Kohler Courage SV470-600 Service Manual
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Kohler Courage SV470-600 Service Manual

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Summary of Contents for Kohler Courage SV470-600

  • Page 1 ERVICE ANUAL OURAGE ERIES ™ SV470-600 ERTICAL RANKSHAFT Not For Resale www.SmallEngineDiscount.com...

  • Page 2: Table Of Contents

    Contents Section 1. Safety and General Information ................Section 2. Special Tools ......................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 3: Section 1. Safety And General Information

    Section 1 SV470-600 Safety and General Information Section 1 Safety and General Information Safety Precautions 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.

  • Page 4: Not For Resale

    Section 1 Safety and General Information WARNING WARNING WARNING Explosive Gas can cause fires and Explosive Fuel can cause fires and Carbon Monoxide can cause severe acid burns. severe burns. severe nausea, fainting or death. Charge battery only in a well Stop engine before filling fuel tank.
  • Page 5 Model AND SERVICE IN US/CANADA SV470 model series CALL: 1-800-544-2444. SV480 www.kohlerengines.com SV530 SV540 SV590 KOHLER CO. KOHLER, WI USA SV600 C. Serial No. 3205810334 Year Manufactured Code Factory Code Code Year 2002 2003 2004 Figure 1-2. Explanation of Engine Identification Numbers.
  • Page 6 Gasoline/Alcohol blends Gasohol (up to 10% ethyl alcohol, 90% unleaded gasoline by volume) is approved as a fuel for Kohler engines. Other gasoline/alcohol blends are not approved. Figure 1-3. Oil Container Logo.
  • Page 7 Replace spark plug. Every 500 Hours ¹Perform these maintenance procedures more frequently under extremely dusty, dirty conditions. ²Have a Kohler Engine Service Dealer perform this service. Storage To empty the system, run the engine until the tank If the engine will be out of service for two months or and system are empty.
  • Page 8 Section 1 Safety and General Information Dimensions in millimeters. Inch equivalents shown in (). Figure 1-4. Typical Engine Dimensions. Not For Resale www.SmallEngineDiscount.com...
  • Page 9 Section 1 Safety and General Information General Specifications¹ Power (@ 3600 RPM, corrected to SAE J1940) SV470 ....................11.2 kW (15 HP) SV480 ....................11.9 kW (16 HP) SV530 ....................12.7 kW (17 HP) SV540 ....................13.4 kW (18 HP) SV590 ....................
  • Page 10 Section 1 Safety and General Information Cam Gears (cont'd.) Cam Gear-to-Cam Shaft Running Assembly ..........0.02/0.10 mm (0.001/0.004 in.) Carburetor Fuel Bowl Retaining Screw Torque ............5.1-6.2 N·m (45-55 in. lb.) Closure Plate Closure Plate Fastener Torque ..............24.5 N·m (216 in. lb.) Balance Weight Guide Channel Width New ....................
  • Page 11 Section 1 Safety and General Information Crankshaft (cont'd.) PTO End Main Bearing Journal O.D. – New ..................41.913/41.935 mm (1.6501/1.6510 in.) O.D. – Max. Wear Limit ..............41.86 mm (1.648 in.) Max. Taper ..................0.020 mm (0.0008 in.) Max. Out of Round ................0.025 mm (0.001 in.) Crankshaft Bore in Closure Plate Running Clearance New ....................
  • Page 12 Section 1 Safety and General Information Cylinder Bore I.D. (cont'd.) Max. Taper ..................0.05 mm (0.002 in.) Max. Out of Round ................0.12 mm (0.0047 in.) Cylinder Head Cylinder Head Fastener Torque (torque in 2 increments) ......20.5, 41.0 N·m (180, 360 in. lb.) Max.
  • Page 13 Section 1 Safety and General Information Oil Filter Pad Pipe Plug 1/8” N.P.T.F. Torque ................. 4.5-5.0 N·m (40-46 in. lb.) Oil Pump Mounting Screw Torque ................4.0 N·m (35 in. lb.) Pump Gears-to-Crankcase Side Clearance ..........0.165/0.315 mm (0.0065/0.0124 in.) Oil Sentry™...
  • Page 14 Section 1 Safety and General Information Stator Stator Mounting Screw Torque ..............6.0 N·m (55 in. lb.) Into new as-cast hole 4.0 N·m (35 in. lb.) Into used hole Throttle/Choke Controls Governor Control Lever Fastener Torque ..........7.0-8.5 N·m (60-75 in. lb.) Valve Cover Valve Cover Fastener Torque ..............
  • Page 15 Section 1 Safety and General Information General Torque Values Metric Fastener Torque Recommendations for Standard Applications Tightening Torque: N·m (in. lb.) + or - 10% Property Class Noncritical 10.9 12.9 Fasteners Into Aluminum Size 1.2 (11) 1.7 (15) 2.9 (26) 4.1 (36) 5.0 (44) 2.0 (18)

