Kohler Courage SV710-740 Service Manual
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Kohler Courage SV710-740 Service Manual

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Summary of Contents for Kohler Courage SV710-740

  • Page 1 ervice anual COURAGE sV710-740 COURAGE PRO sV810-840 ertical rankshaft...

  • Page 3: Table Of Contents

    Contents Section 1. Safety and General Information ................Section 2. Tools & Aids ......................Section 3. Troubleshooting ...................... Section 4. Air Cleaner and Air Intake System ................. Section 5. Fuel System and Governor ..................Section 6. Lubrication System ....................Section 7. Electrical System and Components ..............Section 8.
  • Page 5 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. Warning is used to indicate the presence of a hazard that cause personal injury, death, or substantial property damage if the warning is ignored.
  • Page 6 Explosive Gas can cause fires and Explosive Fuel can cause fires and Carbon Monoxide can cause severe severe acid burns. severe burns. nausea, fainting or death. Charge battery only in a well Do not fill the fuel tank while the Avoid inhaling exhaust fumes, and ventilated area.
  • Page 7 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. The engine identification numbers appear on a decal, or decals, affixed to the engine shrouding. See Figure 1-1.
  • Page 8 Gasohol (up to 10% ethyl alcohol, 90% unleaded A logo or symbol on oil containers identifies the API gasoline by volume) is approved as a fuel for Kohler service class and SAE viscosity grade. See Figure 1-3. engines. Other gasoline/alcohol blends including E20 and E85 are not to be used and not approved.
  • Page 9 Normal maintenance, replacement or repair of emission control devices and systems may be performed by any repair establishment or individual; however, warranty repairs must be performed by a Kohler authorized service center. • Fill fuel tank. Section 5 • Check oil level.
  • Page 11 342.40 357.74 [13.480] [14.084] 420.81 [16.567] 466.27 [18.357] 480.92 [18.934]...
  • Page 12 Power (@ 3600 RPM, Horsepower ratings exceed Society of Automotive Engineers Small Engine Test Code J1940.) SV710, SV810 ......................14.9 kW (20 HP) SV715 ........................16.4 kW (22 HP) SV720, SV820 ......................17.2 kW (23 HP) SV725 ........................17.9 kW (24 HP) SV730, SV830 ......................18.6 kW (25 HP) SV735 ........................19.4 kW (26 HP) SV740, SV840 ......................20.1 kW (27 HP) Bore ..........................83 mm (3.27 in.)
  • Page 13 Cap Fastener Torque (torque in increments)............11.3 N·m (100 in. lb.) Connecting Rod-to-Crankpin Running Clearance New ........................0.030/0.055 mm (0.0012/0.0022 in.) Max. Wear Limit ....................0.070 mm (0.0028 in.) Connecting Rod-to-Crankpin Side Clearance ............0.26/0.63 mm (0.0102/0.0248 in.) Connecting Rod-to-Piston Pin Running Clearance ..........0.015/0.028 mm (0.0006/0.0011 in.) Piston Pin End I.D.
  • Page 14 Oil Pan End Main Bearing Journal O.D. - New ......................40.913/40.935 mm (1.6107/1.6116 in.) O.D. - Max. Wear Limit ..................40.84 mm (1.608 in.) Max. Taper ......................0.022 mm (0.0009 in.) Max. Out-of-Round .....................0.025 mm (0.0010 in.) Connecting Rod Journal O.D. - New ......................35.955/35.973 mm (1.4156/1.4163 in.) O.D.
  • Page 15 Governor Lever Nut Torque ..................6.8 N·m (60 in. lb.) Spark Plug Type (Champion ® or Equivalent) ............RC12YC, XC12YC, or Platinum 3071 Spark Plug Gap ......................0.76 mm (0.030 in.) Spark Plug Torque.....................24.4-29.8 N·m (18-22 ft. lb.) Ignition Module Air Gap ..................0.28/0.33 mm (0.011/0.013 in.) Ignition Module Fastener Torque ................4.0-6.2 N·m (35-55 in.
  • Page 16 Fastener Torque ......................10.7 N·m (95 in. lb.) into new holes 7.3 N·m (65 in. lb.) into used holes Thru Bolt Torque FASCO (Inertia Drive) ..................4.5-5.7 N·m (40-50 in. lb.) Delco-Remy (Solenoid Shift) ................5.6-9.0 N·m (49-79 in. lb.) Mounting Screw Torque (All)..................15.3 N·m (135 in. lb.) Brush Holder Mounting Screw Torque Delco-Remy Starter ....................2.5-3.3 N·m (22-29 in.
  • Page 17 Size 1.2 (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)
  • Page 18 Size 8-32 2.3 (20) 2.8 (25) --------- 2.3 (20) 10-24 3.6 (32) 4.5 (40) --------- 3.6 (32) 10-32 3.6 (32) 4.5 (40) --------- --------- 1/4-20 7.9 (70) 13.0 (115) 18.7 (165) 7.9 (70) 1/4-28 9.6 (85) 15.8 (140) 22.6 (200) --------- 5/16-18 17.0 (150)

