Kohler KS530 Service Manual
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Kohler KS530 Service Manual

5400 series
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KS530-KS595
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
18
21
Troubleshooting
25
26
38
40
42
55
57
60
76
22 690 01 Rev. --
KohlerEngines.com
1

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Summary of Contents for Kohler KS530

  • Page 1 KS530-KS595 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...
  • 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 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). 22 690 01 Rev. --...
  • 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-Flywheel Side 164.8 mm (6.49 in.) 201.3 mm (7.92 in.) 212.4 mm (8.36 in.) 100.0 mm (3.94 in.) to Starter to Oil Filter Ø 10.0 mm (0.39 in.) Oil Fill and Dipstick Throttle Cable Clip 109.0 mm (4.29 in.) Lifting Point Connection for 46.5 mm (1.83 in.)
  • Page 6 Specifi cations Engine Dimensions-Starter Side 2 X Cored for M6 Self Tapping Screw 17.7 mm 179.0 mm (7.05 in.) (0.70 in.) Min. 326.5 mm Exhaust Port Axis to Center of Depth (12.85 in.) Gravity (Accessory Mounting Location) 7/16-20 UNF-2B IN. 145.2 mm (5.72 in.) 64.0 mm (2.52 in.) 81.3 mm (3.20 in.)
  • Page 7 Specifi cations Engine Dimensions-PTO Side Accessory Mounting 116.0 mm (4.57 in.) 55.0 mm (2.17 in.) 150° Surface 2 X 288.8 mm Ø 254.0 mm 35° Rotation Direction (11.37 in.) (10.00 in.) 150.2 mm (5.91 in.) 45° 36.6 mm (1.44 in.) 105.2 mm (4.14 in.) Ø...
  • Page 8 Specifi cations Engine Dimensions-Oil Filter Side 75.5° Speed Control 317.1 mm (12.49 in.) 45.2 mm (1.78 in.) 34.3 mm (1.35 in.) Lever Travel 324.9 mm 226.7 mm (8.93 in.) Optional Fuel Pump Throttle Cable Clip (12.79 in.) Lifting Point 14.5 mm (0.57 in.) Oil 113.6 mm (4.47 in.) to 215.7 mm (8.49 in.) Oil Filter...
  • Page 9 Specifi cations Engine Dimensions-Valve Cover Side Cored for M6 Self Tapping Screw 16.5 mm (0.65 24.3 mm (0.96 in.) 64.2 mm (2.53 in.) 16.0 mm (0.63 in.) in.) Min. Depth to Spark Plug (Accessory Mounting Location) 93.2 mm (3.67 in.) Carburetor Oil Drain Plug 122.7 mm (4.83 in.)
  • Page 10 Kohler engine identifi cation numbers (model, specifi cation and serial) should be referenced for effi cient repair, ordering correct parts, and engine replacement. Model ..... KS530 5400 Series Engine Numerical Designation Specifi...
