Table Of Contents - Kohler Courage SV470-600 Service Manual

Table of Contents

Table Of Contents2
Safety Precautions3
Section 1. Safety And General Information3
Not For Resale4
Explanation Of Engine Identification Numbers5
Oil Recommendations6
Oil Type6
Fuel Recommendations6
Gasoline/Alcohol Blends6
Periodic Maintenance7
Maintenance Schedule7
Storage7
Safety And General Information8
General Specifications9
General Torque Values15
Metric Fastener Torque Recommendations For Standard Applications15
Oil Drain Plugs Tightening Torque: N-M (English Equiv.)15
Torque Conversions15
Flywheel Holding Tool16
Section 2. Special Tools16
Rocker Arm/Crankshaft Tool17
Section 2 Special Tools17
Section 3. Troubleshooting18
External Engine Inspection19
Cleaning The Engine19
Basic Engine Tests20
Crankcase Vacuum Test20
Incorrect Vacuum In Crankcase20
Compression Test21
Cylinder Leakdown Test21
Leakdown Test Instructions21
Leakdown Test Results21
Air Cleaner Assembly-Exploded View22
Precleaner Service22
Section 4. Air Cleaner And Air Intake System22
Paper Element Service23
Inspect Air Cleaner Components23
Bushings In Air Cleaner Base23
Breather Hose24
Disassembly24
Clean Air Intake/Cooling Areas25
Fuel Type26
Gasoline/Ether Blends26
Section 5. Fuel System And Governor26
Fuel System Troubleshooting Guide27
Fuel Filter27
Fuel Pump27
Repair27
Pulse Fuel Pump28
Carburetor28
Troubleshooting–Fuel System28
Carburetor Adjustment29
Fixed Main Jet Carburetor29
Low Idle Mixture Adjustment30
Optimum Low Idle Fuel Setting30
Low Idle Speed Setting30
Carburetor-Exploded View31
Welch Plug Removal31
Main Fuel Jet Removal32
Choke Shaft Removal32
Throttle Shaft Removal32
Cleaning32
Inspection33
Choke Shaft Installation33
Welch Plug Installation33
Carburetor Reassembly33
Fuel Shut-Off Solenoid34
High Altitude Operation34
Unitized Throttle And Choke Control34
Throttle Cable Adjustment34
Adjusting Unitized Throttle/Choke Control35
Typical Throttle/Choke Controls35
Starting An Engine Equipped With Unitized Throttle And Choke Control35
Throttle Position For Starting Engine35
High Speed (Rpm) Adjustment36
Adjusting High Speed (Rpm)36
Choke Adjustment36
Separate Throttle And Choke Control37
Install Separate Control Cables37
Throttle Control Installation37
Choke Control Installation37
Changing The High Speed (Rpm) On The Engines With Separate Controls (Increase Or Decrease Rpm)38
Governed Idle Adjustment38
Location Of Governed Idle Adjusting Screw38
Governor Gear/Flyweight Assembly38
Operation39
Initial Adjustment39
Tightening Governor Lever Nut39
Governor Sensitivity Adjustment40
Governor Spring Location Chart40
Viscosity Grades Table41
Check Oil Level41
Section 6. Lubrication System41
Change Oil And Oil Filter42
Removing Dipstick42
Oil Level Dipstick42
Oil Drain Plug, Oil Filter42
Full-Pressure Lubrication System43
Service43
Oil Filter43
Oil Sentry43
Installation44
Oil Sentry Pressure Switch Location44
Testing The Oil Sentry Switch44
Testing Oil Pressure44
Spark Plug Service45
Section 7. Electrical System And Components45
Electronic Cd Ignition System47
Capacitive Discharge Ignition Module48
Troubleshooting And Testing Cd Ignition Systems48
Preliminary Test48
Cd Ignition System Troubleshooting Guide49
Ignition Tester, Spx Part No. Ko104649
Testing Cd Ignition Module Secondary49
Battery Charging50
Battery Maintenance50
Battery Test50
Electrical Systems Wiring Diagrams And Battery Charging Systems50