  • Page 19: Section 2. Tools & Aids

    Camshaft Seal Protector (Aegis) SE Tools KLR-82417 To protect seal during camshaft installation. Cylinder Leakdown Tester Kohler 25 761 05-S For checking combustion retention and if cylinder, piston, rings, or valves are worn. Electronic Fuel Injection (EFI) Diagnostic Software Kohler 25 761 23-S Use with Laptop or Desktop PC.
  • Page 20 Tools & Aids Tools (Continued) Description Source/Part No. Hydraulic Valve Lifter Tool Kohler 25 761 38-S To remove and install hydraulic lifters. Ignition System Tester Kohler 25 455 01-S For testing output on all systems, except CD. Kohler 24 455 02-S For testing output on capacitive discharge (CD) ignition system.
  • Page 21 Section 2 Tools & Aids Aids Description Source/Part No. Camshaft Lubricant (Valspar ZZ613) Kohler 25 357 14-S Dielectric Grease (GE/Novaguard G661) Kohler 25 357 11-S Dielectric Grease (Fel-Pro) Lubri-Sel Electric Starter Drive Lubricant (Inertia Drive) Kohler 52 357 01-S Electric Starter Drive Lubricant (Solenoid Shift)
  • Page 22 4. Use a flat washer with the correct I.D. to slip on 1. Using an abrasive cut-off wheel, cut out a six the capscrew and approximately 1” O.D. (Kohler tooth segment of the ring gear as shown. Part No. 12 468 05-S). Assemble the capscrew and washer to the joint surface of the rod, as 2.

  • Page 23: Section 3. Troubleshooting

    Section 3 Troubleshooting Section 3 Troubleshooting Troubleshooting Guide Engine Starts Hard 1. PTO drive is engaged. When troubles occur, be sure to check the simple 2. Dirt or water in the fuel system. causes which, at first, may seem too obvious to be 3.
  • Page 24 Section 3 Troubleshooting Engine Will Not Idle Engine Uses Excessive Amount of Oil 1. Dirt or water in the fuel system. 1. Incorrect oil viscosity/type. 2. Stale fuel and/or gum in carburetor. 2. Clogged or improperly assembled breather. 3. Faulty spark plugs. 3.
  • Page 25 To test the crankcase vacuum with the Vacuum/ carefully. Pressure Gauge Kit (Kohler Part No. 25 761 22-S): Make sure all traces of the cleaner are removed before 1. Remove the dipstick or oil fill plug/cap.
  • Page 26 5. Connect an air source of at least 50 psi to the tester. Kohler Part No. 25 761 05-S is a relatively simple, inexpensive leakdown tester for small engines. The 6. Turn the regulator knob in the increase direction...
  • Page 27 Section 3 Troubleshooting Leakdown Test Results Air escaping from crankcase breather ............Rings or cylinder worn. Air escaping from exhaust system ............. Defective exhaust valve/improper seating. Air escaping from carburetor ..............Defective intake valve/improper seating. Gauge reading in “low” (green) zone ............Piston rings and cylinder in good condition. Gauge reading in “moderate”...
  • Page 28 Section 3 Troubleshooting...
  • Page 29 To service the precleaner, see Figures 4-1 and 4-2, and perform the following steps: 1. Open the door on the blower housing to access Air cleaner systems used on these engines will be the air cleaner element and precleaner. (On Pro either the standard size or PRO Series increased models the door can be removed).
  • Page 30 100 hours of operation (more often Replace a dirty, bent, or damaged element with under extremely dusty or dirty conditions). See Figure a genuine Kohler element. Handle new elements 4-1, and follow these steps: carefully; do not use if the sealing surface is bent or damaged.
  • Page 31 To ensure proper cooling, make sure the grass screen, cooling fan fins, and other external surfaces of the If the air cleaner base requires removal, proceed as engine are kept clean at all times. follows: Annually or every 100 hours of operation (more often 1.
  • Page 33 Gasohol (up to 10% ethyl alcohol, 90% unleaded feed fuel to the carburetor. gasoline by volume) is approved as a fuel for Kohler engines. Other gasoline/alcohol blends including E20 Fuel then enters the carburetor float bowl and is and E85 are not to be used and not approved.
  • Page 34 Most engines are equipped with an in-line filter. Periodically inspect the filter and replace annually or every 100 hours with a genuine Kohler filter. When the engine starts hard, or turns over but will not start, it is possible that the problem is in the fuel system.
  • Page 35 Replacement pumps are available through your source of supply. To replace the pulse pump follow these steps. Note the orientation of the pump before On engines equipped with a pulse type fuel pump, the removing. pumping action is created by the oscillation of positive and negative pressures within the crankcase.