  • Page 11 Specifi cations KS530 KS540 KS590 KS595 TORQUE SEQUENCES (Refer to Torque Specifi cations for torque values). Closure Plate Fasteners Cylinder Head Fasteners Oil Passage Cover Fasteners Valve Cover Fasteners 22 690 01 Rev. -- KohlerEngines.com...
  • Page 12 Specifi cations TORQUE SPECIFICATIONS KS530 KS540 KS590 KS595 Auto Choke Smart-Choke Diaphragm Assembly Fastener 1 N·m (9 in. lb.) ™ Barrel Baffl e Fastener 9.3 N·m (82 in. lb.) into new hole 4.0 N·m (35 in. lb.) into used hole Blower Housing to Adapter 4.8 Hi-Lo Fastener...
  • Page 13 Specifi cations TORQUE SPECIFICATIONS KS530 KS540 KS590 KS595 Electric Starter 10/24 Mounting Nut 3.8 N·m (34 in. lb.) 1/4-20 Nut 7.9 N·m (70 in. lb.) Fixed Guard (if equipped) Fastener 0.8 N·m (7 in. lb.) Flywheel M12 Retaining Screw 115 N·m (85 ft. lb.)
  • Page 14 Specifi cations TORQUE SPECIFICATIONS KS530 KS540 KS590 KS595 Speed Control Bracket Assembly Fastener 11.3 N·m (100 in. lb.) into new hole 7.5 N·m (65 in. lb.) into used hole Stator Mounting Screw 8.8 N·m (78 in. lb.) Stator Wire Clip Fastener 6.5 N·m (58 in.
  • Page 15 Specifi cations CLEARANCE SPECIFICATIONS KS530 KS540 KS590 KS595 Crankshaft (continued) Flywheel End Main Bearing Journal O.D. 40.913/40.935 mm (1.6107/1.6116 in.) Max. Wear Limit 40.880 mm (1.6094 in.) Max. Taper 0.0220 mm (0.0009 in.) Max. Out of Round 0.0250 mm (0.0010 in.) PTO End Main Bearing Journal O.D.
  • Page 16 Specifi cations CLEARANCE SPECIFICATIONS KS530 KS540 KS590 KS595 Piston, Piston Rings, and Piston Pin Piston-to-Piston Pin Running Clearance 0.007/0.017 mm (0.0003/0.0007 in.) Pin Bore I.D. 20.007/20.012 mm (0.7877/0.7879 in.) Max. Wear Limit 20.025 mm (0.7884 in.) Pin O.D. 19.995/20.000 mm (0.7872/0.7874 in.) Max.
  • Page 17 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 18 Shrader Valve Adapter Hose DTI-037 Wire Probe Set (2 pieces regular wire with clip; 1 piece fused wire) DTI-031 Hose Removal Tool, Dual Size/End (also sold as individual Kohler tool) DTI-033 K-Line Adapter Jumper Lead Wiring Harness Kohler 25 176 23-S Kohler Wireless Diagnostic System Module (Bluetooth®)
  • Page 19 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 22 690 01 Rev. -- KohlerEngines.com...
  • Page 20 Dielectric Grease (GE/Novaguard G661) Kohler 25 357 11-S Dielectric Grease Loctite ® 51360 Kohler Electric Starter Drive Lubricant (Inertia Drive) Kohler 52 357 01-S Kohler Electric Starter Drive Lubricant (Solenoid Shift) Kohler 52 357 02-S RTV Silicone Sealant Loctite ®...

