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Kohler Aegis 05810334 Service Manual

Kohler liquid cooled vertical crankshaft service manual
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S
M
ERVICE
ANUAL
K
A
®
™
OHLER
EGIS
17,20,23 HP
L
-C
IQUID
OOLED
V
C
ERTICAL
RANKSHAFT
1

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Summary of Contents for Kohler Aegis 05810334

  • Page 1 ERVICE ANUAL ® ™ OHLER EGIS 17,20,23 HP IQUID OOLED ERTICAL RANKSHAFT...

  • Page 2: Table Of 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. Cooling System ... Section 8.

  • Page 3: Section 1. Safety And General Information

    Go Back Safety and General Information Safety Precautions To insure safe operations 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 Warning is used to indicate the presence of a hazard that can cause severe personal injury, death, or substantial property damage if the warning is ignored.
  • Page 4 Section 1 Safety and General Information WARNING Explosive Fuel can cause fires and severe burns. Stop engine before filling fuel tank. Explosive Fuel! 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 5 Engine Identification Numbers 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 6 Section 1 Safety and General Information 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 7 Change engine coolant. Every 1000 Hours Perform these maintenance procedures more frequently under extremely dusty, dirty conditions. Only required for Denso starters. Not necessary on Delco starters. Have a Kohler Engine Service Dealer perform this service. Safety and General Information...
  • Page 8 Section 1 Safety and General Information Storage If the engine will be out of service for two months or more, use the following storage procedure: 1. Clean the exterior surfaces of the radiator and engine. 2. Change the oil and filter while the engine is still warm from operation.
  • Page 9 260.6 Cyl. #2 Fuel Pump Hose 434.1 479.3 Over All 140.0 Mounting Hole ‘‘A’’ 135.7 285.5 Oil Fill 451.0 Oil Fill & Dipstick 430.6 Mounting Surface Mounting Hole ‘‘A’’ 40.8 Oil Drain Plug Oil Drain 3/8 N.P.T inch 95.8 Center of Gravity Figure 1-4.
  • Page 10 Section 1 Safety and General Information General Specifications Power (@ 3600 RPM, corrected to SAE J1995) LV560 ... 12.7 kW (17 HP) LV625 ... 14.9 kW (20 HP) LV675 ... 17.1 kW (23 HP) Peak Torque LV560 (@ 2400 RPM) ... 32.5 N·m (24 ft. lb.) LV625 (@ 2400 RPM) ...
  • Page 11 Carburetor and Intake Manifold Intake Manifold Mounting Fasteners Torque ... 6.2 N·m (55 in. lb.) Carburetor Mounting Fasteners Torque ... 6.2 N·m (55 in. lb.) Connecting Rod Cap Fastener Torque (torque in increments) ... 11.3 N·m (100 in. lb.) Connecting Rod-to-Crankpin Running Clearance New ...
  • Page 12 Section 1 Safety and General Information Crankshaft (Cont'd.) Connecting Rod Journal O.D. - New ... 35.955/35.973 mm (1.4156/1.4163 in.) O.D. - Max. Wear Limit ... 35.94 mm (1.415 in.) Max. Taper ... 0.018 mm (0.0007 in.) Max. Out-of-Round ... 0.025 mm (0.0010 in.) Crankshaft T.I.R.
  • Page 13 Ignition Spark Plug Type (Champion ® or equivalent) ... RC14YC (Kohler Part No. 66 132 01-S) 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 ... 0.2/0.3 mm (0.008/0.012 in.) Ignition Module Fastener Torque ...
  • Page 14 Section 1 Safety and General Information Piston, Piston Rings, and Piston Pin (Cont'd.) Top and Middle Compression Ring End Gap LV560 New Bore Top Ring ... 0.180/0.380 mm (0.0071/0.0150 in.) Middle Ring ... 0.180/0.440 mm (0.0071/0.0173 in.) Used Bore (Max.) ... 0.76 mm (0.029 in.) LV625 New Bore Top Ring ...
  • Page 15 Valves and Valve Lifters (Cont'd.) Intake Valve Guide I.D. New ... 7.038/7.058 mm (0.2771/0.2779 in.) Max. Wear Limit ... 7.134 mm (0.2809 in.) Intake Valve Stem Diameter New ... 6.982/7.000 mm (0.2749/0.2756 in.) Exhaust Valve Guide I.D. New ... 7.038/7.058 mm (0.2771/0.2779 in.) Max.
  • Page 16 Section 1 Safety and General Information English Fastener Torque Recommendations for Standard Applications Tightening Torque: N·m (in. lb.) + or - 20% Bolts, Screws, Nuts and Fasteners Assembled Into Cast Iron or Steel Grade 2 Size 8-32 2.3 (20) 10-24 3.6 (32) 10-32 3.6 (32)