  • Page 16: Section 2. Special Tools

    By using tools designed for the job, you can service engines easier, faster, and safer! In addition, you’ll increase your service capabilities and customer satisfaction by decreasing engine downtime. Kohler special tools are handled by SPX Corp., a division of Owatonna Tool Corp. (OTC). The tools are easy to purchase by contacting SPX/OTC by phone, fax, or mail.

  • Page 17: Section 2 Special Tools

    Obtain a flat washer with the correct I.D. to slip on the capscrew and an O.D. of approximately 1". Kohler Part No. 12 468 05-S can be used if you don’t have the right size on hand.

  • Page 18: Section 3. Troubleshooting

    Section 3 Troubleshooting SV470-600 Section 3 Troubleshooting Troubleshooting Guide Engine Will Not Crank 1. PTO drive is engaged. When troubles occur, be sure to check the simple 2. Battery is discharged. causes which, at first, may seem too obvious to be 3.
  • Page 19 Section 3 Troubleshooting Engine Loses Power • Check the carburetor throat for dirt. Dirt in the 1. Low crankcase oil level. throat is further indication that the air cleaner was 2. High crankcase oil level. not functioning properly. 3. Dirty air cleaner element. 4.
  • Page 20 Section 3 Troubleshooting Basic Engine Tests 2. Start the engine and run at no-load high idle speed (3200 to 3750 RPM). Crankcase Vacuum Test 3. Open the clamp and note the water level in the A partial vacuum should be present in the crankcase tube.
  • Page 21 TDC in either direction. SPX Part No. KO3219 (previously Kohler Part No. 25 761 05-S) is a relatively simple, inexpensive 4. Install the adapter into the spark plug hole, but do leakdown tester for small engines.

  • Page 22: Section 4. Air Cleaner And Air Intake System

    Section 4 SV470-600 Air Cleaner and Air Intake System Section 4 Air Cleaner and Air Intake System Air Cleaner Intake air is drawn in through the upper opening from the blower housing, passes through the precleaner (if These engines are equipped with a replaceable, high so equipped), the paper element and then into the density, paper air cleaner element.
  • Page 23 Do not wash the paper element or use pressurized air, as this will damage the element. Replace a dirty, bent, or damaged element with a genuine Kohler element. Handle new elements carefully; do not use if the rubber seal is damaged.
  • Page 24 Section 4 Air Cleaner and Air Intake System Reassembly The following procedure is for complete assembly of all air cleaner components. Steps 1-3 are necessary only if the air cleaner base and/or the cover mounting studs were removed in “Disassembly”. 1.
  • Page 25 Section 4 Air Cleaner and Air Intake System Air Intake/Cooling System Clean Air Intake/Cooling Areas To ensure proper cooling, make sure the grass screen, cooling fins, and other external surfaces of the engine are kept clean at all times. Annually or every 100 hours of operation, (more often under extremely dusty, dirty conditions), remove the blower housing and any other cooling shrouds.

