Table Of Contents - Kohler KS530 Service Manual

Table of Contents

Contents1
Safety Precautions2
Maintenance Instructions3
Maintenance Schedule3
Repairs/Service Parts3
Every 100 Hours3
Maintenance4
Oil Recommendations4
Storage4
Fuel Recommendations4
Engine Dimensions-Flywheel Side5
Specifications5
Engine Dimensions-Starter Side6
Engine Dimensions-Pto Side7
Engine Dimensions-Oil Filter Side8
Engine Dimensions-Valve Cover Side9
Engine Identification Numbers10
General Specifications10
Torque Sequences10
Connecting Rod Fasteners10
Clearance Specifications14
General Torque Values17
English Fastener Torque Recommendations For Standard Applications17
Metric Fastener Torque Recommendations For Standard Applications17
Tools And Aids18
Separate Tool Suppliers18
Aids20
Flywheel Holding Tool20
Rocker Arm/Crankshaft Tool20
Troubleshooting Guide21
Engine Cranks But Will Not Start21
Engine Starts But Does Not Keep Running21
Engine Starts Hard21
Engine Loses Power22
Engine Uses Excessive Amount Of Oil22
Oil Leaks From Oil Seals, Gaskets22
External Engine Inspection22
Crankcase Vacuum Test23
To Test Crankcase Vacuum With Manometer23
Compression Test24
Cylinder Leakdown Test24
Air Cleaner25
Air Cleaner Components25
Precleaner25
Paper Element25
Breather Tube25
Air Cooling25
Fuel System26
Fuel Line26
Fuel Pump26
Auto Choke26
Fuel System Tests27
Carburetor28
Typical One-Barrel Carburetor Components28
Troubleshooting Checklist28
Troubleshooting-Carburetor Related Causes29
Fuel Shut-Off Solenoid29
Carburetor Circuits30
Carburetor Adjustments30
Carburetor Servicing30
Slow And Mid-Range30
High Altitude Operation31
Smart-Choke32
Smart-Choke Components32
Troubleshooting Smart-Choke33
Smart-Choke System Troubleshooting33
Starting An Engine Equipped With Smart-Choke34
Controls34
Unitized Throttle And Choke Control34
Throttle/Choke Controls Details34
Starting Throttle Control Details35
High Speed (Rpm) Adjustment35
Speed Control Bracket Details35
Governed Idle Adjustment36
Install Separate Control Cables36
Speed Control Bracket Alignment Hole Details36
Choke Control Installation37
Starting An Engine Equipped With Separate Control Cables37
Setting Low Idle Rpm37
Governor System38
Governor Components38
Governor Adjustments39
Governor Sensitivity Adjustment39
Lubrication System40
Lubrication Components40
Check Oil Level40
Change Oil And Filter40
3-Terminal Switch41
Single-Terminal Switch41
Oil Pressure41
Single Terminal Oil Pressure41
Electrical System42
Battery Charging System42
Fixed Ignition System42
Ignition System Components42
Wiring Diagram-12/15 Amp Regulated Battery Charging System43
12/15 Amp Battery Charging Systems47
To Test Charging System47
Ignition System48
Spark Plug48
Wet Fouled48
Electronic Ignition System Tests49
Carbon Fouled49
Overheated49
Test For Spark50
Test Ignition Module With Ohmmeter50
Fuel Shut-Off Relay Circuit51
Troubleshooting-Fuel Shut-Off Relay System51
Fuel Shut-Off Relay Harness Connections51
Engine Operates As Designed52
Engine Cranks But Will Not Start (Voltage At Yellow Wire)52
Blade Stop Stator Brake And Fuel Shut-Off Circuit53
Stator Brake And Fuel Shut-Off Relay Harness Connections53
Troubleshooting-Stator Brake System54
To Test For Dead Battery54
To Test Engine That Will Crank But Will Not Start54
Troubleshooting-Starting Difficulties55
Inertia Drive Electric Starters55
Starter System55
Inertia Drive Starter Tests56
Before Starting56
Test 1 Conclusions56
Emission Compliant Systems57
Evaporative Emission Compliant System57
Carbon Canister System57
Secondary Emission Compliant System58
Secondary Air Induction System58
Remove Inlet Screen59
Inlet Components59
Disassembly/Inspection And Service60
External Engine Components60
Disconnect Spark Plug Lead61
Turn Off Fuel Supply61
Drain Oil From Crankcase And Remove Oil Filter61
Remove Air Cleaner61
Standard Choke62
Remove External Governor Components63
Remove Oil Fill/Dipstick Tube63
Remove Oil Sentry Pressure Switch63
Remove Wiring Harness63
Remove Debris Screen, Fan, And Flywheel64
Flywheel Inspection64
Remove Stator65
Remove Electric Starter65
Remove Cylinder Head Baffle65
Remove Valve Cover65
Remove Cylinder Head66
Inspection And Service67
Valve Details67
Valve Guides67
Exhaust Valve67
Valve Seat Inserts68
Lapping Valves68
Remove Breather68
Remove Closure Plate68
Governor Gear Inspection69
Remove Governor Gear And Oil Passage Cover69
Governor Shaft Inspection69
Remove Governor Shaft69
Remove Camshaft70
Automatic Compression Release (Acr)70
Remove Balance Shafts70
Remove Connecting Rod And Piston71
Piston And Rings Inspection71
Remove Piston From Connecting Rod71
Remove Piston Rings71
Piston And Rings72
Piston And Rings Components And Details72
Install New Piston Rings72
Piston Ring Orientation72
Remove Crankshaft73
Remove Oil Pump Assembly73
Crankshaft And Crankshaft Gear Inspection And Service73
Oil Pump Inspection73
Remove Cam Levers74
Remove Governor Cross Shaft74
Remove Oil Baffle74
Crankcase74
Honing75
Clean Cylinder Bore After Honing75
Measuring Piston-To-Bore Clearance Piston Detail75
Install Pto Side Oil Seal76
Pto Seal Depth Details76
Install Oil Baffle76
Install Governor Cross Shaft76
Install Cam Levers77
Install Oil Pump And Oil Pump Housing Assembly77
Install Crankshaft And Crankshaft Gear77
Install Piston To Connecting Rod78
Connecting Rod Fastener Torque Sequence78
Install Balance Shafts78
Balance Shaft 1 Timing Mark Detail78
Install Camshaft79
Install Flywheel Side Oil Seal79
Oil Seal Depth Details79
Closure Plate Sealant Pattern On Crankcase79
Install Breather80
Breather Cover Sealant Pattern80
Sealant Bead On Closure Plate80
Install Cylinder Head81
Assemble Cylinder Head81
Cylinder Head Torque Sequence81
Install Rocker Arms And Push Rods81
Valve Cover Sealant Pattern82
Valve Cover Torque Sequence82
Install Spark Plug82
Install Cylinder Head Baffle82
Install Stator83
Install Fan And Flywheel83
Install Wiring Harness83
Install Ignition Module84
Install Rectifier-Regulator84
Install Oil Sentry Or Pipe Plug84
Install Oil Fill Tube84
Install Intake Manifold85
Install Carburetor85
Connect Wire Controls86
Mounting Speed Control Bracket86
Governor Spring Detail86
Reassembly88
Install Blower Housing88
Install Fixed Guard88
Install Fuel Pump88