Kohler Courage SV710 Service Manual
  1. Manuals
  2. Brands
  3. Kohler Manuals
  4. Engine
  5. Courage SV710
  6. Service manual

Kohler Courage SV710 Service Manual

Hide thumbs Also See for Courage SV710:
Table of Contents

Advertisement

Quick Links

See also: Owner's Manual
SV710-SV740
SV810-SV840
Service Manual
IMPORTANT:
Read all safety precautions and instructions carefully before operating equipment. Refer to operating
instruction of equipment that this engine powers.
Ensure engine is stopped and level before performing any maintenance or service.
2
Safety
3
5
Specifi cations
14
17
Troubleshooting
21
22
Fuel System
30
31
33
45
51
54
68
Reassembly
32 690 01 Rev. G
KohlerEngines.com
1

Advertisement

Table of Contents
loading

Related Manuals for Kohler Courage SV710

Summary of Contents for Kohler Courage SV710

  • Page 1 SV710-SV740 SV810-SV840 Service Manual IMPORTANT: Read all safety precautions and instructions carefully before operating equipment. Refer to operating instruction of equipment that this engine powers. Ensure engine is stopped and level before performing any maintenance or service. Safety Maintenance Specifi cations Tools and Aids Troubleshooting Air Cleaner/Intake...
  • Page 2 Safety SAFETY PRECAUTIONS WARNING: A hazard that could result in death, serious injury, or substantial property damage. CAUTION: A hazard that could result in minor personal injury or property damage. NOTE: is used to notify people of important installation, operation, or maintenance information. CAUTION WARNING WARNING...
  • Page 3 ² Have a Kohler authorized dealer perform this service. REPAIRS/SERVICE PARTS Kohler genuine service parts can be purchased from Kohler authorized dealers. To fi nd a local Kohler authorized dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada). 32 690 01 Rev. G...
  • Page 4 OIL RECOMMENDATIONS STORAGE If engine will be out of service for 2 months or more We recommend use of Kohler oils for best performance. follow procedure below. Other high-quality detergent oils (including synthetic) of API (American Petroleum Institute) service class SJ 1.
  • Page 5 Specifi cations Engine Dimensions Dimensions in millimeters. Inch equivalents shown in [ ]. 32 690 01 Rev. G KohlerEngines.com...
  • Page 6 Specifi cations Engine Dimensions Dimensions in millimeters. Inch equivalents shown in [ ]. KohlerEngines.com 32 690 01 Rev. G...
  • Page 7 Lubricate threads with engine oil prior to assembly. Any and all horsepower (hp) references by Kohler are Certifi ed Power Ratings and per SAE J1940 & J1995 hp standards. Details on Certifi ed Power Ratings can be found at KohlerEngines.com.
  • Page 8 Specifi cations TORQUE SPECIFICATIONS SV710 SV715 SV720 SV725 SV730 SV735 SV740 SV810 SV820 SV830 SV840 Cylinder Head Head Bolt Fastener (torque in 2 increments) fi rst to 22.6 N·m (200 in. lb.) fi nally to 41.8 N·m (370 in. lb.) Rocker Arm Screw 11.3 N·m (100 in.
  • Page 9 Specifi cations TORQUE SPECIFICATIONS SV710 SV715 SV720 SV725 SV730 SV735 SV740 SV810 SV820 SV830 SV840 Oil Sentry ™ Pressure Switch 4.5 N·m (40 in. lb.) Solenoid (Starter) Mounting Hardware 4.0-6.0 N·m (35-53 in. lb.) Nut, Positive (+) Brush Lead 8.0-11.0 N·m (71-97 in. lb.) Speed Control Bracket Fastener 10.7 N·m (95 in.
  • Page 10 Specifi cations CLEARANCE SPECIFICATIONS SV710 SV715 SV720 SV725 SV730 SV735 SV740 SV810 SV820 SV830 SV840 Crankshaft End Play (free) 0.070/0.590 mm (0.0028/0.0230 in.) Bore (in crankcase) 40.965/41.003 mm (1.6128/1.6143 in.) Max. Wear Limit 41.016 mm (1.6148 in.) Bore (in oil pan) 40.974/40.987 mm (1.6131/1.6136 in.) Crankshaft Bore (in oil pan)-to-Crankshaft Running Clearance...
  • Page 11 Specifi cations CLEARANCE SPECIFICATIONS SV710 SV715 SV720 SV725 SV730 SV735 SV740 SV810 SV820 SV830 SV840 Piston, Piston Rings, and Piston Pin Piston Style A Piston-to-Piston Pin Running Clearance 0.006/0.017 mm (0.0002/0.0007 in.) Pin Bore I.D. 17.006/17.012 mm (0.6695/0.6698 in.) Max. Wear Limit 17.025 mm (0.6703 in.) Pin O.D.
  • Page 12 Specifi cations CLEARANCE SPECIFICATIONS SV710 SV715 SV720 SV725 SV730 SV735 SV740 SV810 SV820 SV830 SV840 Valves and Valve Tappets Clearance 0.101/0.152 mm (0.004/0.006 in.) Valve Tappet to Crankcase Running Clearance 0.013/0.073 mm (0.0005/0.0029 in.) Intake Valve Stem-to-Valve Guide Running Clearance 0.038/0.076 mm (0.0015/0.0030 in.) Exhaust Valve Stem-to-Valve Guide Running Clearance 0.050/0.088 mm (0.0020/0.0035 in.)
  • Page 13 Specifi cations GENERAL TORQUE VALUES English Fastener Torque Recommendations for Standard Applications Bolts, Screws, Nuts and Fasteners Assembled Into Cast Iron or Steel Grade 2 or 5 Fasteners Into Aluminum Size Grade 2 Grade 5 Grade 8 Tightening Torque: N·m (in. lb.) ± 20% 8-32 2.3 (20) 2.8 (25)
  • Page 14 Here is a list of tools and their source. SEPARATE TOOL SUPPLIERS Kohler Tools SE Tools Design Technology Inc. Contact your local Kohler source of 415 Howard St. 768 Burr Oak Drive supply. Lapeer, MI 48446 Westmont, IL 60559...
  • Page 15 For reaming worn valve guides to accept replacement oversize valves. Can be used in low-speed drill press or with handle below for hand reaming. Reamer Handle Design Technology Inc. For hand reaming using Kohler 25 455 12-S reamer. DTI-K830 Valve Guide Service Kit (Courage, Aegis, Command, OHC) SE Tools KLR-82415 For servicing worn valve guides.
  • Page 16 Tools and Aids FLYWHEEL HOLDING TOOL ROCKER ARM/CRANKSHAFT TOOL A fl ywheel holding tool can be made out of an old junk A spanner wrench to lift rocker arms or turn crankshaft fl ywheel ring gear and used in place of a strap wrench. may be made out of an old junk connecting rod.