  • Page 26: Section 5. Fuel System And Governor

    Fuel System and Governor Fuel Recommendations Gasoline/Alcohol blends Gasohol (up to 10% ethyl alcohol, 90% unleaded gasoline by volume) is approved as a fuel for Kohler WARNING: Explosive Fuel! engines. Other gasoline/alcohol blends are not Gasoline is extremely flammable and its vapors can approved.
  • Page 27 Periodically inspect the filter and replace when dirty. the fuel is forced past the outlet check valve, to the Replacement is recommended annually or every 100 carburetor. hours. Use a genuine Kohler filter. Repair Fuel Pump Pulse fuel pumps are not serviceable and must be Some engines are equipped with an optional pulse fuel replaced when faulty.
  • Page 28 Section 5 Fuel System and Governor Troubleshooting – Fuel System If engine troubles are experienced that appear to be fuel system related, check the following areas before adjusting or disassembling the carburetor. • Make sure the fuel tank is filled with clean, fresh gasoline.
  • Page 29 Section 5 Fuel System and Governor Troubleshooting – Fuel System Possible Cause/Probable Remedy Condition 1. Engine starts hard, runs roughly or 1a. Low idle fuel mixture/speed improperly adjusted. Adjust the low idle stalls at idle speed. speed screw, then adjust the low idle fuel needle. b.
  • Page 30 Section 5 Fuel System and Governor Low Idle Mixture Adjustment* Low Idle Speed Setting NOTE: Engines will have fixed idle (no adjustment 1. Start the engine and run at half throttle for 5 to 10 possible) or a limiter cap on the idle fuel minutes to warm up.
  • Page 31 Section 5 Fuel System and Governor Disassembly Throttle Lever and Shaft Dust Seal Throttle Plate Screw(s) Choke Lever and Shaft Choke Return Spring Throttle Plate Low Idle Speed Adjusting Choke Plate Screw and Spring Fuel Inlet Low Idle Fuel Adjusting Needle Needle and Spring with Float...
  • Page 32 Section 5 Fuel System and Governor 2. The choke plate is inserted into a slot in the choke shaft. Grasp the choke plate with pliers, and pull it out of the slot. See Figure 5-8. Tool No. KO1018 Pry Out Plug Do Not Allow Tip to Strike Carburetor Body...
  • Page 33 Section 5 Fuel System and Governor Welch Plug Installation • Throttle plate, choke plate, throttle shaft, and Use SPX Tool No. KO1017 and install new plugs as choke shaft. follows: NOTE: Do not submerge the carburetor in 1. Position the carburetor body with the welch plug cleaner or solvent when plastic, fiber, cavities to the top.
  • Page 34 Section 5 Fuel System and Governor Figure 5-10. Installing Float and Fuel Inlet Needle. Figure 5-11. Fuel Shut-Off Solenoid. 4. Install the bowl gasket, fuel bowl, bowl retaining High Altitude Operation screw gasket, and bowl retaining screw or fuel When operating the engine at altitudes of 1830 m solenoid.
  • Page 35 Section 5 Fuel System and Governor 2. Place the throttle control lever of the equipment into the “fast” or high speed position. The actuating “tab” of the choke lever should be just below the end of the choke adjusting screw. See Figure 5-13.
  • Page 36 Do Figure 5-17. Adjusting High Speed (RPM). not jump start using another battery (refer to “Battery”). See your Kohler Engine Service Dealer for trouble To increase the high speed (RPM), move the analysis.
  • Page 37 Section 5 Fuel System and Governor 2. While observing the choke link, move the throttle 4. Push on the choke cable, ahead of the clamp on control lever to the low idle (slow) position, then the engine control plate, until the choke lever back to full throttle (fast).
  • Page 38 Section 5 Fuel System and Governor 3. Release the governor lever and allow the engine Changing the High Speed (RPM) on the Engines with Separate Controls (Increase or Decrease to return to the governed idle speed. Check it with RPM) a tachometer against the equipment manufacturers recommended idle speed.
  • Page 39 Section 5 Fuel System and Governor Operation 1. Move the governor lever toward the carburetor As the governor gear rotates, centrifugal force causes (wide open throttle). Do not apply excess force the flyweights to move outward as speed increases. As flexing or distorting the throttle link.
  • Page 40 Section 5 Fuel System and Governor The desired high speed setting (RPM) will determine Governor Sensitivity Adjustment the governor spring position in the governor lever and Governor sensitivity is adjusted by repositioning the the throttle lever, as well as the spring used. See governor spring in the holes in the governor lever.

  • Page 41: Section 6. Lubrication System

    Section 6 Lubrication System SV470-600 Section 6 Lubrication System Oil Recommendations Using the proper type and weight of oil in the crankcase is extremely important. So is checking oil daily and changing oil regularly. Failure to use the correct oil, or using dirty oil, causes premature engine wear and failure.
  • Page 42 Make sure the engine is level when filling or checking oil. Change the oil and filter as follows (see Figure 6-6). Always use a genuine Figure 6-3. Removing Dipstick. Kohler oil filter. Oil Filter Oil Drain Plug Figure 6-4. Dipstick Seated.
  • Page 43 Section 6 Lubrication System 7. Install the replacement oil filter to the mounting pad. Turn the oil filter clockwise until the rubber gasket contacts the pad, and then tighten the filter an additional 2/3 to 1 turn. 8. Fill the crankcase with new oil of the proper type, to the “F”...
  • Page 44 Section 6 Lubrication System On vehicular applications (lawn tractors, mowers, etc.), Testing the Oil Sentry ™ Switch the pressure switch can be used to activate a ‘‘low oil’’ The Oil Sentry ™ pressure monitor is a normally closed warning light. On stationary or unattended applications, switch.

