Kohler Courage SV710 Service Manual

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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

Specifications

Tools and Aids

Troubleshooting

Air Cleaner/Intake

Fuel System

Governor System

Lubrication System

Electrical System

Starter System

Emission Compliant Systems

Disassembly/Inspection and Service

Reassembly

32 690 01 Rev. D

KohlerEngines.com

Table of Contents

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 Specifications...
Page 2: Safety Precautions
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: Maintenance Instructions
² Have a Kohler authorized dealer perform this service. REPAIRS/SERVICE PARTS Kohler genuine service parts can be purchased from Kohler authorized dealers. To find a local Kohler authorized dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada). 32 690 01 Rev. D...
Page 4: Oil Recommendations
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: Specifications
Specifications Engine Dimensions Dimensions in millimeters. Inch equivalents shown in [ ]. 32 690 01 Rev. D KohlerEngines.com...
Page 6 Specifications Engine Dimensions Dimensions in millimeters. Inch equivalents shown in [ ]. KohlerEngines.com 32 690 01 Rev. D...
Page 7: Engine Identification Numbers
Kohler engine identification numbers (model, specification and serial) should be referenced for efficient repair, ordering correct parts, and engine replacement. Model ..... SV710 Courage Engine...
Page 8 Specifications TORQUE SPECIFICATIONS SV710 SV715 SV720 SV725 SV730 SV735 SV740 SV810 SV820 SV830 SV840 Cylinder Head Head Bolt Fastener (torque in 2 increments) first to 22.6 N·m (200 in. lb.) finally to 41.8 N·m (370 in. lb.) Rocker Arm Screw 11.3 N·m (100 in.
Page 9: Clearance Specifications
Specifications TORQUE SPECIFICATIONS SV710 SV715 SV720 SV725 SV730 SV735 SV740 SV810 SV820 SV830 SV840 Starter Assembly Thru Bolt Inertia Drive 4.5-5.7 N·m (40-50 in. lb.) Solenoid Shift 5.6-9.0 N·m (49-79 in. lb.) Mounting Screw 15.3 N·m (135 in. lb.) Brush Holder Mounting Screw 2.5-3.3 N·m (22-29 in.
Page 10 Specifications 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.)
Page 11 Specifications CLEARANCE SPECIFICATIONS SV710 SV715 SV720 SV725 SV730 SV735 SV740 SV810 SV820 SV830 SV840 Ignition Spark Plug Gap 0.76 mm (0.030 in.) Module Air Gap 0.28/0.33 mm (0.011/0.013 in.) Piston, Piston Rings, and Piston Pin Piston-to-Piston Pin Running Clearance 0.006/0.017 mm (0.0002/0.0007 in.) Pin Bore I.D.
Page 12: General Torque Values
Specifications 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 13: Tools And Aids
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 14 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 15 Tools and Aids FLYWHEEL HOLDING TOOL ROCKER ARM/CRANKSHAFT TOOL A flywheel holding tool can be made out of an old junk A spanner wrench to lift rocker arms or turn crankshaft flywheel ring gear and used in place of a strap wrench. may be made out of an old junk connecting rod.
Page 16: Troubleshooting Guide
Troubleshooting TROUBLESHOOTING GUIDE When troubles occur, be sure to check 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 and vary by engine specification. Use these to locate causing factors.
Page 17 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 18: Crankcase Vacuum Test
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 19: Compression Test
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 20: Air Cleaner/Intake
Air Cleaner/Intake AIR CLEANER Open air cleaner access door on blower housing and unhook latch. These systems are CARB/EPA certified and components should not be altered or modified in any way. Precleaner (if equipped) Air Cleaner Components 1. Remove precleaner. 2.
Page 21: Fuel Pump
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 22 Fuel System CARBURETOR Keihin One-Barrel Carburetor Components WARNING Explosive Fuel can cause fires and severe burns. Do not fill fuel tank while engine is hot or running. 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.
Page 23 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 24 Fuel System FUEL SYSTEM Carburetor Adjustments NOTE: Carburetor adjustments should be made only Fuel Shut-off Solenoid after engine has warmed up. Most carburetors are equipped with a fuel shut-off Carburetor is designed to deliver correct fuel-to-air solenoid. Solenoid is attached to fuel bowl. Solenoid has mixture to engine under all operating conditions.
Page 25 NOTE: Main and slow jets are fixed and size specific 1219 meters (4000 ft.). To obtain high altitude kit and can be removed if required. Fixed jets for information or to find a Kohler authorized dealer visit high altitudes are available. KohlerEngines.com or call1-800-544-2444 (U.S. and ●...