  • Page 36: Section 5. Fuel System And Governor

    Section 5 Fuel System and Governor Slow Circuit: (See Figure 5-2) At low speeds the engine operates only on the slow circuit. As a metered amount of air is drawn through the slow air bleed jet, fuel is drawn through the main jet and further metered through the slow jet.
  • Page 37 Section 5 Fuel System and Governor Main Circuit: (See Figure 5-3) At high speeds/loads the engine operates on the main circuit. As a metered amount of air is drawn through the main air bleed jet, fuel is drawn through the main jet. The air and fuel are mixed in the main nozzle and then enter the main body of airflow, where further mixing of the fuel and air takes place.
  • Page 38 1. Engine starts hard, runs roughly 1. Low idle fuel mixture (some models)/speed improperly adjusted. or stalls at idle speed. Adjust the low idle speed tab, then adjust the low idle fuel needle. 2. Engine runs rich (indicated by 2a. Clogged air cleaner. Clean or replace. black, sooty exhaust smoke, b.
  • Page 39 To obtain high altitude kit information or locate a dealer near you, call 1-800-544-2444 to find the names of the nearest Kohler Co. Service Centers or, access our web site at: www.kohlerengines.com and click on the “Service & Dealer Locator” located in the upper right hand corner.
  • Page 40 4. Low Idle Speed Setting: Place the throttle control NOTE: The tip of the idle fuel adjusting screw is into the idle or slow position. Set the low idle tapered to critical dimensions. Damage speed to 1200 RPM* (± 75 RPM) by turning the to the needle end and the seat in the low idle speed adjusting screw in or out.
  • Page 41 3. Release the governor lever and allow the engine to return to the governed idle speed. Check it with a tachometer against the equipment manufacturers recommended idle speed. Governed Idle Speed (RPM) is typically 300 RPM (approximate) higher than the low idle speed. If adjustment is necessary, bend the adjusting tab on the speed control assembly to set.
  • Page 42 NOTE: Be sure to measure from the casting 5. Install the float and inlet needle down into the surface, not the rubber gasket, if still seat and carburetor body. Insert the new pivot attached. pin through the float hinge and secure with the new retaining screw.
  • Page 43 NOTE: Further disassembly of fuel bowl is not 4. Remove the two screws securing the top cover, necessary unless a Fuel Solenoid Kit gasket, and ground lead (fuel solenoid-equipped models). Discard the gasket and screws only. (obtained separately), is also being installed. 5.
  • Page 44 9. Install the slow jet and new plug into end of slow 11. Install the float and inlet needle down into the jet tube. See Figures 5-19 and 5-20. seat and carburetor body. Insert the new pivot pin through the float hinge and secure with the new retaining screw.
  • Page 45 16. Install the new cover gasket and top cover on the carburetor. Secure with the two large-head screws and attach the ground lead (if equipped with a fuel solenoid), to the original screw location. Torque the top cover screws to 2.5 ±...
  • Page 46 1. Remove the carburetor from the engine. Discard the old mounting gaskets for the air cleaner and carburetor. 2. Clean the areas around the choke shaft and the self-relieving choke mechanism thoroughly. 3. Remove and discard the plastic cap from the top of the choke lever/shaft assembly.
  • Page 47 If symptoms described in the carburetor troubleshooting guide indicate float level problems, remove the carburetor from the engine to check and/ or replace the float. Use a float kit to replace float, pin and inlet needle or valve. 1. Remove the air cleaner and air intake components from the carburetor as described in Section 4.
  • Page 48 float components are to be replaced). Refer to cover to the body, remove the cover gasket. Figure 5-33 for parts identification. The Kohler part number and the Nikki lot number are stamped on 7. Remove the idle fuel adjusting needle and spring the choke side flange on top of the carburetor body.
  • Page 49 1. Carburetor Body 2. Idle Fuel Adjusting Screw* 3. Idle Fuel Adjusting Spring* 4. Passage Cover 5. Cover Gasket* 6. Cover Retaining Screw 7. Main Jet 8. Ground Lead (Solenoid only) 9. Fuel Bowl Gasket 10. Float Kit 11. Fuel Bowl 12.
  • Page 50 • When the engine is at rest, and the throttle is Always use new gaskets when servicing or in the fast position, the tension of the governor reinstalling carburetors. Repair kits are available spring holds the throttle plate open. When the which include new gaskets and other components.
  • Page 51 Make this adjustment whenever the governor arm is 1. To increase the sensitivity, move the spring closer loosened or removed from the cross shaft. See Figure to the governor lever pivot point. 5-34 and adjust as follows: 2. To decrease the sensitivity, move the spring away 1.