  • Page 45: Section 7. Electrical System And Components

    Section 7 SV470-600 Electrical System and Components Section 7 Electrical System and Components This section covers the operation, service, and repair of the electrical system and electrical system components. Major electrical systems and components covered in this section include the ignition system, battery, battery charging systems, electric starter, and optional Oil Sentry ™...
  • Page 46 Section 7 Electrical System and Components Inspection Inspect the spark plug as soon as it is removed from the cylinder head. The deposits on the tip are an indication of the general condition of the piston rings, valves, and carburetor. Normal and fouled plugs are shown in the following photos.
  • Page 47 Section 7 Electrical System and Components Electronic CD Ignition System Spark Plug Boot Spark Plug Terminal (C) Spark Plug Air Gap 0.203/0.305 mm (0.008-0.012 in.) Ignition Module Lamination (A) Kill Terminal (B) Magnet Flywheel Kill Switch or Off Position of Key Switch Figure 7-2.
  • Page 48 Section 7 Electrical System and Components Spark Plug Figure 7-3. Capacitive Discharge Ignition Module. Operation NOTE: The CD ignition systems are sensitive to As the flywheel rotates, and the magnet passes the excessive load on the kill lead. Customer ignition module, the magnetic field induces current in complaints of hard starting, low power, or the input coil (L1).