  • Page 21: 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 22 Troubleshooting Sludge is a natural by-product of combustion; a small Engine Loses Power accumulation is normal. Excessive sludge formation ● Dirty air cleaner element. could indicate over rich fuel settings, weak ignition, ● Engine overheated. overextended oil change interval or wrong weight or ●...
  • Page 23 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 24 Troubleshooting COMPRESSION TEST These engines are equipped with an automatic compression release (ACR) mechanism. It is diffi cult to obtain an accurate compression reading because of ACR mechanism. As an alternative, use cylinder leakdown test described below. CYLINDER LEAKDOWN TEST A cylinder leakdown test can be a valuable alternative to a compression test.
  • Page 25 Air Cleaner/Intake AIR CLEANER Paper Element These systems are CARB/EPA certifi ed and components 1. Remove element from air cleaner adapter; service should not be altered or modifi ed in any way. precleaner. Discard element. Air Cleaner Components 2. Install precleaner over new paper element and install on air cleaner adapter.

  • Page 26: Fuel System

    2. Connect inlet, outlet, and pulse lines to their respective fi ttings on pump. Secure with clamps. Low permeation fuel line must be installed on carbureted Kohler Co. engines to maintain EPA and CARB 3. Position air cleaner cover on housing and line up regulatory compliance.
  • Page 27 Fuel System FUEL SYSTEM TESTS When engine starts hard or turns over but will not start, fuel system might be causing problems. Test fuel system by performing following test. 1. Check for fuel in combustion chamber. a. Disconnect and ground spark plug lead. b.
  • Page 28 Fuel System CARBURETOR Shut-off Solenoid Gasket Assembly WARNING Fuel Bowl Screw Float Pin Explosive Fuel can cause fi res and severe Idle Speed Screw Float burns. and Spring Do not fi ll fuel tank while engine is hot or Throttle Plate Screw Throttle Plate running.
  • Page 29 Fuel System Troubleshooting-Carburetor Related Causes Condition Possible Cause Conclusion Engine starts hard, runs rough, or Low idle fuel mixture/speed Adjust low idle speed screw, then stalls at idle speed. improperly adjusted. adjust low idle fuel needle. Improper choke adjustment. Correct choke adjustment. Engine runs rich (indicated by black, Choke partially closed during Check choke lever/linkage to ensure...
  • Page 30 Fuel System Carburetor Circuits Carburetor Servicing Float NOTE: Main and slow jets are fi xed and size specifi c. Fuel level in bowl is maintained by fl oat and fuel inlet Fixed jets for high altitudes are available. needle. Buoyant force of fl oat stops fuel fl ow when ●...
  • Page 31 To obtain high altitude carburetor kit Turn idle speed screw out (counterclockwise) two full information or to fi nd a Kohler authorized dealer, visit turns to allow throttle valve to seat in a fully closed KohlerEngines.com or call 1-800-544-2444 (U.S. and position with throttle bore.
  • Page 32 Fuel System Smart-Choke ™ Diaphragm assembly consists of a spring controlled diaphragm for initial choke pull-off and a thermostat to completely open choke while engine warms up. A vacuum signal from intake manifold is routed through a check valve to diaphragm and partially opens choke once engine starts.
  • Page 33 Fuel System Troubleshooting Smart-Choke Related Causes ™ Condition Possible Cause Conclusion Engine starts hard, runs rough, or Choke not closing. Check choke lever/linkage to ensure stalls at idle speed. choke is operating properly. Check that bimetallic spring actuates freely. Engine runs rich (indicated by black, Choke partially closed during Check choke lever/linkage to ensure sooty exhaust smoke, misfi...
  • Page 34 Do not make further attempts to start engine until condition is corrected. Do not jump start NOTE: Choke is placed ON by moving throttle control using another battery. See your Kohler authorized slightly past fast position. If throttle control does dealer for trouble analysis.
  • Page 35 Do not make further attempts to start To increase high speed (RPM), move bracket toward engine until condition is corrected. Do not jump start carburetor. using another battery. See your Kohler authorized dealer for trouble analysis. To decrease high speed (RPM), move bracket away from carburetor.
  • Page 36 Fuel System SEPARATE THROTTLE AND CHOKE CONTROL Governed Idle Adjustment Some engines are equipped with separate throttle and This procedure must follow High Speed Adjustment choke controls. This allows you to adjust choke and just described. If not already completed, perform that throttle controls individually.
  • Page 37 Fuel System Choke Control Installation Changing High Speed (RPM) on Engines with Separate Controls (Increase or Decrease RPM) In this engine series, choke cable connects to carburetor choke lever and is secured to air cleaner adapter with a Speed Control Bracket Details cable clamp.

  • Page 38: 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 39 Governor System This governor design works as follows: Governor Adjustments ● Centrifugal force acting on rotating governor gear NOTE: Do not tamper with governor setting. Overspeed assembly causes fl yweights to move outward as is hazardous and could cause personal injury. speed increases.

  • Page 40: Lubrication System

    Lubrication System This engine uses a full pressure lubrication system which delivers oil under pressure to crankshaft, camshaft, and connecting rod 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 41 Lubrication System 2. Gradually increase pressure to switch. As pressure Testing increases through range of 2-5 PSI, tester should Compressed air, a pressure regulator, pressure gauge, indicated a change to continuity (contacts closed) and a continuity tester are required to test switch. between terminal #1 and terminal #3 on switch.