  • Page 53: Section 6. Lubrication System

    5W-20, 5W-30 such as API SERVICE CLASS SJ. The symbol may show additional categories such as SH, SG/CC, or Kohler 10W-30 CD. The center portion shows the viscosity grade such °F -20 as SAE 10W-30. If the bottom portion shows "Energy °C -30...
  • Page 54 Refill with service class SJ oil as specified in the ‘‘Viscosity Grades’’ table. Always use a genuine Kohler oil filter. Change the oil while the engine is still warm. The oil will flow more freely and carry away more impurities.
  • Page 55 4. Remove the old filter and wipe off the filter adapter with a clean cloth. See Figure 6-6. To service the oil cooler, clean the outside of fins with a soft brush. See Figure 6- 7. Remove the mounting screws holding the cooler unit to the blower housing. Tilt the cooler outward as shown in Figure 6-8.
  • Page 56 On stationary or unattended applications (pumps, To install the switch, follow these steps: generators, etc.), the pressure switch can be used to ® ® ground the ignition module to stop the engine. On 1. Apply pipe sealant with Teflon (Loctite vehicular applications (lawn tractors, mowers, etc.) 59241 or equivalent) to the threads of the switch.
  • Page 57 The standard spark plug is a Champion RC12YC (Kohler Part No. 12 132 02-S). RFI compliant engines use a Champion ® XC12YC (Kohler 25 132 14-S) spark plug. A high-performance spark plug, Champion ® Platinum 3071 (Kohler Part No. 25 132 12-S) is also available.
  • Page 58 Normal: A plug taken from an engine operating under Wet Fouled: A wet plug is caused by excess fuel or normal conditions will have light tan or gray colored oil in the combustion chamber. Excess fuel could deposits. If the center electrode is not worn, a plug be caused by a restricted air cleaner, a carburetor in this condition could be set to the proper gap and problem, or operating the engine with too much...
  • Page 59 2. Keep the cables, terminals, and external surfaces of the battery clean. A build-up of corrosive acid or grime on the external surfaces can cause the battery to self-discharge. Self-discharge occurs A 12-volt battery with minimum of 400 cold cranking rapidly when moisture is present.
  • Page 60 There are three different types of ignition systems used on the Courage twin cylinder engines. 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).
  • Page 61 The timing of the spark is controlled by the location of the flywheel magnet group as referenced to engine top dead center. NOTE: The CD ignition systems are sensitive to The CD ignition systems are designed to be trouble excessive load on the kill lead. If a customer free for the life of the engine.
  • Page 62 Each DSAI module performs its function isolated until all testing is completed. independently for each engine cylinder. 2. Test for spark on both cylinders with Kohler ignition tester, (Kohler Part No. 24 455 02-S). The DSAI ignition system is designed to be trouble Disconnect one spark plug lead and connect it to free for the life of the engine.
  • Page 63 Connect the spark plug lead to post lead terminal so it cannot touch ground. Try to terminal of spark tester (Kohler Part No. start the engine to verify whether the reported 25 455 01-S), and attach tester clip to a good problem is still present.
  • Page 64 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. If both cylinders have good spark but the engine runs poorly, or existing plug(s) condition or appearance is questionable, install new spark plugs gapped at...
  • Page 65 4. Turn the key switch to the ON position and When the charge on the delay capacitor exceeds the check for 12 volts at the center/power (red) lead charge on the charge pump capacitor, the capacitor terminal of the DSAI module. Use the same changes state, activating the pulse generator.
  • Page 66 The timing of the spark is controlled by the location of the flywheel magnet group as referenced to engine top dead center and the delay created by the spark advance module.
  • Page 67 1. With the engine stopped, disconnect one spark plug lead. Connect the spark plug lead to post terminal of spark tester (Kohler Part No. • Hand Tachometer 24 455 02-S), and attach tester clip to a good •...
  • Page 68 3. Repeat the spark test on the opposite cylinder if cylinders are being tested individually. a. If both cylinders have good spark but the engine runs poorly, install new spark plugs gapped at 0.76 mm (0.030 in.), and retest engine performance. If problem persists, go to Test 3.
  • Page 69 5) Loosen the mounting screws, allow the NOTE: The resistance values apply only to magnet to pull the module down against modules that have been on a running the feeler gauge, and retighten the mounting engine. New service modules may have screws.
  • Page 70 Brown tester lead with black band or terminal 4. Seal the base of the ignition module connections to the short brown module lead. with GE/Novaguard G661 (Kohler Part No. 25 357 11-S) or Fel-Pro Lubri-Sel dielectric Caution: Do not allow the alligator clip leads to touch compound.
  • Page 71 The tester is powered by a 9-volt battery. ______ ______ ______ 24 584 31 Most SAM’s are designed to operate down to a minimum of 7.25 volts. If the tester battery drops below that level, incorrect test readings will result. The tester battery should be checked periodically by connecting a DC voltmeter ______ ______...