  • Page 49: Section 8. Disassembly

    Section 7 Electrical System and Components CD Ignition System Troubleshooting Guide The following guide will help locate and correct ignition system problems. Conclusion Problem Test 1. Make sure the spark plug lead is connected to the spark plug. 2. Check the condition of spark plug. Make 2.
  • Page 50 Section 7 Electrical System and Components Battery NOTE: Do not allow the baking soda solution to enter the cells of the battery, as this will A 12 volt battery with a minimum current rating of 250 destroy the electrolyte. cold cranking amps is recommended. The actual cold cranking amp requirement depends on engine size, Battery Test application and starting temperatures.
  • Page 51 Section 7 Electrical System and Components 3 Amp Charging Stator Lighting Lead (Yellow) Diode Lighting Stator Charging Lead (Black) Figure 7-7. 3 Amp/70 Watt Stator. Optional Oil Sentry Switch (Indicator Light) White Ground-To- Ignition Kill Lead Module Stator Spark Regulator- Plug Flywheel Rectifier...
  • Page 52 Section 7 Electrical System and Components Troubleshooting Guide 3 amp Battery Charging System with 70 Watt Lighting Stator NOTE: Zero ohmmeteres on each scale to ensure accurate readings. Voltage tests should be made with engine running at full throttle - no load. Battery must be fully charged. Problem Test Conclusion...
  • Page 53 Section 7 Electrical System and Components Troubleshooting Guide 3 amp/70 Watt Braking Stator NOTE: Zero ohmmeteres on each scale to ensure accurate readings. Voltage tests should be made with engine running at full throttle - no load. Battery must be fully charged. Problem Test Conclusion...
  • Page 54 Section 7 Electrical System and Components Troubleshooting Guide 3 amp/70 Watt Braking Stator (cont.) Conclusion Problem Test 1. Make sure lights are not burned out. 1. Replace burned out lights. 2. Disconnect the braking lead (green) from 2. If voltage is 35 volts or more, stator is OK.
  • Page 55 Section 7 Electrical System and Components 9 or 15 amp Battery Charging System Ground-to-Kill Lead White Ignition Module Stator Key Switch Rectifier- Spark Flywheel Regulator Plug Violet Green Engine Green Optional Connector Optional Fuel Fuse Solenoid Optional Oil Sentry™ Indicator Light Optional Oil Sentry™...
  • Page 56 Section 7 Electrical System and Components Rectifier-Regulator 9 or 15 Amp Stator Figure 7-10. 9 or 15 amp Stator and Rectifier-Regulator. DC Volt Meter Rectifier-Regulator Flywheel Stator Ammeter Battery Figure 7-11. Proper Connection to Test 9 or 15 amp Charging System. Not For Resale 7.12 www.SmallEngineDiscount.com...
  • Page 57 Section 7 Electrical System and Components Troubleshooting Guide 9 or 15 amp Regulated Battery Charging System NOTE: Zero ohmmeters on each scale to ensure accurate readings. Voltage tests should be made with engine running at full throttle - no load. The battery must be fully charged. Problem Test Conclusion...
  • Page 58 Section 7 Electrical System and Components NOTE: If the engine develops sufficient speed to Electric Starters disengage the inertia drive starter but does These engines use inertia drive starting motors. not keep running (a false start), the engine rotation must be allowed to come to a Operation complete stop before attempting to restart the When power is applied to the starter, the armature...
  • Page 59 Drive Pinion Drive Nut (Collar) Figure 7-12. Drive Components. 1. Disassemble removal tool Kohler Part No. 25 761 18-S. Figure 7-14. Holding Tool and Turning Center 2 Referring to Figure 7-12, grasp the spring retainer Screw (Clockwise) to Remove Retaining Ring.
  • Page 60 Section 7 Electrical System and Components Retaining Ring Installation 3. Remove the thru bolts and recessed hex. nuts. 1. Position the retaining ring in the groove in one of the inner halves. Assemble the other half over the 4. Remove the commutator end cap and lift out the top and slide on the outer collar.
  • Page 61 Section 7 Electrical System and Components 2. Insert the armature into the starter frame. The Brush Replacement magnets will hold it in place. See Figure 7-19. 1. Remove the hex. flange nut and insulating washer from the positive (+) brush lead stud. 2.
  • Page 62 1.6-2.8 N·m (12-25 in. lb.), do not over torque. 9. Lubricate the drive shaft with Kohler bendix starter drive lubricant (Part No. 52 357 01-S). Install the drive components following the instructions for servicing the drive.
  • Page 63 Section 8 SV470-600 Disassembly Section 8 Disassembly WARNING: Accidental Starts! Disabling engine. Accidental starting can cause severe injury or death. Before working on the engine or equipment, disable the engine as follows: 1) Disconnect the spark plug lead. 2) Disconnect negative (-) battery cable from battery.
  • Page 64 Section 8 Disassembly Remove Muffler Remove Oil Sentry Pressure Switch ™ 1. Remove the hex. flange nuts from the exhaust (on models so equipped) studs. If a muffler bracket is used, remove the 1. Disconnect the lead from the Oil Sentry™ hex.
  • Page 65 Section 8 Disassembly 3. Remove the two hex. flange nuts, or single nut and long mounting screw securing the air cleaner base. See Figure 8-9. Figure 8-6. Removing Electric Starter. Remove Air Cleaner 1. Loosen the two knobs and remove the air cleaner Figure 8-9.
  • Page 66 Section 8 Disassembly 1. Shut off the fuel supply. Disconnect the fuel line from the carburetor inlet fitting. See Figure 8-11. If a fuel pump is used, disconnect the pulse line from the fitting on the closure plate. See Figure 8-12.
  • Page 67 Section 8 Disassembly 5. Mark the mounted position of the speed control bracket in the slotted holes and remove the two screws securing the speed control bracket to the closure plate. Note or mark the governor spring hole for correct installation later. Unhook the governor spring, then remove the control bracket (with fuel pump attached, if equipped) and linkages from the engine.
  • Page 68 Section 8 Disassembly Remove Ignition Module 1. Disconnect the kill lead from the ignition module. 2. Rotate the flywheel magnet away from the module. 3. Remove the RFI sheathed spark plug lead with from retaining clip, if so equipped. See Figure 8-20.
  • Page 69 Section 8 Disassembly Figure 8-26. Removing Valve Cover Screws. Figure 8-24. Removing Flywheel Using Puller. 5. Remove the flywheel key from the crankshaft. 2. Remove the valve cover and gasket from the cylinder head. See Figure 8-27. Remove the Stator 1.
  • Page 70 Section 8 Disassembly 4. Remove the six hex. flange screws securing the cylinder head. Note the thick washer used on the screw closest to the exhaust port. See Figure 8-29. Washer Figure 8-31. Removing Drain Back Check Ball from Crankcase. Disassemble Cylinder Head NOTE: Before disassembly, mark all valve train Figure 8-29.
  • Page 71 Section 8 Disassembly Figure 8-33. Disassembling Rocker Arm Figure 8-35. Removing Closure Plate Screws. Components. 2. A gasket is used between the closure plate and 4. Remove the valves. crankcase. If necessary, carefully tap on the bosses for the starter or oil filter with a soft-faced a.
  • Page 72 Section 8 Disassembly NOTE: The ACR weight and spring normally captured Disassemble Closure Plate by the thrust washer and installation of 1. Remove the governor gear and regulating pin closure plate, will fall out if the exhaust cam assembly. Gently pry upward using the blades of gear is turned upside down.
  • Page 73 Section 8 Disassembly Figure 8-43. Separating Oil Pump Assembly from Figure 8-41. Removing Exhaust Side Cam Shaft Intake Side Cam Shaft. and Slotted Thrust Washer. Remove Connecting Rod and Piston 4. Remove the two screws securing the oil pump and intake side cam shaft to the crankcase. 1.
  • Page 74 Section 8 Disassembly Figure 8-45. Removing Piston and Connecting Figure 8-47. Removing Piston Rings. Rod. Remove Crankshaft and Balance Weight Remove Piston from Connecting Rod Assembly 1. Remove the wrist pin retainer and wrist pin. 1. Carefully lift the crankshaft and balance weight Separate the piston from the connecting rod.
  • Page 75 Section 8 Disassembly Remove Governor Cross Shaft 1. Remove the hitch pin and washer located on the outside of the governor cross shaft. See Figure 8-52. Figure 8-49. Removing Crank Gear Key. 3. Remove the long hex. flange screw securing the two balance weight halves together on the crankshaft.
  • Page 76 Section 8 Disassembly Remove PTO and Flywheel Side Oil Seals 1. Use a seal puller to remove the PTO and flywheel side oil seals. See Figure 8-54. Figure 8-54. Removing Seal with a Seal Puller. Not For Resale 8.14 www.SmallEngineDiscount.com...