  • Page 17: Troubleshooting

    Troubleshooting TROUBLESHOOTING GUIDE When troubles occur, be sure to check simple causes which, at fi rst, 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 and vary by engine specifi cation. Use these to locate causing factors.
  • Page 18 Troubleshooting EXTERNAL ENGINE INSPECTION Engine Loses Power NOTE: It is good practice to drain oil at a location away ● Dirty air cleaner element. from workbench. Be sure to allow ample time for ● Engine overheated. complete drainage. ● Excessive engine load. ●...
  • Page 19 Troubleshooting CRANKCASE VACUUM TEST WARNING WARNING Carbon Monoxide can cause severe nausea, Rotating Parts can cause severe injury. fainting or death. Stay away while engine is in operation. Avoid inhaling exhaust fumes. Engine exhaust gases contain poisonous carbon Keep hands, feet, hair, and clothing away from all monoxide.
  • Page 20 Troubleshooting COMPRESSION TEST For Command Twins: A compression test is best performed on a warm engine. Clean any dirt or debris away from base of spark plug(s) before removing them. Be sure choke is off, and throttle is wide open during test. Compression should be at least 160 psi and should not vary more than 15% between cylinders.
  • Page 21 Air Cleaner/Intake AIR CLEANER Open air cleaner access door on blower housing and unhook latch. These systems are CARB/EPA certifi ed and components should not be altered or modifi ed in any way. Precleaner (if equipped) Air Cleaner Components 1. Remove precleaner. 2.