  • Page 72: Section 7. Electrical System And Components

    Section 7 Electrical System and Components Figure 7-16. Wiring Diagram – Fixed Timing Ignition System. 7.16...
  • Page 73 Section 7 Electrical System and Components Figure 7-17. Wiring Diagram – DSAI Ignition System. 7.17...
  • Page 74 Section 7 Electrical System and Components Figure 7-18. Wiring Diagram – DSAM Ignition System. 7.18...
  • Page 75 Testing of the rectifier-regulator may be performed as follows, using the appropriate Rectifier-Regulator Tester. 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.
  • Page 76 3. Plug the tester into a 110 volt AC outlet and turn on the power switch. See Figure 7-23. The 1. Connect the single lead adapter in between the B+ POWER light should be illuminated and one of (center) terminal of the rectifier-regulator being the four status lights may be on as well.
  • Page 77 b. If any other light is displayed* in either of the 6. Press the TEST button until a click is heard and tests, the rectifier-regulator is faulty and then release. See Figure 7-24. Momentarily one should not be used. of the four status lights will illuminate indicating the partial condition of the part.
  • Page 78 1. If voltage is 13.8-14.7 and charge rate increases 1. Trace B+ lead from rectifier-regulator to when load is applied, the charging system is key switch, or other accessible connection. OK and battery was fully charged. Disconnect it from switch or connection. Connect an ammeter from loose end of B+ If voltage is less than 13.8 or charge rate does lead to positive terminal of battery.
  • Page 79 NOTE: If the starter does not crank the engine, shut off the starter immediately. Do not make Refer to the Disassembly and Reassembly Sections for further attempts to start the engine until the starter removal and installation procedures. condition is corrected. NOTE: Do not drop the starter or strike the starter This subsection covers the operation, troubleshooting, frame.
  • Page 80 3. Remove the retaining ring from the armature shaft using either a retaining ring pliers or snap ring removal tool (Kohler Part No. 25 761 18-S), as described in Steps 4, and 5. See Figures 7-30, 7-31, and 7-32. Do not reuse the old retainer.
  • Page 81 See Figure 7-33. Lubricate as necessary with tool around the armature shaft with the retaining Kohler starter drive lubricant (Kohler Part No. ring in the inner groove (see Figure 7-31). Slide 52 357 01-S). Reinstall or replace the drive...
  • Page 82 Clean the commutator with a coarse, lint free cloth. Do not use emery cloth. If the commutator is badly worn or grooved, turn it down on a lathe or replace the starter. 1. Insert the armature into the starter frame. Make sure the magnets are closer to the drive shaft end of the armature.
  • Page 83 (+) brush lead/bracket from the solenoid terminal. 2. Remove the three Torx head screws securing the 6. Lubricate the drive shaft with Kohler starter drive solenoid to the starter. See Figure 7-39. lubricant (Kohler Part No. 52 357 01-S). Install the drive components following the instructions for servicing the starter drive.
  • Page 84 6. Remove the frame from the armature and drive end cap. See Figure 7-44. 4. Remove the two thru (larger) bolts. See Figure 7-42. 7. Remove the drive lever pivot bushing and backing plate from the end cap. See Figure 7-45. 5.
  • Page 85 8. Take out the drive lever and pull the armature 11. Remove the retainer from the armature shaft. out of the drive end cap. See Figure 7-46. Save the stop collar. 9. Remove the thrust washer from the armature NOTE: Do not reuse the old retainer.
  • Page 86 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.
  • Page 87 The brushes and springs are serviced as a set (4). Use Brush and Spring Kit, Kohler Part No. 25 221 01-S, 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).
  • Page 88 5. Lubricate the fork end and center pivot of the pliers to compress it in the groove. drive lever with drive lubricant (Kohler Part No. 52 357 02-S). Position the fork end into the space c. Slide the stop collar up and lock it into place,...
  • Page 89 7. 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 7-58. 10.
  • Page 90 b. Position each of the brushes back in their slots so they are flush with the I.D. of the brush 11. Install the end cap onto the armature and frame, holder assembly. Insert the Brush Installation aligning the thin raised rib in the end cap with Tool with extension, or use the tube described the corresponding slot in the grommet of the above from a prior brush installation, through...
  • Page 91 Disconnect all leads from the solenoid including the positive brush lead attached to the lower stud terminal. Remove the mounting hardware and separate the solenoid from the starter for testing. Use a 12 volt power supply and two test leads. Connect one lead to the flat spade S/start terminal on the solenoid.
  • Page 92 Use an ohmmeter set to the audible or Rx2K scale, and Use an ohmmeter set to the audible or Rx2K scale, and connect the two ohmmeter leads to the two large post connect the two ohmmeter leads to the two large post terminals.

  • Page 93: Section 8. Disassembly

    Section 8 Disassembly Section 8 Disassembly WARNING: Accidental Starts! Disabling engine. Accidental starting can cause severe injury or death. Before working on the engine or equipment, Clean all parts thoroughly as the engine is 21. Remove camshaft and valve tappets. disassembled.
  • Page 94 Section 8 Disassembly Notch Adapter Oil Fill Cap/Dipstick Locating Nipple Drain Plug Figure 8-2. Removing Oil Fill Cap/Dipstick. Figure 8-4. Removing Oil Filter Adapter. 5. If an oil cooler is used remove the mounting screws securing the cooler unit to the blower housing.

  • Page 95: Remove Throttle Controls

    Section 8 Disassembly 1. Remove the exhaust system and attaching hardware from the engine. Remove Fuel Pump (Equipped Models) WARNING: Explosive Fuel! Four Locations Two in Front (Not Shown) 1. Disconnect the pulse (vacuum) hose and outlet fuel line from the fuel pump. See Figure 8-7. Figure 8-8.

  • Page 96: Remove Air Cleaner And Carburetor

    Section 8 Disassembly 2. Disconnect the choke linkage from the choke actuator lever. Unhook the governor spring, and dampener spring from the governor lever. Note the hole locations for reassembly. See Figure 8-12. Figure 8-13. Removing Governor Lever. Remove Air Cleaner and Carburetor Mounting Locations WARNING: Explosive Fuel! Figure 8-11.
  • Page 97 Section 8 Disassembly 5. Remove the carburetor gasket. 6. If necessary, the carburetor, throttle linkage and governor lever can be separated. Reattach the bushings to the linkage following separation to avoid losing them. Remove Electric Starter Motor 1. Disconnect the leads from the starter. 2.

  • Page 98: Remove Ignition Modules

    Section 8 Disassembly Standard (Fixed) Timing Ignition 1. Remove the mounting screws securing the two Module (Single Lead) shown inner baffles to the crankcase. Note the position of any lifting bracket(s). Remove the inner baffles. See Figure 8-20. (# 2) Side Lifting DSAM or SMART-SPARK™...