  • Page 77: Section 9. Inspection And Reconditioning

    Section 9 SV470-600 Inspection and Reconditioning Section 9 Inspection and Reconditioning This section covers the operation, inspection, and repair/reconditioning of major internal engine components. The following components are not covered in this section. They are covered in sections of their own: Air Cleaner, Section 4 Carburetor &...
  • Page 78 Section 9 Inspection and Reconditioning Benefits Crankcase Reducing the compression at cranking speeds results in several important benefits. Inspection and Service Check all gasket surfaces to make sure they are free 1. The starter and battery can be smaller, more of gasket fragments and deep scratches or nicks.
  • Page 79 Section 9 Inspection and Reconditioning 3. When the bore is within 0.064 mm (0.0025 in.) of Measuring Piston-to-Bore Clearance desired size, remove the coarse stones and Before installing the piston into the cylinder bore, it is replace with burnishing stones. Continue with the necessary that the clearance be accurately checked.
  • Page 80 Section 9 Inspection and Reconditioning Balance Weight-to-Eccentric Clearance 3. The running clearance is the eccentric diameter Before the balance weight assembly is reassembled to subtracted from the balance weight bearing the crankshaft, the running clearance to the crankshaft diameter (step 1 minus step 2). If the eccentrics must be accurately checked.
  • Page 81 Section 9 Inspection and Reconditioning If any of the measurements taken are outside the 3. Use an outside micrometer again and measure the O.D. of the balance weight guide pin. See maximum wear limits listed in Section 1, the affected component(s) must be replaced.
  • Page 82 Section 9 Inspection and Reconditioning Cylinder Head and Valves Inspection and Service Carefully inspect the valve mechanism parts. Inspect the valve springs and related hardware for excessive wear or distortion. Check the valves and valve seats for evidence of deep pitting, cracks, or distortion. Check the running clearance between the valve stems and guides.
  • Page 83 Section 9 Inspection and Reconditioning Hard starting, or loss of power accompanied by high fuel consumption, may be symptoms of faulty valves. Although these symptoms could also be attributed to worn rings, remove and check the valves first. After removal, clean the valve heads, faces, and stems with a power wire brush. Then, carefully inspect each valve for defects such as warped head, excessive corrosion, or worn stem end.
  • Page 84 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 are the most common causes of valve temperatures, usually due to a lean fuel mixture. stem corrosion.
  • Page 85 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 burned valve faces or seats, loss of compression, and Valve Seat Cutter excessive oil consumption.
  • Page 86 Section 9 Inspection and Reconditioning When cylinder temperatures get too high, lacquer and Replacement pistons are available in STD and 0.08 varnish collect on pistons causing rings to stick which mm (0.003 in.) oversize, which include new rings and results in rapid wear. A worn ring usually takes on a piston pins.
  • Page 87 Section 9 Inspection and Reconditioning Some important points to remember when servicing piston rings: 1. If the cylinder bore is within the wear limits (refer to Section 1) and the old piston is within wear limits, free of score or scuff marks, the old piston may be reused.