  • Page 22: Fuel System

    3. Connect pulse line to new fuel pump and make sure Low permeation fuel line must be installed on carbureted opposite end is properly connected into valve cover. Kohler Co. engines to maintain EPA and CARB regulatory compliance. 4. Attach new fuel pump using screws. Torque screws to 2.3 N·m (20 in.
  • Page 23 Fuel System CARBURETOR Keihin One-Barrel Carburetor Components WARNING Explosive Fuel can cause fi res and severe burns. Do not fi ll fuel tank while engine is hot or running. Gasoline is extremely fl ammable and its vapors can explode if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied buildings, away from sparks or fl...
  • Page 24 Fuel System Walbro One-Barrel Carburetor Components Idle Fuel Idle Speed Screw Adjusting Screw Carburetor Body Idle Jet Plug Main Jet Float Fuel Bowl Shut-off Solenoid Choke Lever Assembly Engines in this series are equipped with either a Keihin, Nikki or Walbro fi xed main jet carburetor. Most carburetors utilize a fuel shut-off solenoid and feature a self-relieving choke.
  • Page 25 Fuel System Troubleshooting-Carburetor Related Causes Condition Possible Cause Conclusion Engine starts hard, runs rough, or Low idle fuel mixture (some models)/ Adjust low idle speed tab, then adjust stalls at idle speed. speed improperly adjusted. low idle fuel needle. Engine runs rich (indicated by black, Clogged air cleaner.
  • Page 26 Fuel System Slow and Mid-Range Low Idle Fuel Adjustment At low speeds engine operates only on slow circuit. As Optimum Low Idle Fuel Setting a metered amount of air is drawn through slow air bleed jets, fuel is drawn through main jet and further metered through slow jet.
  • Page 27 1219 meters (4000 ft.). To obtain high altitude kit Disconnect and ground spark plug lead(s) information or to fi nd a Kohler authorized dealer visit before servicing. KohlerEngines.com or call1-800-544-2444 (U.S. and Canada).
  • Page 28 Fuel System UNITIZED THROTTLE AND CHOKE CONTROL Some engines are equipped with a unitized throttle and choke control. This assembly controls choke and engine speed with a single lever. Engines with a unitized throttle and choke control will have either a left side pull or a right side pull.
  • Page 29 If starter does not turn engine over, shut starter off immediately. Do not make further attempts to start engine until condition is corrected. Do not jump start using another battery. See your Kohler authorized dealer for trouble analysis. 4. For Operation – After engine starts, move throttle/...

  • Page 30: Governor System

    Governor System GOVERNOR Governed speed setting is determined by position of throttle control. It can be variable or constant, depending on engine application. Governor is designed to hold engine speed constant under changing load conditions. Most engines are equipped with a centrifugal fl...

  • Page 31: Lubrication System

    Lubrication System This engine uses a combination pressure/splash lubrication system, delivering oil under pressure to crankshaft, connecting rod and main bearing surfaces. Other component areas are splash lubricated. A high-effi ciency gerotor oil pump maintains high oil fl ow and oil pressure, even at low speeds and high operating temperatures.
  • Page 32 Lubrication System OIL SENTRY (if equipped) Installation ™ NOTE: Make sure oil level is checked before each use, 1. Apply pipe sealant with Tefl on (Loctite 592™ ® ® ® and is maintained up to FULL or F mark on Thread Sealant or equivalent) to threads of switch.