  • Page 99: Remove Valve Covers And Cylinder Heads

    Section 8 Disassembly 3. Remove the two screws securing the rectifier- regulator to the backing plate and disconnect the plug. See Figure 8-23. 4. Use the tip of a small screwdriver or similar small flat tool to bend the locking tang, then remove the B+ (center lead) from the terminal plug as shown in Figure 8-24.
  • Page 100 Section 8 Disassembly Stamped Steel Valve Covers with RTV Sealant 1. Remove the four hex flange screws, or Torx screws securing each valve cover. NOTE: The valve cover is sealed to the cylinder head using RTV silicone sealant. When removing valve cover, use care not to damage the gasket surfaces of the cover and cylinder head. To break the RTV seal, hold a block of wood against one of the flat faces of the valve cover. Strike the wood firmly with a mallet. If the seal doesn't break loose after 1 or 2 attempts, repeat the procedure on the other Head Screws side. Figure 8-28. Removing Cylinder Head Screws (Center Pivot Adjustment Style Shown). Remove Cylinder Heads 2. Loosen the rocker arm pivot screws, or inner 5. Remove the cylinder head and head gasket. See setscrews (T25 TORX) based on design, and back...
  • Page 101 Section 8 Disassembly NOTE: The exhaust side is located on the output 2. Compress the valve springs using a valve spring shaft side of the engine, while the intake side compressor. See Figure 8-32. is located on the fan side of the engine. The cylinder head number is embossed on the outside of each cylinder head.
  • Page 102 Section 8 Disassembly 2. Remove the retaining screw, washer, and the fan mounting plate, securing the fan and flywheel to the crankshaft. See Figure 8-36. Intake Valve Stem Seal Figure 8-34. Intake Valve Stem Seal* (Some Models). *NOTE: On engines with valve stem seals on the Figure 8-36.

  • Page 103: Remove Outer Breather Assembly

    Section 8 Disassembly Remove Outer Breather Assembly 1. RTV sealant is used between the outer breather cover and the crankcase. Remove the hex nut and sealing (flat) washer securing the breather cover to the crankcase. Carefully pry under the small tab of the cover flange to separate and remove.

  • Page 104: Remove Camshaft And Valve Tappets

    Section 8 Disassembly Remove Camshaft and Valve Tappets 1. Position the crankcase so the flywheel side is down. Remove the camshaft and shim. See Figure 8-45. Shim Camshaft Figure 8-43. Removing Oil Pan Screws. 2. Locate the splitting tab cast into the perimeter of the oil pan.

  • Page 105: Remove Connecting Rods With Pistons And Rings

    Section 8 Disassembly Remove Connecting Rods with Pistons and Rings 1. Remove the two hex flange screws securing the closest connecting rod end cap. Remove the end cap. See Figure 8-49. Retainer Washer Figure 8-47. Removing Governor Cross Shaft Retainer. 2.

  • Page 106: Remove Crankshaft

    Section 8 Disassembly Remove Crankshaft Remove Flywheel and PTO End Oil Seals 1. Carefully pull the crankshaft from the crankcase. 1. Remove the oil seals from the crankcase and oil See Figure 8-51. pan. See Figure 8-53. Crankcase Seal Figure 8-51. Removing Crankshaft. Remove Inner Breather Assembly Oil Pan Seal 1.

  • Page 107: Section 9. Inspection And Reconditioning

    Section 9 Inspection and Reconditioning Section 9 Inspection and Reconditioning This section covers the operation, inspection, and Automatic Compression Release (ACR) repair/reconditioning of major internal engine Some engines may be equipped with the optional components. The following components are not Automatic Compression Release (ACR) mechanism.
  • Page 108 Section 9 Inspection and Reconditioning Inspect the crankpin for score marks or metallic NOTE: Kohler pistons are custom-machined to pickup. Slight score marks can be cleaned with crocus exacting tolerances. When over-sizing a cloth soaked in oil. If wear limits, as stated in Section cylinder, it should be machined exactly 1, Specifications and Tolerances are exceeded, it will...
  • Page 109 Inspect the ring gear for cracks or damage. Kohler engine oil to prevent rusting. does not provide ring gears as a serviceable part.
  • Page 110 Section 9 Inspection and Reconditioning Stamped Steel Valve Cover Using a brass wire brush and gasket remover or similar solvent, clean the old RTV from the surface of the cylinder head and valve cover. The sealing surface of stamped steel valve covers must be checked for flatness prior to reinstallation.
  • Page 111 Section 9 Inspection and Reconditioning Leakage: A poor grind on face or seat of valve will Normal: Even after long hours of operation a valve allow leakage resulting in a burned valve on one side can be reconditioned and reused if the face and only.
  • Page 112 Section 9 Inspection and Reconditioning Excessive Combustion Temperatures: The white Stem Corrosion: Moisture in fuel or from deposits seen here indicate very high combustion condensation is the most common causes of valve stem corrosion. Condensation occurs from improper temperatures, usually due to a lean fuel mixture. preservation during storage and when engine is repeatedly stopped before it has a chance to reach normal operating temperatures.
  • Page 113 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 Valve Seat Cutter excessive oil consumption.
  • Page 114 Section 9 Inspection and Reconditioning Ring failure is usually indicated by excessive oil charge ignites spontaneously from heat and pressure consumption and blue exhaust smoke. When rings shortly after ignition. This creates two flame fronts, fail, oil is allowed to enter the combustion chamber which meet and explode to create extreme hammering where it is burned along with the fuel.
  • Page 115 Section 9 Inspection and Reconditioning Replacement pistons are available in STD bore size, and 0.25 mm (0.010 in.) oversize. Replacement pistons include new piston ring sets and new piston pins. Replacement ring sets are also available separately for STD, and 0.25 mm (0.010 in.) oversize pistons. Always use new piston rings when installing pistons.
  • Page 116 The corresponding camshaft lobe(s) should also be checked for wear or damage. Compression Whenever tappets are replaced, apply a liberal coating Ring of Kohler lubricant 25 357 14-S to the base of each new tappet before it is installed. Center Compression Ring...