  • Page 88: Section 10. Reassembly

    Section 9 Inspection and Reconditioning Procedure to Remove Governor Shaft: 1. Oil Control Ring (Bottom Groove): Install the 1. Remove the blower housing, flywheel, and cooling expander and then the rails. Make sure the ends fan. of the expander are not overlapped. 2.
  • Page 89 Section 9 Inspection and Reconditioning 3. Make sure governor gear assembly rotates freely. 6. Complete engine reassembly following “Reassembly” procedures. 4. Check that timing marks are still aligned. 7. When engine reassembly is completed, reset 5. Install a new closure plate gasket and install the initial governor adjustment according to closure plate.

  • Page 90: Table Of Contents

    Section 10 Reassembly SV470-600 Section 10 Reassembly The following sequence is suggested for complete 23. Install and adjust governor lever, mounting speed engine reassembly. This procedure assumes that all control bracket. components are new or have been reconditioned, and 24. Install fuel pump (some models). all component subassembly work has been 25.

  • Page 91: Install Governor Cross Shaft

    Section 10 Reassembly Hitch Pin Thick Washer Oil Seal Figure 10-4. Securing Governor Shaft. Seal Depth Install Oil Pump Assembly and Intake Cam 5.5 mm (0.216 in.) Shaft 1. If the oil pump assembly was removed from the Figure 10-2. PTO Seal Depth Details. intake cam shaft, reassemble it onto the shaft.
  • Page 92 Section 10 Reassembly Pump Outlet Seal Figure 10-6. Assembled Intake Cam Shaft Details. Figure 10-8. Installing Oil Pump Outlet Seal. 1. Intake Cam Shaft 2. 3 mm Diameter Pin 3. Oil Pump Assembly 4. 2.5 mm Diameter Pin 5. #1 Hole Location 6.
  • Page 93 Section 10 Reassembly 3/32" Allen Wrench PTO Side Guide Pin Figure 10-10. Checking Outlet Seal Passage Figure 10-12. Assembling Balance Weight to Opening (Open Style). Crankshaft. d. Carefully install crank gear key in keyway. See Figure 10-13. Intake Tube Crank Gear Key Oil Pump Oil Passage Seal Figure 10-11.

  • Page 94: Install Piston To Connecting Rod

    Section 10 Reassembly Figure 10-16. Assembled Piston and Connecting Figure 10-14. Installing Crankshaft Assembly. Rod. 4. Install the balance weight guide shoe onto the Install Piston and Connecting Rod guide pin with the solid end toward the crankshaft. See Figure 10-15. NOTE: Proper orientation of the piston/connecting rod inside the engine is extremely important.

  • Page 95: Install Cam Levers

    Section 10 Reassembly Install Cam Levers 1. Install the two cam levers as shown in Figure 10-20. The “dimple” for seating the push rod must face “up”. Secure each cam lever using an M6 hex. flange screw. Torque the screws to 7.5 N·m (65 in.
  • Page 96 Section 10 Reassembly 2. Apply a dab of grease to the formed groove in the thrust washer. Slide the washer onto the cam shaft so the short drive pin is seated in the groove. The grease will hold the washer in position.
  • Page 97 Section 10 Reassembly Install Intake Cam on Cam Shaft Install Flywheel Side Oil Seal 1. Lift the intake cam lever and install the intake cam 1. Lubricate the outside diameter and lip of the flywheel end oil seal. Support the closure plate gear onto the intake cam shaft, engaging the slot and install the oil seal.

  • Page 98: Assemble Cylinder Head

    Section 10 Reassembly Guide Channel Guide Shoe Figure 10-29. Aligning and Installing Closure Plate. Figure 10-31. Closure Plate Fastener Torque 4. Install the fourteen hex. flange screws securing Sequence. the closure plate to the crankcase, with any clamps for the wiring harness and the sheathed RFI suppression spark plug lead (#5 location, if Assemble Cylinder Head so equipped), positioned as shown in Figure...

  • Page 99: Install Rocker Arms And Push Rods

    Section 10 Reassembly IMPORTANT- 2. If the crankshaft has not been turned since the installation of the crank gear, turn it one (1) complete revolution. This will set the piston at top dead center (TDC) of the compression stroke, for proper valve lash adjustment later. Washer (Position 6) 3.

