red lead terminal of the DSAI module Use the same ground location for the multi meter as in Step 3 a Ifalltests are OK and module has no spark or fails to advance replace the affected module b Ifany of the tests are bad determine cause and fix as required then retest Section 7 Electrical System and Components Battery Charging System General Most engines are equipped with a 15 20 or 25 amp regulated charging system See Figures 7 9 through 7 13 NOTE Observe the following guidelines to avoid damage to the electrical system and components e Make sure the battery polarity is correct A negative ground system is used e Disconnect the rectifier regulator plug and or the wiring harness plug before doing any electric welding on the equipment powered by the engine Also disconnect all other electrical accessories in common ground with the engine e Prevent the stator AC leads from touching or shorting while the engine is running This could damage the stator 15 20 25 Amp Stator and Rectifier Regulator Figure 7 9 25 Amp Stator and Rectifier Regulator Figure 7 10 15 Amp Stator and Rectifier Regulator NOTE 20 amp charging systems use a 15 amp stator with a 25 amp rectifier regulator 7 9 Electrical System and Components 15
149. unction Test Connect one 12 volt test lead to the flat spade S start terminal on the solenoid and the other lead to the body or mounting surface of the solenoid Then manually push the plunger In and check if the Hold In coil holds the plunger retracted See Figure 7 53 Do not allow the test leads to remain connected to the solenoid for a prolonged period of time If the plunger fails to stay retracted the solenoid should be replaced Manually Push Plunger In 12 volt Test Leads Connect Only Long Enough to Test Figure 7 53 Testing Hold In Coil Function Test 7 25 Section 7 Electrical System and Components Test 4 Solenoid Hold In Coil Contact Continuity Test Use an ohmmeter set to the audible or Rx2K scale and connect the two ohmmeter leads to the two large post terminals Perform the preceding test 3 and check for continuity See Figure 7 54 The meter should indicate continuity if no continuity is indicated the solenoid should be replaced Repeat test several times to confirm condition 7 26 VOM Meter Leads Plunger Pushed In 12 volt Test Leads Figure 7 54 Testing Hold In Coil Solenoid Contact Continuity Section 8 Disassembly A WARNING Accidental Starts Disabling engine Accidental starting can cause severe injury or death Before working on the engine or equipment disable the engine as follows 1 Disconnect the spark plug lead s 2 Disconnect negative bat
150. up to the F mark and reinstall the dipstick See Figure 10 111 4 Adjust the carburetor idle fuel needles or idle speed adjusting screw as necessary Refer to Section 5 the Fuel System and Governor 10 28 Testing the Engine It is recommended that the engine be operated on a test stand or bench prior to installation in the piece of equipment 1 Set the engine up on a test stand Install an oil pressure gauge Start the engine and check to be certain that oil pressure 20 psi or more is present Run the engine at idle for 2 3 minutes then 5 6 minutes more between idle and midrange Adjust the carburetor mixture settings as necessary as available 2 Adjust the governed idle and high speed RPM to required settings Make sure the maximum engine speed does not exceed 3900 RPM no load Section 10 Reassembly 10 29 10 30 e ISSUED 1 09 NGI N ES LITHO IN U S A FOR SALES AND SERVICE INFORMATION IN U S AND CANADA CALL 1 800 544 2444 an 1PTP 2581 KohlerEngines com WT ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 See p
151. ure 5 24 unless a Choke Repair Kit will be installed Idle Speed Screw and 6 Clean the carburetor body main jets vent ports seats etc using a good commercially available carburetor solvent Keep away from plastic or rubber parts if non compatible Use clean dry compressed air to blow out the internal channels and ports Do not use metal tools or wire to clean orifices and jets Inspect and thoroughly check the carburetor for cracks wear or damage Inspect the fuel inlet seat for wear or damage Check the spring loaded choke plate to make sure it moves freely on the shaft 2 EN HH ux e Figure 5 24 Installing Idle Speed Adjusting Screw and Spring 7 Clean the carburetor fuel bowl as required 8 Install the two main nozzles into the towers of the carburetor body The end of the main nozzles with the two raised shoulders should be out down adjacent to the main jets Make sure the nozzles are completely bottomed Carefully install the main jets into the towers of the carburetor body on the appropriate side as identified when removal was performed See Figure 5 23 12 Attach the inlet needle to the plastic tang of the float with the wire clip The formed 90 lip should point up with the needle valve hanging down See Figure 5 25 Nozzle End with WS Figure 5 25 Float and Inlet Needle Details Two Shoulders n Out Down u 13 Install the float and inlet needle down into the seat and carbu