3 Amp Unregulated Battery Charging System/70 Watt Lighting51
Troubleshooting Guide 3 Amp Battery Charging System With 70 Watt Lighting Stator52
Troubleshooting Guide 3 Amp/70 Watt Braking Stator53
9 Or 15 Amp Regulated Battery Charging System55
9 Or 15 Amp Stator And Rectifier-Regulator56
Proper Connection To Test 9 Or 15 Amp Charging System56
Troubleshooting Guide 9 Or 15 Amp Regulated Battery Charging System57
Electric Starters58
Troubleshooting Guide-Starting Difficulties58
Starter Removal And Installation59
Starter Drive Service59
Drive Components59
Assembling Inner Half Of Tool Around The Armature Shaft And Retaining Ring59
Retaining Ring Installation60
Assembling Larger Inner Half Around Spring Retainer60
Starter Disassembly60
Inertia Drive Electric Starter60
Brush Replacement61
Removing Brush Carrier Assembly61
Commutator Service61
Starter Reassembly61
Installing Brush Carrier Using Staples62
Torquing Thru Bolts62
Assembled Starter62
Typical Disassembly Sequence63
Drain Oil From Crankcase And Remove Oil Filter63
Oil Drain Location, Oil Filter, And Oil Fill Cap/Dipstick63
Section 8. Disassembly63
Remove Oil Sentry Pressure Switch (On Models So Equipped)64
Remove Blower Housing64
Remove Muffler64
Remove Electric Starter64
Removing Electric Starter65
Remove Air Cleaner65
Air Cleaner Components65
Remove External Governor Components, Carburetor, And Fuel Pump65
Disconnecting Fuel Line From Carburetor66
Disconnecting Pulse Line From Fitting66
Removing Heat Deflector Screw And Ground Lead66
Disconnecting Fuel Solenoid Lead66
Removing Speed Control Bracket From Closure Plate67
Disconnecting Governor Spring67
Removing Governor Lever67
Removing Heat Deflector67
Remove Ignition Module68
Removing Lead From Clip (Rfi Suppression Equipped Units)68
Remove Grass Screen, Fan, And Flywheel68
Removing Fan And Flywheel Mounting Hardware68
Removing Flywheel Using Puller69
Remove The Stator69
Remove Valve Cover And Cylinder Head69
Valve Cover And Gasket Details69
Removing Cylinder Head Bolts And Washer70
Removing Cylinder Head And Gasket70
Disassemble Cylinder Head70
Removing Spark Plug70
Disassembling Rocker Arm Components71
Removing Valves With Spring Compressor71
Remove Closure Plate71
Closure Plate And Gasket Removed From Crankcase71
Disassemble Closure Plate72
Removing Governor Gear72
Remove Cam Gears, Cam Shafts, And Oil Pump72
Removing Exhaust Side Cam Shaft And Slotted Thrust Washer73
Intake Cam Shaft And Oil Pump Assembly73
Remove Connecting Rod And Piston73
Removing Connecting Rod Cap73
Remove Piston From Connecting Rod74
Remove Piston Rings74
Remove Crankshaft And Balance Weight Assembly74
Balance Weight Disassembly74
Removing Crank Gear Key75
Removing Balance Weight Screw75
Disassembled Balance Weight75
Remove Governor Cross Shaft75
Remove Pto And Flywheel Side Oil Seals76
Automatic Compression Release (Acr)77
Acr Details77
Section 9. Inspection And Reconditioning77
Cam Gears78
Crankshaft And Crank Gear78
Crankcase78
Honing78
Measuring Piston-To-Bore Clearance79
Measuring Piston Diameter79
Balance Weight Assembly79
Balance Weight-To-Eccentric Clearance80
Measuring Balance Weight To Crankshaft Eccentric Ring(S) Clearance80
Measuring Balance Weight Guide Pin And Guide Shoe-To-Closure Plate Guide Channel Running Clearance80
Measuring Guide Pin O.d.81
Measuring Guide Shoe Hole I.d.81
Flywheel81
Cylinder Head And Valves82