Page 26 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 27 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 28: 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 flyweight mechanical governor.
Page 29: 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-efficiency gerotor oil pump maintains high oil flow and oil pressure, even at low speeds and high operating temperatures.
Page 30 Lubrication System OIL SENTRY (if equipped) Installation ™ NOTE: Make sure oil level is checked before each use, 1. Apply pipe sealant with Teflon (Loctite 592™ ® ® ® and is maintained up to FULL or F mark on Thread Sealant or equivalent) to threads of switch. dipstick.
Page 31: 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 32 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 33 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 flywheel magnet group as referenced to engine TDC. A typical fixed ignition system consists of: ●...
Page 34 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 35 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 affixed to flywheel. ●...
Page 36 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 findings. 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 37 Electrical System Test Timing Advance (DSAI and DSAM only) 1. Make a line near edge of flywheel 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 38 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 39 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 40 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 flash three times and test will begin. NOTE: DSAM must be at room temperature when A reverse numerical sequence will be displayed, tested.
Page 41: Battery Charging System
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 rectifier-regulator plug and/or wiring harness plug before doing any electric welding on equipment powered by engine.
Page 42 Electrical System 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 43: 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 sufficient 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 44 If splines are dirty, clean them with solvent. 7. Splines should have a light film of lubricant. Lubricate as necessary with Kohler starter drive lubricant. Reinstall or replace drive components, assembling them in reverse order they were removed.
Page 45 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 46 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 47 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 flush or below machined surface of...
Page 48 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 49: Emission Compliant Systems
To Carburetor Filter For engine to be Tier III compliant, it may be fitted 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 50 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 51 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 52: Disassembly/Inspection And Service
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 53 Disassembly/Inspection and Service Clean all parts thoroughly as engine is disassembled. Remove Blower Housing and Outer Baffles Only clean parts can be accurately inspected 1. Remove screws securing blower housing. and gauged for wear or damage. There are many commercially available cleaners that will quickly remove 2.
Page 54 Disassembly/Inspection and Service Remove Air Cleaner and Carburetor Remove Electric Starter Motor 1. Disconnect leads from starter. WARNING 2. Remove screws and starter. Explosive Fuel can cause fires and severe 3. Pull out oil fill tube with lifting strap from crankcase. burns.
Page 55 Disassembly/Inspection and Service Cylinder Head Components Gasket Valve Cylinder Head 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 Valve Cover 3. Sealing surface of stamped steel valve covers must Remove Spark Plugs be checked for flatness prior to reinstallation.
Page 56 Disassembly/Inspection and Service 3. Once valve spring is compressed, remove following Disassemble Cylinder Heads items. NOTE: On engines with valve stem seals on intake ● Valve spring keepers. valves; use a new seal whenever valve is ● Valve spring retainers. removed or if seal is deteriorated or damaged.
Page 57 Disassembly/Inspection and Service Valve Guides Flywheel/Ignition/Breather Components If a valve guide is worn beyond specifications, it will not guide 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 valve guide and, using a split-ball gauge, measure inside diameter of guide.
Page 58 Replace flywheel if it is cracked. Replace flywheel, crankshaft, and key if flywheel 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 flywheel if ring gear is damaged.
Page 59 Disassembly/Inspection and Service 3. Carefully inspect governor gear shaft and replace it Remove Oil Pan Assembly only if it is damaged. After removing damaged shaft, 1. Remove screws securing oil pan to crankcase. press or lightly tap replacement shaft into oil pan to depth shown.