  • Page 100: Install Valve Cover

    Section 10 Reassembly 4. With the engine at TDC of the compression stroke, insert a 0.076 mm (0.003 in.) flat feeler gauge between one of the valve stems and the rocker arm. Tighten the adjustment nut with a wrench until a slight “drag” is felt on the feeler gauge.

  • Page 101: Install Stator And Wiring Harness

    Section 10 Reassembly Install Wiring Harness 3. Torque the valve cover screws to 11.0 N·m (95 in. lb.) into new, as-cast holes, or 7.5 N·m 1. Check that the locking tang on the terminal of the violet B+ wiring harness lead is angled upward. (65 in.
  • Page 102 Section 10 Reassembly Install Fan and Flywheel 4. Install the fan mounting plate onto the fan, aligning the four cutouts, followed by the heavy flat washer and hex. flange screw. See Figure WARNING: Damaging Crankshaft and 10-45. Flywheel can Cause Personal Injury! Using improper procedures to install the flywheel can crack or damage the crankshaft and/or flywheel.

  • Page 103: Install Electric Starter

    Section 10 Reassembly Install Electric Starter 1. Install the electric starter to the closure plate and secure with the two #10-24 hex. nuts. Make sure the wires are clear of any moving parts and torque the hex. nuts to 3.6 N·m (32 in. lb.). See Figure 10-47.
  • Page 104 Section 10 Reassembly Install New Spark Plug 3. Install a new intake gasket onto the carburetor stud, then install the heat deflector. The curved 1. Use a new Champion ® RC12YC or QC12YC (or section should be down, toward the engine, with equivalent) spark plug.
  • Page 105 Section 10 Reassembly 6. Attach the choke and throttle linkages to the carburetor and install the carburetor assembly. See Figure 10-55. If the governor lever was not disconnected, slide it onto the governor shaft with the lever up. Throttle Linkage Choke Linkage Figure 10-57.
  • Page 106 Section 10 Reassembly c. Torque the nut(s) to 5.5 N·m (48 in. lb.). Torque the screw to 8.0 N·m (70 in. lb.) into a new hole, or 5.5 N·m (48 in. lb.) into a used hole, do not over tighten. See Figure 10-62. The M6 screw for the upper tab will be installed when the blower housing is mounted.
  • Page 107 Section 10 Reassembly 2. Move the governor lever toward the carburetor, to 2. Attach the speed control bracket to the mounting locations on the engine with the M6 screws. the limit of its travel (wide-open throttle) and hold in this position. Do not apply excessive pressure, Position the bracket as marked during flexing or distorting the linkage.

  • Page 108: Install Rectifier-Regulator

    Section 10 Reassembly 3. Connect the pulse and fuel lines to the fuel pump and secure with clamps. See Figure 10-68. Figure 10-70. Installing Blower Housing. 2. Check that the stator leads are within the notch of Figure 10-68. Installing Fuel Pump. the blower housing.
  • Page 109 Section 10 Reassembly Oil Sentry™ Switch Figure 10-74. Installed Oil Sentry™ Switch. Figure 10-72. Installing Grass Screen. Install Oil Sentry™ or Pipe Plug Install Air Cleaner Element, Precleaner, 1. Apply pipe sealant with Teflon ® (Loctite ® and Air Cleaner Cover 59241 or equivalent), to the threads of the 1/8”...

  • Page 110: Install Muffler

    Section 10 Reassembly Figure 10-76. Installing Precleaner. Figure 10-78. Torquing Exhaust Flange Nuts. 3. Install the air cleaner cover and secure with the Install Drain Plug, Oil Filter, and Oil two retaining knobs. See Figure 10-77. 1. Install the oil drain plug and torque to 14 N·m (125 in.
  • Page 111 Section 10 Reassembly Prepare the Engine for Operation Testing the Engine The engine is now completely reassembled. Before It is recommended that the engine be operated on a starting or operating the engine, be sure the following test stand or bench prior to installation in the piece of have been done.
  • Page 112 FORM NO.: TP-2548 ISSUED: 9/03 REVISED: MAILED: 10/03 LITHO IN U.S.A. FOR SALES AND SERVICE INFORMATION IN U.S. AND CANADA, CALL 1-800-544-2444 ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044 Not For Resale www.SmallEngineDiscount.com...

This manual is also suitable for:

Courage sv470Courage sv480Courage sv530Courage sv540Courage sv590Courage sv600

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