  • Page 117: Section 10. Reassembly

    Section 9 Inspection and Reconditioning Governor Assembly (Internal) Gear Shaft Inspection 19.40 mm (0.7638 in.) 34.0 mm (1.3386 in.) Inspect the governor gear teeth. Replace the gear if it 33.5 mm (1.3189 in.) is worn, chipped, or if any teeth are missing. Inspect the governor weights.
  • Page 118 Section 9 Inspection and Reconditioning Retaining Ring Figure 9-16. Removing Oil Pump Mounting Figure 9-18. Oil Pump Details. Screws. Reassembly 3. The outer Gerotor gear is typically held captive 1. Lubricate the outer Gerotor gear with oil. If the in the oil pump housing. If the gear becomes outer gear was separated from the oil pump separated, see Step 1 under Reassembly for housing examine the outer edges.
  • Page 119 Section 9 Inspection and Reconditioning Cover Screw Filter Breather Housing Breather Stud Washer Reed Retainer Figure 9-20. Oil Pump Torque Sequence. Breather Breather Reed Hose a. Start fastener 1 into hole, apply only minimal torque to position the pump. b. Torque fastener 2 to full value. c.
  • Page 120 Section 9 Inspection and Reconditioning 9.14...
  • Page 121 18. Install ignition modules. 19. Install intake manifold. NOTE: Make sure the engine is assembled using 20. Install rectifier-regulator. all specified torque values, tightening sequences, and clearances. Failure to observe 21. Install inner and outer cylinder baffles. 22. Install carburetor and air cleaner. specifications could cause severe engine wear or damage.
  • Page 122 3. Install the oil seal into the crankcase using a seal NOTE: Make sure the drainback hole in the gasket driver. Make sure the oil seal is installed straight and cover is aligned and open after the cover and true in the bore and the tool bottoms against is secured.
  • Page 123 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 10-8. 1. Lubricate the flywheel side main bearing surface and the lips of the oil seal in the crankcase with clean engine oil.
  • Page 124 6. Repeat the above procedure for the other connecting rod and piston assembly. 1. Apply camshaft lubricant (Kohler Part No. 25 357 14-S) to the contact surface of the valve tappets. See Figure 10-12 .Note the mark or tag identifying the tappets and install them in their appropriate crankcase locations.
  • Page 125 2. Liberally apply camshaft lubricant to the lobes of the camshaft. Lubricate the camshaft bearing surfaces of the crankcase and camshaft with 1. If a camshaft shim was used, install the shim engine oil. See Figure 10-14. removed during disassembly onto the camshaft. 2.
  • Page 126 4. If the camshaft endplay is not within the specified 3. Drive the oil seal into the oil pan using a seal range, remove the endplay tool and shim driver. Make sure the oil seal is installed straight accordingly. See Figure 10-17. Shims are color- and true in the bore, to the depth shown in coded by thickness and listed below.
  • Page 127 5. Position the adapter, aligning the locating pin 3. Slide the oil feed tube through the oil pan and with the corresponding recess in oil pan. Install into the hole for the main bearing. See Figure the flat washer (plastic adapters only) onto the 10-21.
  • Page 128 RTV sealant is used as a gasket between the oil pan and the crankcase. Refer to Section 2, Special Tools for a listing of approved sealants. Always use fresh sealant. Using outdated sealant can result in leakage. 1. Be sure the sealing surfaces have been cleaned and prepared as described at the beginning of Section 10.
  • Page 129 Figure 10-29. Use Loctite 5900 or 5910, Position the hose so the opposite end is away Kohler Part No. 25 597 07-S. from the crankshaft. See Figure 10-31. NOTE: The RTV sealant should be allowed to cure a minimum of one hour before the engine is started.
  • Page 130 4. Route the stator leads in the crankcase recess, then install the backing plate. Secure with the four hex flange screws. See Figures 10-32 and 10-33. Torque the screws in the indicated sequence to 7.3 N·m (65 in. lb.). 2. Install the flywheel onto the crankshaft being NOTE: Before installing the flywheel, make sure the careful not to shift the woodruff...
  • Page 131 3. Install the fan onto the flywheel, so the locating pins fit into the corresponding recesses. 1. Snap the screen onto the fan. See Figure 10-39. 4. Install the fan mounting plate onto the fan, aligning the four cutouts, followed by the heavy flat washer and hex flange screw.
  • Page 132 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 10-41 and 10-42. •...
  • Page 133 4. Torque the hex flange screws in two stages; first to 22.6 N·m (200 in. lb.), then finally to 41.8 N·m 2. Apply grease to the contact surfaces of the (370 in. lb.), following the sequence in Figure adjusters, rocker arms and rocker arm pivots. 10-46.