Page 60 Replace tappet(s) if condition is questionable in any way. Corresponding camshaft lobe(s) should also be checked for wear or damage. Whenever tappets are replaced, apply a liberal coating of Kohler lubricant to base of each new tappet before it is installed. Remove Governor Cross Shaft...
Page 61 Disassembly/Inspection and Service A piston pin is included as part of piston assembly – if Connecting Rods pin boss in piston or pin are worn or damaged, a new Offset, stepped-cap connecting rods are used in all piston assembly is required. these engines.
Page 62 Inspect crankpin for score marks or metallic pickup. Slight score marks can be cleaned with crocus cloth NOTE: Kohler pistons are custom-machined to exacting soaked in oil. If wear limits are exceeded, as stated in tolerances. When over-sizing a cylinder, it Specifications, it will be necessary to replace crankshaft.
Page 63 Disassembly/Inspection and Service 1. Lower hone into bore and after centering, adjust so Measuring Piston-to-Bore Clearance stones are in contact with cylinder wall. Use of a Piston Detail commercial cutting-cooling agent is recommended. 2. With lower edge of each stone positioned even with lowest edge of bore, start drill and honing process.
Page 64 Reassembly NOTE: Make sure engine is assembled using all Install Flywheel End Oil Seal specified torque values, tightening sequences, 1. Make sure seal bore of crankcase is clean and free and clearances. Failure to observe specifications of any nicks or burrs. could cause severe engine wear or damage.
Page 65 Reassembly Crankshaft/Governor Gear/Oil Pump Components Install Crankshaft 1. Lubricate flywheel side main bearing surface and lips of oil seal in crankcase with clean engine oil. 2. Carefully slide flywheel end of crankshaft through main bearing in crankcase. Install Connecting Rods with Pistons and Rings Piston and Connecting Rod Details Side 1 Side 2...
Page 66 Reassembly Install Valve Tappets and Camshaft Install Oil Seal in Oil Pan NOTE: Exhaust valve tappets are located on output Oil Seal Component and Detail shaft side of engine, while intake valve tappets are located on fan side of engine. Cylinder number is embossed on outside of each cylinder on crankcase.
Page 67 Reassembly Install Oil Pan Assembly Flywheel/Ignition/Breather Components Sealant Pattern Fastener Torque Sequence RTV sealant is used as a gasket between oil pan and crankcase. Refer to Tools and Aids for a listing of approved sealants. Always use fresh sealant. Using outdated sealant can result in leakage.
Page 68 Reassembly Install Breather Reed and Outer Cover Install Flywheel and Fan Breather Cover Sealant 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 flywheel.
Page 69 Reassembly 5. Insert a 0.30 mm (0.012 in.) flat feeler gauge 8. Rotate flywheel back and forth checking for between magnet and ignition module. Loosen clearance between magnet and ignition modules. screws enough to allow magnet to pull module Make sure magnet does not strike modules. Check against feeler gauge.
Page 70 Reassembly Assemble and Install Cylinder Heads Adjust Valve Clearance Valve Stem Seals Adjusters Retaining Push Rods Some engines use a valve stem seal on intake valves. If engine being serviced used a valve stem seal, use a new seal whenever valve is removed, or if seal is deteriorated or damaged.
Page 71 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 72 Reassembly External Engine Components Air Cleaner Fixed Guard Debris Screen Blower Housing Access Door Hose Clamp Fuel Pump Hose Clip Fuel Line Fuel Filter Oil Filter Nipple O-Ring Oil Feed Tube Oil Feed Tube Outer Baffle Electric Starter (Oil Pump Outlet) (Filter to Pan) Inner Baffle Ignition Module...
Page 73 Reassembly Install Intake Manifold Install Carburetor Torque Sequence WARNING Explosive Fuel can cause fires and severe burns. Do not fill fuel tank while engine is hot or running. Gasoline is extremely flammable 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 74 Reassembly RPM Chart Throttle and Choke Components High Idle Governor Lever Governor Spring Hole No. Color Code 2900 Black 3300 Orange 1. Connect choke linkage to choke actuator lever on main control bracket assembly. 2. Install main control bracket to cylinder heads using screws.
Page 75 Reassembly Install Fuel Pump Install Muffler 1. Install muffler and attaching hardware to muffler WARNING bracket. Torque screws to 9.9 N·m (88 in. lb.). Explosive Fuel can cause fires and severe 2. Install M8 nuts or 5/16-18 head capscrews (based burns.

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Kohler Courage SV710 Service Manual

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