  • Page 42: Electrical System

    Electrical System BATTERY CHARGING SYSTEM Fixed Ignition System This system uses an inductive discharge (ID) coil. CAUTION Ignition timing and spark remains constant regardless of Electrical Shock can cause injury. engine speed. Timing of spark is controlled by location of fl...
  • Page 43 Electrical System Wiring Diagram-12/15 Amp Regulated Battery Charging System Green Violet White Optional Fuel Shut-off Optional Oil Sentry Spark Plug Bendix Starter ™ Solenoid Switch (Indicator) Engine Connector Starter Solenoid Ground-To-Kill Lead Key Switch Optional Oil Sentry Optional Fuse Battery Rectifi...
  • Page 44 Electrical System Wiring Diagram-12/15 Amp Regulated Battery Charging System with Smart-Choke Green Violet White 3-Terminal Oil Spark Plug Fuel Shut-off Solenoid Sentry Bendix Starter ™ Switch (Indicator) Engine Connector Starter Solenoid Ground-To-Kill Lead Key Switch Optional Oil Sentry Optional Fuse Battery Rectifi...
  • Page 45 Electrical System Wiring Diagram-12/15 Amp Regulated Battery Charging System with Fuel Relay Green Violet White Optional Oil Sentry Spark Plug Fuel Shut-off Solenoid Bendix Starter ™ Switch (Indicator) Engine Connector Starter Solenoid Ground-To-Kill Lead Key Switch Optional Oil Sentry Optional Fuse Battery Rectifi...
  • Page 46 Electrical System Wiring Diagram-12/15 Amp Regulated Battery Charging System with Fuel Relay and Stator Brake Relay Green Violet White Optional Oil Sentry Spark Plug Fuel Shut-off Solenoid Bendix Starter ™ Switch (Indicator) Engine Connector Starter Solenoid Ground-To-Kill Lead Key Switch Optional Oil Sentry Optional Fuse Battery...
  • Page 47 Electrical System 12/15 Amp Battery Charging Systems NOTE: Always zero digital volt-ohm meter (DVOM) on each scale before testing to ensure accurate readings. Voltage test should be made with engine running at specifi c test condition noted. Battery should be checked for state of charge (non-operating voltage 12.5 VDC or lower, battery should be charged or replaced).
  • Page 48 Electrical System IGNITION SYSTEM Normal Spark Plug Component and Details Plug taken from an engine operating under normal conditions will have light tan or gray colored deposits. If center electrode is not worn, plug can be set to proper gap and reused. Worn Wire Gauge Spark Plug...
  • Page 49 Electrical System Carbon Fouled Overheated Soft, sooty, black deposits indicate incomplete Chalky, white deposits indicate very high combustion combustion caused by a restricted air cleaner, over rich temperatures. This condition is usually accompanied carburetion, weak ignition, or poor compression. by excessive gap erosion. Lean carburetor settings, an intake air leak, or incorrect spark timing are normal causes for high combustion temperatures.
  • Page 50 Electrical System Test for Spark NOTE: To maintain engine speeds normally obtained during cranking, do not remove engine spark plug. 1. Make sure spark plug lead is connected to spark plug. 2. Check condition of spark plug. Make sure gap is set to 0.76 mm (0.030 in.). If plug is in good condition, check/ adjust gap and reinstall.
  • Page 51 Electrical System FUEL SHUT-OFF RELAY CIRCUIT Troubleshooting-Fuel Shut-Off Relay System Some engines are equipped with a fuel shut-off relay. NOTE: Refer to Fuel Shut-Off Solenoid in Fuel System This relay is part of wiring harness and is activated with section for individual testing of solenoid valve. voltage supplied by equipment.
  • Page 52 Electrical System Condition Engine operates as designed. Key Switch Safety Circuit Yellow Wire (Volts) Solenoid (Volts) Operate Operate START Operate Possible Cause None, system OK. Conclusion None, system OK. Condition Engine cranks but will not start (voltage at yellow wire). Key Switch Safety Circuit Yellow Wire (Volts)
  • Page 53 Electrical System BLADE STOP STATOR BRAKE AND FUEL SHUT-OFF Stator Brake and Fuel Shut-off Relay Harness CIRCUIT Connections Some engines are equipped with a fuel shut-off relay and a stator brake relay. These relays are part of wiring harness. Refer to FUEL SHUT-OFF RELAY CIRCUIT (on previous pages) for troubleshooting fuel relay part of circuit.
  • Page 54 Stator Brake Relay 2. Remove engine shutdown (kill) white lead from application wire harness and attempt to start engine Problems that could occur with Kohler portion of circuit again. generally could be caused by component failures, which Condition Conclusion will create following conditions.