  • Page 134 4. Note the mark or tag identifying the push rod as either intake or exhaust and cylinder #1 or #2. Check that each push rod is straight and not bent. Dip the ends of the push rods in engine oil and install in their original positions, making sure that each push rod ball seats in its tappet socket.
  • Page 135 See Figures 10-51 and 10-52. Important: Rotate the crankshaft a minimum of two revolutions to check longblock assembly and overall proper operation. The plastic valve covers contain integral bolt hole spacers molded in place. Sealing of plastic valve covers is accomplished using a yellow colored O-ring. In stamped steel valve covers sealing is accomplished using RTV sealant.
  • Page 136 4. Torque the valve cover fasteners to 6.2 N·m RTV silicone sealant is used as a gasket between the (55 in. lb.), using the sequence shown in Figure valve cover and cylinder head. Refer to page 2.3 for a 10-55. listing of approved sealants.
  • Page 137 8. Rotate the flywheel back and forth checking for clearance between the magnet and ignition 1. Rotate the flywheel to position the magnet away modules. Make sure the magnet does not from the ignition module bosses. strike the modules. Check the gap with a feeler gauge and readjust if necessary.
  • Page 138 DSAM, reattach the leads and seal the base of the terminal connectors with GE/ Novaguard G661 (Kohler Part No. 25 357 11-S) or Fel-Pro Lubri-Sel dielectric compound. The beads should overlap between the terminals to form a solid bridge of compound.
  • Page 139 Torque the baffle mounting screws: M5 screws: 6.2 N·m (55 in. lb.) into a new cored hole, or 4.0 N·m (35 in. lb.) into a used hole. M6 screws: 10.7 N·m (95 in. lb.) into a new cored hole, or 7.3 N·m (65 in. lb.) into a used hole. 1.
  • Page 140 1. Install the governor lever onto the governor cross shaft if disconnected previously. See Figure 10-70. 1. Install a new carburetor gasket. Make sure all holes align and are open. 2. Install the carburetor, throttle linkage and governor lever as an assembly. See Figure 10-68. 2.
  • Page 141 5. Connect the breather hose to the air cleaner base and secure with the clamp. See Figure 10-73. 1. Install the air cleaner element (with precleaner if equipped), onto the air cleaner base. Secure with the latch. See Figure 10-75. 6.
  • Page 142 1. Connect the choke linkage to the choke actuator lever on the main control bracket assembly. See Figure 10-76. 2. Install the main control bracket to the cylinder heads using the four hex flange screws. The two lower screws should also secure the inner baffles. Torque the screws to 10.7 N·m (95 in.
  • Page 143 1. Install the starter motor, lift bracket, and oil fill/ dipstick tube (if not separated from bracket), using the two hex flange screws. Position the lift bracket as shown to also secure the dipstick tube. See Figure 10-81. 2. Torque the two hex flange screws to 15.3 N·m (135 in.
  • Page 144 4. If separated earlier, install the dipstick tube and 2. Torque the screws as follows: align the mounting hole with the threaded hole in the lift bracket. Secure with the M5 hex flange M5 Blower Housing Screws: 6.2 N·m (55 in. lb.) screw.
  • Page 145 2. Prefill a new oil filter following the instructions in Section 6, Lubrication System. 3. Apply a thin film of clean oil to the rubber gasket on the oil filter and thread it onto the adapter nipple. See Figure 10-86. 4.
  • Page 146 5. Add oil to bring the level up to the F/Full mark. Turn the oil fill cap/dipstick counterclockwise 1. Connect the leads to the spark plugs. See Figure until the oil fill cap drops down to the lowest 10-90. point of the thread leads. Do not thread the oil fill cap onto the tube.
  • Page 147 For the 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 the Original Equipment Manufacturer (OEM). Details on the Kohler system are included below. Operation: Fuel vapors travel from the fuel tank through tubing to the carbon canister. On the intake stroke of the engine fuel vapors are drawn in through a port in the carburetor and burned with the fuel charge.
  • Page 148 For the engine to be Tier III compliant, it may be fitted with a secondary air induction system (SAI). Operation: The intake pulse of the engine activates the secondary air valve. Air is drawn through an inlet screen of the secondary air valve. The air is then drawn into the exhaust manifold and muffler where it mixes with any unburned hydrocarbons, which then burn in the heat of the muffler.
  • Page 150 FORM NO.: 32 690 01 Rev. A ISSUED: 8/10 REVISED: 11/10 FOR SALES AND SERVICE INFORMATION IN U.S. AND CANADA, CALL 1-800-544-2444 KohlerEngines.com ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044 © 2010 by Kohler Co. All rights reserved.

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