  • Page 33: Electrical System

    Electrical System SPARK PLUGS Inspection Inspect each spark plug as it is removed from cylinder CAUTION head. Deposits on tip are an indication of general Electrical Shock can cause injury. condition of piston rings, valves, and carburetor. Do not touch wires while engine is running. Normal and fouled plugs are shown in following photos: Normal Spark Plug Component and Details...
  • Page 34 Electrical System Carbon Fouled ELECTRONIC IGNITION SYSTEMS There are 3 different types of ignition systems used on these engines. All systems use an ignition module which energizes spark plug. Difference in system is in way ignition timing is triggered. All ignition systems are designed to be trouble free for life of engine.
  • Page 35 Electrical System Fixed Ignition System This system uses a capacitive discharge (CD) coil. Ignition timing and spark remains constant regardless of engine speed. Timing of spark is controlled by location of fl ywheel magnet group as referenced to engine TDC. A typical fi xed ignition system consists of: ●...
  • Page 36 Electrical System Digital Spark Advance Ignition (DSAI) Ignition System This system uses a digital microprocessor which is located in ignition modules. Ignition timing varies depending upon engine speed with this system. There are 2 inductive-style ignition modules that control ignition timing based on engine RPM.
  • Page 37 Electrical System Digital Spark Advance Module (DSAM) Ignition System DSAM, previously known as Smart-Spark , equipped engines utilize an electronic capacitive discharge ignition ™ system with electronic spark advance. A typical application consists of following components: ● 1 magnet assembly which is permanently affi xed to fl ywheel. ●...
  • Page 38 Electrical System Electronic Ignition Systems Tests NOTE: Ignition tester must be used to test ignition on these engines. Use of any other tester can result in inaccurate fi ndings. Battery on unit must be fully charged and properly connected before performing tests (a battery that is hooked up or charged backward will crank engine but it won’t have spark).
  • Page 39 Electrical System Test Timing Advance (DSAI and DSAM only) 1. Make a line near edge of fl ywheel screen with a marking pen, chalk, or narrow tape. 2. Connect an automotive timing light to cylinder that had good spark. 3. Run engine at idle and use timing light beam to locate line on screen. Draw a line on blower housing next to line on screen.
  • Page 40 Electrical System 5. Check and/or adjust ignition module air gap(s). An air gap of 0.28/0.33 mm (0.011/0.013 in.) must be maintained under all three legs of ignition module(s). Checking/adjusting should be performed with parts at room temperature. Condition Possible Cause Conclusion Module was not loosened or Ignition Module Air Gap...
  • Page 41 Electrical System Test DSAM 1. Trace red power source lead from DSAM to harness connection. Separate connector and connect red lead of a DC voltmeter to harness terminal. Trace ground lead (green) from SAM to grounding screw. Connect black voltmeter lead to eyelet terminal of ground lead or ground screw/bolt. Check voltage with key switch in both START and RUN positions.
  • Page 42 Electrical System To test DSAM using spark advance module (SAM) 3. Depress tester button repeatedly until correct test tester: number appears on display. After a few seconds, test number will fl ash three times and test will begin. NOTE: DSAM must be at room temperature when A reverse numerical sequence will be displayed, tested.
  • Page 43 Electrical System BATTERY CHARGING SYSTEM NOTE: Observe following guidelines to avoid damage to electrical system and components: ● Make sure battery polarity is correct. A negative (-) ground system is used. ● Disconnect rectifi er-regulator plug and/or wiring harness plug before doing any electric welding on equipment powered by engine.
  • Page 44 Electrical System 12/15/25 Amp Battery Charging Systems NOTE: Always zero ohmmeter on each scale before testing to ensure accurate readings. Voltage tests should be made with engine running at 3600 RPM with no load. Battery must be good and fully charged. When problems occur in keeping battery charged or battery charges at high rate, charging system or battery might be causing problems.