  • Page 55: 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 56 Starter System Inertia Drive Starter Tests NOTE: Please perform following testing as near to conditions during failure. Before Starting ● Disable ignition system: disconnect spark plug lead from spark plug, then ground spark plug lead to engine block using mechanical means. ●...
  • Page 57 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 58 Emission Compliant Systems SECONDARY EMISSION COMPLIANT SYSTEM Secondary Air Induction System Secondary Air Hose To Exhaust Hose To Carburetor Inlet Screen Valve Assembly Manifold For engine to be Tier III compliant, it may be fi tted with a secondary air induction system (SAI). Operation Maintenance Intake pulse of engine activates secondary air valve.
  • Page 59 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 60 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 61 Disassembly/Inspection and Service Clean all parts thoroughly as engine is disassembled. Remove Blower Housing Only clean parts can be accurately inspected NOTE: Unless fuel pump bracket is damaged and gauged for wear or damage. There are many disassembly from blower housing is commercially available cleaners that will quickly remove unnecessary.
  • Page 62 Disassembly/Inspection and Service 3. Move hose clamp on breather hose away from air Standard Choke intake elbow. Using Hose Removal Tool (see Tools and Aids), carefully remove breather hose from air cleaner adapter. Air Cleaner Adapter Gasket Carburetor Stud Gasket Intake Manifold Smart-Choke Retainer...
  • Page 63 Disassembly/Inspection and Service Remove External Governor Components Remove Ignition Module Speed Control Screw Bracket 1. Mark mounted position of speed control bracket in slotted holes and remove screws securing speed control bracket to closure plate. Note or mark governor spring hole for correct installation later and unhook governor spring.
  • Page 64 Disassembly/Inspection and Service Remove Debris Screen, Fan, and Flywheel Anchor Bolt Assembly Anchor Bolt Assembly in Opposite Direction 6. Position fl ywheel puller with center screw on fl ywheel screw. Secure each anchor bolt evenly to puller as shown. Debris Screen Flywheel Screw Washer Fan Mounting Plate...
  • Page 65 Disassembly/Inspection and Service Remove Stator Remove Cylinder Head Baffl e Stator Wire Clip Screw Screw Stator Cylinder Head Screw 1. Remove screw securing stator wire clip; remove clip. Baffl e 2. Remove screws securing stator to closure plate Remove screws attaching cylinder head baffl e to cylinder bosses.
  • Page 66 Disassembly/Inspection and Service Remove Cylinder Head Cylinder Head Gasket Exhaust Valve Intake Valve Cylinder Head Spark Plug Valve Stem Seal Valve Spring Valve Spring Cap Retainer Lock Push Rod Guide Plate Rocker Stud Push Rod Rocker Pivot Rocker Arm Set Screw Cylinder Head Screw Assembly NOTE: Before disassembly, mark all valve train components that will be reused, to ensure they are reassembled on...
  • Page 67 Disassembly/Inspection and Service Inspection and Service Valve Details EXHAUST VALVE INTAKE VALVE Dimension Intake Exhaust Seat Angle 44.5° 44.5° Insert O.D. 40.094/40.11 mm (1.578/1.579 in.) 35.094/35.11 mm (1.381/1.382 in.) Guide Depth 11.85/12.25 mm (0.466/0.482 in.) 10.80/11.20 mm (0.425/0.440 in.) Guide I.D. 6.038/6.058 mm (0.2377/0.2385 in.) 6.038/6.058 mm (0.2377/0.2385 in.) Valve Head Diameter...