Valve Details82
Valve Guides85
Valve Seat Inserts85
Lapping Valves85
Pistons And Rings85
Common Types Of Piston And Ring Damage86
Some Important Points To Remember When Servicing Piston Rings87
Measuring Piston Ring End Gap87
Measuring Piston Ring Side Clearance87
Install Piston Rings87
Connecting Rods88
Oil Pump Assembly And Pressure Relief Valve88
Governor Gear And Shaft88
Procedure To Install Governor Shaft88
Install Pto Side Oil Seal90
Section 10. Reassembly90
Www.smallenginediscount.com90
Pto Seal Depth Details91
Install Governor Cross Shaft91
Install Oil Pump Assembly And Intake Cam Shaft91
Installing Oil Pump And Lower Drive Pin On Intake Cam Shaft91
Assembled Intake Cam Shaft Details92
Gerotor Gears Installed In Oil Pump92
Installing Oil Pump Outlet Seal92
Oil Pump Outlet Seals92
Checking Outlet Seal Passage Opening (Open Style)93
Torquing Oil Pump Mounting Screws93
Install Crankshaft And Balance Weight93
Installing Crank Gear Key93
Installing Crankshaft Assembly94
Install Piston To Connecting Rod94
Install Piston And Connecting Rod94
Assembled Piston And Connecting Rod94
Direction Arrow On Piston95
Installing Piston And Connecting Rod95
Installing Cam Levers95
Install The Exhaust Cam Shaft And Cam Gear95
Exhaust Cam Shaft Installation96
Spring Installed On Acr Weight96
Hooking Acr Spring Onto Exhaust Cam Gear96
Installing Exhaust Cam Gear96
Install Intake Cam On Cam Shaft97
Install Crank Gear97
Install Flywheel Side Oil Seal97
Install Closure Plate Gasket, Closure Plate, And Wiring Harness97
Aligning And Installing Closure Plate98
Closure Plate Installed98
Assemble Cylinder Head98
Install Cylinder Head98
Installing Drain Back Check Ball99
Installing Head Gasket99
Installing Cylinder Head Fasteners99
Install Rocker Arms And Push Rods99
Installing Push Rods And Rocker Arm Assemblies100
Adjusting Valve Clearance (Lash)100
Locking Adjustment Nut Set Screw100
Install Valve Cover100
Install Stator And Wiring Harness101
Installing B+Lead Into Connector101
Install Pipe Plug Or Fitting And Pulse Line For Fuel Pump101
Connecting Pulse Line To Fitting101
Install Fan And Flywheel102
Installing Fan And Mounting Hardware To Flywheel102
Torquing Flywheel102
Install Electric Starter103
Install Ignition Module103
Setting Air Gap103
Tightening Clip Around Sheathing103
Install New Spark Plug104
Install Heat Deflector, Carburetor, Linkage And Air Cleaner Base104
Mounting Stud Installed104
Installing Intake Gasket And Heat Deflector104
Installing Carburetor Assembly With Linkages105
Securing Ground Lead105
Fuel Solenoid Lead Secured With Tie Strap105
Connecting Fuel Line To Carburetor105
Installing Air Cleaner Base106
Installing Mounting Screw106
Torquing Air Cleaner Fasteners106
Install And Adjust Governor Lever106
Mounting Speed Control Bracket107
Connecting Choke Linkage And Governor Spring107
Attaching Speed Control Bracket107
Install Fuel Pump (If Equipped)107
Installing Fuel Pump108
Install Rectifier-Regulator108
Install Blower Housing And Flywheel Screen108
Installing Blower Housing Screws108
Installing Grass Screen109
Install Oil Sentry Or Pipe Plug109
Installing Pipe Plug Or Adapter109
Install Air Cleaner Element, Precleaner, And Air Cleaner Cover109
Installing Precleaner110
Installing Air Cleaner Cover110
Install Muffler110
Install Drain Plug, Oil Filter, And Oil110
Prepare The Engine For Operation111
Testing The Engine111