  • Page 45: Starter System

    Starter System NOTE: Do not crank engine continuously for more than 10 seconds. Allow a 60 second cool-down period between starting attempts. Failure to follow these guidelines can burn out starter motor. NOTE: If engine develops suffi cient speed to disengage starter but does not keep running (a false start), engine rotation must be allowed to come to a complete stop before attempting to restart engine.
  • Page 46 If splines are dirty, clean them with solvent. 7. Splines should have a light fi lm of lubricant. Lubricate as necessary with Kohler starter drive lubricant. Reinstall or replace drive components, assembling them in reverse order they were removed.
  • Page 47 5. Install thru bolts and torque to 4.5-5.7 N·m Plate Plug (40-50 in. lb.). Solenoid Frame and Field 6. Lubricate drive shaft with Kohler starter drive Brush Holder lubricant. Install drive components following Commutator End instructions for servicing starter drive. Screw...
  • Page 48 Brush Replacement 4 brushes and springs are serviced as a set. Use a new Kohler brush and spring kit if replacement is necessary. 1. Perform steps 1-5 in Starter Disassembly. 2. Remove screws securing brush holder assembly to end cap (plate).
  • Page 49 Starter System 10. Starter reassembly when replacing brushes/brush Starter Reassembly holder assembly: NOTE: Always use a new retainer. Do not reuse old a. Hold starter assembly vertically on end housing, retainers that have been removed. and carefully position assembled brush holder NOTE: Correctly installed, center pivot section of drive assembly, with supplied protective tube, against lever will be fl...
  • Page 50 Starter System Solenoid Tests NOTE: DO NOT leave 12 volt test leads connected to solenoid for any time over what is necessary for performing each of individual tests. Internal damage to solenoid may occur. Disconnect all leads from solenoid including positive brush lead attached to lower stud terminal. Remove mounting hardware and separate solenoid from starter for testing.
  • Page 51 To Carburetor Filter For engine to be Tier III compliant, it may be fi tted with a Kohler supplied canister vapor recovery system, or a system developed and installed by Original Equipment Manufacturer (OEM). Details on Kohler system are included below.
  • Page 52 Emission Compliant Systems SECONDARY EMISSION COMPLIANT SYSTEM Twin Secondary Air Induction System Hose To Exhaust Secondary Air Inlet Screen Hose To Carburetor Manifold Valve Assembly Hose To Exhaust Manifold Single Secondary Air Induction System Secondary Air Hose To Exhaust Hose To Carburetor Inlet Screen Valve Assembly Manifold...
  • Page 53 Emission Compliant Systems Remove Inlet Screen Inlet Components Secondary Air Valve Assembly Barb Inlet Screen 1. Remove inlet screen from secondary air valve assembly by grasping inlet screen at base and gently pulling away from valve assembly. 2. Use a soft brush to remove debris from screen. 3.
  • Page 54 Disassembly/Inspection and Service WARNING Before working on engine or equipment, disable engine as Accidental Starts can cause severe injury or follows: 1) Disconnect spark plug lead(s). 2) Disconnect death. negative (–) battery cable from battery. Disconnect and ground spark plug lead(s) before servicing.
  • Page 55 Disassembly/Inspection and Service Inner Baffl e Ignition Module Intake Manifold Carburetor Gasket Air Cleaner Base Air Cleaner Rectifi er-Regulator Clean all parts thoroughly as engine is disassembled. Remove Blower Housing and Outer Baffl es Only clean parts can be accurately inspected 1.
  • Page 56 Disassembly/Inspection and Service Remove Air Cleaner and Carburetor Remove Ignition Modules 1. Rotate fl ywheel so magnet is away from modules. WARNING 2. Disconnect lead(s) from each ignition module. Fixed Explosive Fuel can cause fi res and severe Timing Models and DSAI Models have 1 lead per burns.