  • Page 68 Disassembly/Inspection and Service Valve Seat Inserts Remove Closure Plate Hardened steel alloy intake and exhaust valve seat inserts are press fi tted into cylinder head. Inserts are not replaceable, but they can be reconditioned if not too badly pitted or distorted. If seats are cracked or badly warped, cylinder head should be replaced.
  • Page 69 Disassembly/Inspection and Service Governor Gear Inspection Install Governor Shaft Inspect governor gear teeth. Look for any evidence of Governor Shaft Components and Details worn, chipped, or cracked teeth. If one or more of these problems is noted, replace governor gear. Gear is held onto governor shaft by molded tabs, which are damaged when gear is removed.
  • Page 70 Disassembly/Inspection and Service 4. Engines with ACR start much faster in cold weather Remove Camshaft than engines without ACR. 5. Engines with ACR can be started with spark plugs which are worn or fouled. Engines without ACR are more diffi cult to start with those same spark plugs. Cam Gear Inspection and Service Inspect gear teeth and cam lobes of camshaft.
  • Page 71 Disassembly/Inspection and Service Remove Connecting Rod and Piston Piston and Rings Inspection Scuffi ng and scoring of pistons and cylinder walls occurs when internal temperatures approach welding point of piston. Temperatures high enough to do this are created by friction, which is usually attributed to improper lubrication, and/or overheating of engine.
  • Page 72 Disassembly/Inspection and Service Some important points to remember when servicing Install New Piston Rings piston rings: Piston Ring Orientation 1. Cylinder bore must be deglazed before service ring sets are used. 2. If cylinder bore is within wear limits (refer to Specifi...
  • Page 73 Disassembly/Inspection and Service Remove Crankshaft Remove Oil Pump Assembly Crankshaft Gear Crankshaft Oil Pump Housing Assembly Oil Pump Assembly 1. Carefully remove crankshaft from crankcase. Oil Pump Housing Screws 2. Remove crankshaft gear from crankshaft and 1. Remove screws and lift oil pump housing assembly carefully remove key from keyway.
  • Page 74 Disassembly/Inspection and Service Remove Cam Levers Remove Oil Baffl e Cam Lever Screw Cam Levers NOTE: It is not necessary to remove cam levers unless replacement is intended. If cam lever screw is removed for any reason, discard screw, do not Oil Baffl...
  • Page 75 Disassembly/Inspection and Service Honing Clean Cylinder Bore after Honing Proper cleaning of cylinder walls following honing is Detail critical. Grit left in cylinder bore can destroy an engine in less than one hour of operation after a rebuild. Final cleaning operation should always be a thorough scrubbing with a brush and hot, soapy water.
  • Page 76 Reassembly NOTE: Make sure engine is assembled using all Install Oil Baffl e specifi ed torque values, torque sequences, and clearances. Failure to observe specifi cations could cause severe engine wear or damage. Always use new gaskets. Apply a small amount of oil to threads of critical fasteners before assembly, unless a sealant or Loctite ®...
  • Page 77 Reassembly 3. Install camshaft into oil pump housing; turn to drop Install Cam Levers into place. Turn camshaft to align timing mark to center of crankshaft PTO bore. 4. Lift camshaft out. Install Crankshaft and Crankshaft Gear Cam Lever Screw Cam Levers NOTE: Do not reinstall a cam lever screw that has been removed.