152. ush rod guide plate and rocker arm pivot studs onto the cylinder heads if removed previously Torque the pivot studs to 12 4 N m 110 in Ib See Figure 10 49 NOTE Install the push rod guide plate so the flange is down towards cylinder on the No 1 side and up away from cylinder on the No 2 side 2 Note the mark or tag identifying the push rod as either intake or exhaust and cylinder 1 or 2 Dip the ends of the push rods in engine oil and install making sure that each push rod ball seats in its hydraulic lifter socket See Figure 10 50 Push Rods EL Figure 10 49 Installing Guide Plate Pivot Studs and Push Rods Section 10 Reassembly NOTE Push rods should always be installed in the same position as before disassembly 3 Apply grease to the contact surfaces of the rocker arms and rocker arm pivots Install the rocker arms rocker arm pivots and adjusters on the 1 cylinder head Figure 10 50 Installing Rocker Arms Pivots and Adjusters Adjust Valve Clearance With Pre Bled Lifters Before Installation 1 Turn the adjusters in the rocker arms by hand clockwise down only enough to capture push rods in the recesses See Figure 10 51 te Figure 10 51 Turning Adju rs In To Retain Push Rods 2 Rotate the crankshaft to establish Top Dead Center TDC on the Compression Stroke for the 1 cylinder 10 13 Section 10 Reassembly Check for a Compression will be
153. valve guide is 7 134 mm 0 2809 in while 7 159 mm 0 2819 in is the maximum allowed on the exhaust guide The guides are not removable but can be reamed 0 25 mm 0 010 in oversize Valves with 0 25 mm oversize stems must then be used If the guides are within limits but the valve stems are worn beyond limits install new valves Valve Seat Inserts Hardened steel alloy intake and exhaust valve seat inserts are press fitted into the cylinder head The inserts are not replaceable but can be reconditioned if not too badly pitted or distorted If cracked or badly warped the cylinder head should be replaced Recondition the valve seat inserts following the instructions provided with the valve seat cutter being used A typical cutter is shown in Figure 9 7 The final cut should be made with an 89 cutter as specified for the valve seat angle in Figure 9 6 Cutting the proper 45 valve face angle as specified in Figure 9 6 and the proper valve seat angle 44 5 half of the full 89 angle will achieve the desired 0 5 1 0 full cut interference angle where the maximum pressure occurs on the outside diameters of the valve face and Seat 9 8 Valve Seat Cutter Figure 9 7 Typical Valve Seat Cutter Lapping Valves Reground or new valves must be lapped in to provide proper fit Use a hand valve grinder with a suction cup for final lapping Lightly coat the valve face with a fine grade of grinding compound then rotate
154. ved earlier Insert the terminal into the center location of the connector until it locks into place Figure 10 72 B Charging Lead Details 6 Install the wiring harness under the two molded clips in the backing shroud assembly See Figure 10 73 Figure 10 73 Installing Wiring Harness Section 10 Reassembly 7 Position the rectifier regulator onto the mounting posts with the cooling fins up Attach the ground lead to the outer screw and washer then torque the mounting screws to 2 0 N m 18 in Ib Connect the plug to the rectifier regulator See Figure 10 74 Ground ae 1 Rectifier E Regulator J i a Figure 10 74 Installing Rectifier Regulator Install Flywheel A WARNING Damaging Crankshaft and Flywheel Can Cause Personal Injury Using improper procedures to install the flywheel can crack or damage the crankshaft and or flywheel This not only causes extensive engine damage but can also cause personal injury since broken fragments could be thrown from the engine Always observe and use the following precautions and procedures when installing the flywheel NOTE Before installing the flywheel make sure the crankshaft taper and the flywheel hub are clean dry and completely free of any lubricants The presence of lubricants can cause the flywheel to be over stressed and damaged when the hex flange screw is torqued to specifications Figure 10 75 Clean and Dry Taper of