  • Page 57 Disassembly/Inspection and Service Cylinder Head Components Gasket Valve Cylinder Head Valve Spring Cap Valve Stem Seal Valve Spring Valve Spring Retainer Valve Spring Keeper Stud Spark Plug Guide Plate Push Rod Rocker Arm Rocker Arm Pivots Adjusters O-Ring Cylinder Head Plastic Valve Cover Stamped Steel Valve (with Cast in Valve...
  • Page 58 Disassembly/Inspection and Service 2. Mark location of push rods as either intake or 2. Compress valve springs using a valve spring exhaust and cylinder 1 or 2. Push rods should compressor. always be installed in same positions. 3. Once valve spring is compressed, remove following 3.
  • Page 59 Disassembly/Inspection and Service After cleaning, check fl atness of cylinder head and Lapping Valves corresponding top surface of crankcase, using a surface NOTE: Exhaust valves that are black in color cannot be plate or piece of glass and feeler gauge. Maximum ground and do not require lapping.
  • Page 60 fl ywheel, crankshaft, and key if fl ywheel key is sheared or keyway is damaged. Inspect ring gear for cracks or damage. Kohler does not provide ring gears as a serviceable part. Replace fl ywheel if ring gear is damaged.
  • Page 61 Disassembly/Inspection and Service Crankshaft/Governor Gear/Oil Pump Components Governor Cross Crankshaft Valve Tappets Camshaft Shaft Locking Tab Thrust Regulating Pin Shaft Governor Gear Washer Oil Feed Tube Oil Pan (Style A) Drain Plug Oil Seal (Filter to Pan) (Style A) Oil Feed Tube Gerotor Gears Oil Pump (Style A) (Oil Pump Outlet)
  • Page 62 Disassembly/Inspection and Service 1. Use 2 small screwdrivers and carefully pry upward to Remove Oil Pan Assembly remove regulating pin and governor gear assembly. 1. Remove screws securing oil pan to crankcase. 2. Remove locking tab thrust washer located under 2.
  • Page 63 Disassembly of oil pump is not be checked for wear or damage. Whenever tappets are recommended. replaced, apply a liberal coating of Kohler lubricant to Reassembly base of each new tappet before it is installed. 1. Lubricate outer gerotor gear with oil. Install outer...
  • Page 64 Disassembly/Inspection and Service Inspection and Service Connecting Rods/Piston/Breather Components Check bearing area (big end) for excessive wear, score marks, running and side clearances (See Specifi cations). Replace rod and cap if scored or excessively worn. Service replacement connecting rods are available in STD size and 0.25 mm (0.010 in.) undersize.
  • Page 65 Disassembly/Inspection and Service Ring failure is usually indicated by excessive oil Piston Style B consumption and blue exhaust smoke. When rings fail, 1. Cylinder bore must be de-glazed before service ring oil is allowed to enter combustion chamber where it is sets are used.
  • Page 66 (refer to Specifi cations). crankcase. Oversize Kohler replacement piston will then fi t When pistons move downward, crankcase gases are correctly. pushed past reed through mesh fi lter into intake system.
  • Page 67 Disassembly/Inspection and Service 4. After resizing, check bore for roundness, taper, and size. Use an inside micrometer, telescoping gauge, or bore gauge to take measurements. These measurements should be taken at 3 locations in cylinder – at top, middle, and bottom. Two measurements should be taken (perpendicular to each other) at 3 locations.
  • Page 68 Reassembly NOTE: Make sure engine is assembled using all Install Flywheel End Oil Seal specifi ed torque values, tightening sequences, 1. Make sure seal bore of crankcase is clean and free and clearances. Failure to observe specifi cations of any nicks or burrs. could cause severe engine wear or damage.
  • Page 69 Reassembly Crankshaft/Governor Gear/Oil Pump Components Governor Cross Crankshaft Valve Tappets Camshaft Shaft Locking Tab Thrust Regulating Pin Shaft Governor Gear Washer Oil Feed Tube Oil Pan (Style A) Drain Plug Oil Seal (Filter to Pan) (Style A) Oil Feed Tube Gerotor Gears Oil Pump (Style A) (Oil Pump Outlet)