  • Page 78 Reassembly 4. Guide connecting rod down and rotate crankshaft to Install Piston to Connecting Rod mate journals. Install rod cap. 5. Install screws and torque in 2 increments, in sequence shown, fi rst to 5.5 N·m (50 in. lb.), fi nally to 11.8 N·m (105 in.
  • Page 79 Reassembly Install Camshaft Install Closure Plate Closure Plate Sealant Pattern on Crankcase Camshaft Crankcase 1. Ensure cam levers are in proper position toward Sealant Bead on Crankcase cylinder. 2. Install camshaft aligning timing mark with crankshaft Closure Plate Fastener Torque Sequence gear mark.
  • Page 80 Reassembly Install Breather Breather Cover Sealant Pattern Components Sealant Bead on Closure Plate NOTE: Always use fresh sealant. Using outdated sealant can result in leakage. Refer to Tools and Aids for a listing of approved sealants. Breather Cover 1. Install breather fi lter into closure plate. Breather Filter Alignment Pin 2.
  • Page 81 Reassembly Install Cylinder Head Cylinder Head Gasket Exhaust Valve Intake Valve Cylinder Head Spark Plug Valve Stem Seal Valve Spring Valve Spring Cap Retainer Lock Push Rod Guide Plate Rocker Stud Push Rod Rocker Pivot Rocker Arm Set Screw Cylinder Head Screw Assembly NOTE: Do not reuse cylinder head screws or gasket, Assemble Cylinder Head...
  • Page 82 Reassembly 1. Position push rod guide plate on cylinder head with 1. Make sure sealing surfaces of valve cover and extruded edges down over push rod bores. Secure cylinder head are clean, and free of any nicks or by installing rocker arm pivot studs. Torque studs to burrs.
  • Page 83 Reassembly Install Stator CAUTION Damaging Crankshaft and Flywheel can cause personal injury. Using improper procedures can lead to broken fragments. Broken fragments could be thrown from engine. Always observe and use precautions and procedures when installing fl ywheel. NOTE: Before installing fl ywheel make sure crankshaft taper and fl...
  • Page 84 Reassembly Install Ignition Module Install Oil Sentry or Pipe Plug ™ Apply pipe sealant with Tefl on (Loctite 592™ ® ® ® Thread Sealant or equivalent), to threads of 1/8” pipe plug. Install and tighten into port on closure plate. Torque pipe plug to 4.5-5.0 N·m (40-45 in.
  • Page 85 Reassembly Smart-Choke Install Intake Manifold Intake Manifold Intake Port Stud Gasket Indicator Tab Down Intake Manifold 1. Install a new gasket on intake port studs with Air Cleaner Adapter Indicator tab on gasket pointing down. Carburetor Gasket Indicator Tab Up (on 2.
  • Page 86 M6 screws. Position bracket as marked during disassembly. Torque screws to 11.3 N·m (100 in. lb.) into new holes, or 7.5 N·m (65 in. lb.) into used holes. Governor Spring Detail KS530 Governor Spring Throttle Stop Color 3600...
  • Page 87 Reassembly External Engine Components Oil Fill/Dipstick Oil Fill/Dipstick Tube Oil Filter Oil Drain Plug Standard Air Cleaner Air Cleaner Adapter Intake Manifold Intake Manifold Nut Cover PRO Air Cleaner Precleaner Paper Element Fuel Filter Cover Line Retained in Pulse Line Outlet Fuel Line Fuel Pump Housing...
  • Page 88 Reassembly Install Blower Housing Prepare Engine for Operation 1. Position blower housing on engine. Engine is now completely reassembled. Before starting or operating engine, be sure following have been done. 2. Align mounting locations, then install M6 shouldered mounting screws. 1.
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This manual is also suitable for:

Ks540Ks590Ks595

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