155. vice engines easier faster and safer In addition you ll increase your service capabilities and customer satisfaction by decreasing engine downtime Here is the list of tools and their source Separate Tool Suppliers Kohler Tools SE Tools Design Technology Inc Contact your source 415 Howard St 768 Burr Oak Drive of supply Lapeer MI 48446 Westmont IL 60559 Phone 810 664 2981 Phone 630 920 1300 Toll Free 800 664 2981 Fax 810 664 8181 Tools DI Source Part No pem ddr P and if cylinder piston rings or valves are worn Individual Components Available Design Technology Inc Pressure Tester IDTI 019 Noid Light DTI 021 90 Adapter DTI 023 Oetiker Clamp Pliers DTI 025 Code Plug Red Wire DTI 027 Code Plug Blue Wire DTI 029 Flywheel Holding Tool CS Series SE Tools KLR 82407 Enyce eer SE Tools KLR 82408 To remove flywheel from engine Flywheel Strap Wrench To hold flywheel during removal E OOK aaa 2 1 Section 2 Tools amp Aids Tools Continued MEINEN Source Part No Hydraulic Valve Lifter Tool To remove and install hydraulic lifters Kohler 25 761 38 5 ignition idm n Hm Kohler 25 455 01 S Or tes Ing ou pu ona SYS ems excep Kohler 24 455 02 S For testing output on capacitive discharge CD ignition system Offset Wrench K amp M Series To remove and reinstall cylinder barrel retaining nuts SEOs eaten cere bon EH Kohler 25 761 06 5 To test and verify oil pressure Rectifier Regulat
156. vot pin through the float hinge and secure with the new retaining screw See Figure 5 15 Retaining Screw Y 1 Hold the carburetor body so the float assembly hangs vertically and rests lightly against the fuel inlet needle The inlet needle should be fully seated but the center pin of the needle on retainer clip end should not be depressed Check the float height adjustment NOTE The inlet needle center pin is spring loaded Make sure the float rests against the fuel inlet needle without depressing the center pin The correct float height setting is 17 mm 0 669 in 1 5 mm 0 059 in measured from the float bottom to the body of the carburetor See Figure 5 16 Replace the float if the height is different than specified DO NOT attempt to adjust by bending float tab Section 5 Fuel System and Governor NOTE Be sure to measure from the casting surface not the rubber gasket if still attached Figure 5 16 Checking Float Height 9 Figure 5 17 Installing Fuel Bowl 10 When the proper float height is obtained carefully reinstall the fuel bowl using new O Rings onto the carburetor Secure with the four original screws Torque the screws to 2 5 0 3 N m 23 2 6 in Ib See Figure 5 17 Install the carburetor and reassemble the engine as outlined in Section 10 Reassembly Disassembly Overhaul 1 Clean the exterior surfaces of dirt or foreign material before disassembling t
157. wheel to become cracked or damaged Wiring Harness 1 Disconnect the plug from the rectifier regulator If the B center lead must be removed from the plug use the tip of the dipstick or a similar small flat tool to bend the locking tang Then remove the lead 8 8 Remove the mounting screws securing the rectifier regulator to the backing shroud assembly Note the location of the ground lead If the rectifier regulator is not being replaced it may remain mounted to the backing shroud assembly See Figure 8 33 6 Ground y P4 gi ead v4 v Rectifier 2 Regulator VILLE loe di Plug ar 9 d Figure 8 33 Rectifier Regulator Details 3 Remove the two screws securing the stator to the crankcase and carefully separate the stator wires from the molded clips See Figure 8 34 Mounting Screws Figure 8 34 Removing Stator 4 Unhook the wiring harness from the molded clips if being serviced separately See Figure 8 35 Section 8 Disassembly Wiring Harness Figure 8 35 Removng Wiring Harness Remove Backing Shroud Assembly 1 Remove the four screws securing the backing shroud assembly to the crankcase See Figure 8 36 Figure 8 36 Removing Backing Shroud Mounting Screws Remove Spark Plugs 1 Remove the spark plug from each cylinder head Figure 8 37 Removing Spark Plugs 8 9 Section 8 Disassembly Remove Valve Covers 1 Remove the screw and grommet secu