  • Page 70 Reassembly Install Crankshaft Install Valve Tappets and Camshaft 1. Lubricate fl ywheel side main bearing surface and NOTE: Exhaust valve tappets are located on output lips of oil seal in crankcase with clean engine oil. shaft side of engine, while intake valve tappets are located on fan side of engine.
  • Page 71 Reassembly Install Oil Seal in Oil Pan Install Oil Pan Assembly Oil Seal Component and Detail Sealant Pattern Style A Style B 6.5 mm (0.255 in.) Oil Seal 1. Check to make sure there are no nicks or burrs in Fastener Torque Sequence crankshaft bore of oil pan.
  • Page 72 Reassembly Flywheel/Ignition/Breather Components Install Breather Reed and Outer Cover Breather Cover Sealant Sealant Bead NOTE: RTV sealant should be allowed to cure a minimum of 1 hour before engine is started. 1. Install breather reed, followed by retainer over passage hole and mounting hole in crankcase. Hold in position and secure with mounting stud.
  • Page 73 Reassembly Install Flywheel and Fan Install Ignition Modules Fixed or DSAM Ignition System CAUTION 1. Rotate fl ywheel to position magnet away from ignition module bosses. Damaging Crankshaft and Flywheel can cause personal injury. 2. DSAM ignition system ignition modules are installed in similar ways with tabs out.
  • Page 74 Reassembly Cylinder Head Components Gasket Valve Cylinder Head Valve Spring Cap Valve Stem Seal Valve Spring Valve Spring Retainer Valve Spring Keeper Stud Spark Plug Guide Plate Push Rod Rocker Arm Rocker Arm Pivots Adjuster O-Ring Cylinder Head (with Plastic Valve Cover Torque Sequence Cast in Valve Washer (Intake Side)
  • Page 75 Reassembly Install Cylinder Heads Adjust Valve Clearance NOTE: Match numbers embossed on cylinder heads and crankcase. Adjusters Retaining Push Rods NOTE: When installing cylinder heads, new screws should always be used. New screws are supplied in gasket sets. NOTE: Push rods should always be installed in same position as before disassembly.
  • Page 76 Reassembly Check Assembly Stamped Steel Valve Cover Torque Sequence Rotate crankshaft a minimum of 2 revolutions to check longblock assembly and overall proper operation. 1&5 Install Valve Covers Plastic valve covers contain integral bolt hole spacers molded in place. Sealing of plastic valve covers is accomplished using a yellow colored O-ring.
  • Page 77 Reassembly External Engine Components Air Cleaner Fixed Guard Debris Screen Blower Housing Access Door Hose Clamp Fuel Pump Hose Clip Fuel Line Nipple O-Ring Fuel Filter Oil Filter (Style A Oil Pan) (Style A Oil Pan) Oil Feed Tube Oil Feed Tube (Oil Pump Outlet) (Filter to Pan) Outer Baffl...
  • Page 78 Reassembly Install Intake Manifold Install Carburetor Torque Sequence WARNING Explosive Fuel can cause fi res and severe burns. Do not fi ll fuel tank while engine is hot or running. Gasoline is extremely fl ammable and its vapors can explode if ignited. Store gasoline only in approved NOTE: If wires were disconnected from ignition modules containers, in well ventilated, unoccupied buildings, on engines with DSAM, reattach leads and seal...
  • Page 79 Reassembly Throttle and Choke Components Install Throttle and Choke Controls Governor Lever Hole Position Screw Choke Lever Throttle Actuator Throttle Lever Governor Lever Hole 1 Lever Hole 2 Hole 3 Control Bracket Choke Return Spring Hole 4 Lock Nut M5x0.8 Shoulder Washer RPM Chart Flat Washer...
  • Page 80 Reassembly Install Blower Housing Install Muffl er NOTE: Do not completely tighten screws until all are 1. Install muffl er and attaching hardware to muffl er installed to allow shifting for hole alignment. bracket. Torque screws to 9.9 N·m (88 in. lb.). 1.
  • Page 81 32 690 01 Rev. G KohlerEngines.com...
  • Page 82 KohlerEngines.com 32 690 01 Rev. G...
  • Page 83 32 690 01 Rev. G KohlerEngines.com...
  • Page 84 © 2014 by Kohler Co. All rights reserved. KohlerEngines.com 32 690 01 Rev. G...

This manual is also suitable for:

Courage sv715Courage sv735Courage sv740Courage pro sv810Courage sv720Courage pro sv820 ... Show all

Table of Contents