158. with either portable drills or drill presses the use of a low speed drill press is preferred as it facilitates more accurate alignment of the bore in relation to the crankshaft crossbore Honing is best Section 9 Inspection and Reconditioning accomplished at a drill speed of about 250 RPM and taken at three locations in the cylinder at the 60 strokes per minute After installing coarse stones in top middle and bottom Two measurements hone proceed as follows should be taken perpendicular to each other at each of the three locations 1 Lower hone into bore and after centering adjust so the stones are in contact with the cylinder Clean Cylinder Bore After Honing wall Use of a commercial cutting cooling agentis Proper cleaning of the cylinder walls following boring recommended and or honing is very critical to a successful overhaul Machining grit left in the cylinder bore can destroy 2 With the lower edge of each stone positioned an engine in less than one hour of operation after a even with the lowest edge of the bore start drill rebuild and honing process Move the hone up and down while resizing to prevent the formation of cutting The final cleaning operation should always be a ridges Check the size frequently thorough scrubbing with a brush and hot soapy water Use a strong detergent that is capable of NOTE Kohler pistons are custom machined to breaking down the machining oil while maintaining exacting tolerances Whe
159. y charged during storage Store the engine in a clean dry place 1 5 Section 1 Safety and General Information Dimensions in millimeters Inch equivalents shown in 484 33 135 00 19 068 5 315 365 50 90 22 10 08 14 390 3 552 5 118 A l Boras MCN MN NN s A By 5 I ery j 577 09 152 36 22 720 R 5 999 T 9 143 5 9 IN 344 54 23 Nya 13 565 i 325 30 12 807 62 70 2 468 3 536 Optional Guard Tum t m P PI oral fat s s pe Br rn ZA aT ae IL V AN g c J at 470 64 411 64 TI 18 529 16 206 ETE H 376 56 I 14 825 Uke 124 10 i6 B43 m CERE Hu t 4 886 115 12 EI remm ET W Agi 5 ied 4 532 LED IET Le D 168 95 zi UP DE il 6 652 e e TFT Ae TCH THOTE 17 00 669 111 30 4 382 7 HOLES 89 80 3 536 254 00 10 00 25 0 0 98 DEEP 35 00 1 378 Figure 1 4 Typical CV PRO Series Engine Dimensions with Heavy Duty Air Cleaner 1 6 Section 1 Safety and General Information General Specifications Power 3600 RPM exceeds Society of Automotive Engineers Small Engine Test Code J1940 mi c 25 3 kW 34 HP A rU 26 9 kW 36 HP d 28 3 kW 38 HP GAUL 29 8 kW
160. y washers if used See Figure 8 22 Figure 8 22 Removing Oil Cooler Mounting Screws 2 Loosen the clamps and disconnect each of the hoses from the oil cooler See Figure 8 23 NOTE New clamps are recommended any time disassembly is performed or if clamps have been loosened expanded several times Figure 8 23 Disconnecting Hoses From Oil Cooler Remove Oil Filter Housing 1 Remove the screw securing the oil filter housing and individual O Rings to the crankcase then carefully separate the parts See Figure 8 24 NOTE Further disassembly of the oil filter housing assembly is not necessary unless being serviced individually Follow Substeps a b and c Section 8 Disassembly c Remove the rubber valve and spring from the Cil Filter cup See Figure 8 27 Housing Mounting Rubber Valve emm M Perform the following only if the oil filter housing assembly requires individual servicing Figure 8 27 Rubber Valve and Spring Removed from Cup Spring a Remove the nipple from the cup and oil filter housing using a 5 16 Allen wrench bit See 2 Figure 8 25 j Remove Ignition Modules 1 Rotate the flywheel so the magnet is away from the modules 2 Remove the mounting screws and disconnect the kill lead from the ignition modules Note the position of the ignition modules and wiring harness clip See Figure 8 28 Mounting Screws t 1 d r i EN 4 i sad X c E V
161. ywheel End Main Bearing If the flywheel end main bearing was removed in servicing install a new bearing using an arbor press and driver 1 Make sure the crankcase bore for the main bearing is clean dry and free of nicks or burrs 2 Press the flywheel end main bearing in place with the notch oriented in the 12 o clock position using an arbor press and driver See Figure 10 5 Make sure the bearing is fully seated against the flange and the oil feed hole is open in the crankcase See Figure 10 6 3 Apply a light coat of clean engine oil to the inner surface of the main bearing Figure 10 5 Installing Main Bearing Section 10 Reassembly 2 If the governor gear shaft was removed press or lightly tap the replacement shaft into the oil pan to depth shown in Figure 10 10 Governor Gear Shaft LI p B A Figure 10 6 Installed Main Bearing Install Governor Shafts Seal and Governor Gear If the governor shafts seal and or governor gear were removed in disassembly reassemble as follows Governor 1 Lightly lubricate the lip and outside diameter of Gear Shaft the new governor cross shaft seal with oil Install the seal into the crankcase to the depth shown in Figure 10 8 Figure 10 10 Governor Gear Shaft Press Depth 3 Lubricate the governor cross shaft bearing surfaces in the crankcase with engine oil Insert the end with the flat for the governor gear yoke an into the crankcase firs

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