  • Page 17: Section 2. Special Tools

    Cylinder Leakdown Tester ... 25 761 05-S Ignition System Tester ... 24 455 02-S Starter Ring Tool ... 25 761 18-S *These items can be ordered through your Kohler distributor or purchased directly from SPX Corp. by phoning 1-800-533-0492. Ignition System Tester Use Kohler Part No.

  • Page 18: Section 2 Special Tools

    Section 2 Special Tools Special Tools You Can Make Flywheel Holding Tool Flywheel removal and reinstallation becomes a ‘‘snap’’ using a handy holding tool you can make out of a piece of an old ‘‘junk’’ flywheel ring gear as shown in Figure 2-2.

  • Page 19: Section 3. Troubleshooting

    Go Back Troubleshooting Guide When troubles occur, be sure to check the 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 common causes of engine troubles are listed below.
  • Page 20 Section 3 Troubleshooting Engine Overheats (cont'd.) 7. Radiator cap faulty or loose. 8. Lean fuel mixture. 9. Water pump belt failed/off. 10. Water pump malfunction. Engine Knocks 1. Excessive engine load. 2. Low crankcase oil level. 3. Old or improper fuel. 4.
  • Page 21 Crankcase vacuum is best measured with either a water manometer (Kohler Part No. 25 761 02-S) or a vacuum gauge (Kohler Part No. 25 761 22-S). Complete instructions are provided in kits. Test the crankcase vacuum with the manometer as follows: 1.
  • Page 22 Section 3 Troubleshooting Leakdown Test Instructions 1. Run engine 3-5 minutes to warm it up. 2. Remove spark plugs, dipstick, and air filter from engine. 3. Rotate crankshaft until piston (of cylinder being tested) is at top dead center (TDC) of compression stroke.

  • Page 23: Section 4. Air Cleaner And Air Intake System

    Go Back Air Cleaner and Air Intake System Air Intake System General All intake air, for both cooling and combustion, is drawn in through the screen in the upper blower housing. Service Check the air intake screen daily or before starting the engine.
  • Page 24 Section 4 Air Cleaner and Air Intake System Figure 4-4. Cleaning Separated Screen Assembly. Always reinstall the upper blower assembly after it has been removed for service. Do not operate the engine with the upper blowing housing or screen removed. Air Cleaner General These engines are equipped with a replaceable, high-...
  • Page 25 5. Clean the air cleaner base area, upper blower housing, an screen assembly of any debris accumulation. 6. Install the new paper element; Kohler Part No. 66 083 01-S and secure with the filter element retainer strap. Disassembly/Reassembly - Standard Type If the air cleaner base has to be removed, proceed as follows.
  • Page 26 Section 4 Air Cleaner and Air Intake System 4. Disconnect the breather hose from the air cleaner base. Breather Hose Figure 4-9. Base Plate Removal on Standard Type. 5. Slide the clamp and air cleaner base off the stud. 6. Reverse procedure to reassemble components. Torque the hex.

  • Page 27: Section 5. Fuel System And Governor

    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. Gasoline/Ether blends Methyl Tertiary Butyl Ether (MTBE) and unleaded gasoline blends (up to a maximum of 15% MTBE by volume) are approved as a fuel for Kohler engines.
  • Page 28 Section 5 Fuel System and Governor Fuel System Tests When the engine starts hard, or turns over but will not start, it is possible that the problem is in the fuel system. To find out if the fuel system is causing the problem, perform the following tests. Troubleshooting –...
  • Page 29 Fuel Pump General These engines are equipped with an external pulse fuel pump. The pumping action is created by the oscillation of positive and negative pressures within the crankcase. This pressure is transmitted to the pulse pump through a rubber hose connected between the pump and crankcase.
  • Page 30 Section 5 Fuel System and Governor Slow Circuit: (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. Air and fuel are mixed in the body of the slow jet and exit to the transfer port.
  • Page 31 Main Circuit: (Figure 5-3) At high speeds the engine operates mostly 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 air flow, where further mixing of the fuel and air takes place.
  • Page 32 Section 5 Fuel System and Governor Troubleshooting – Carburetor Related Causes Condition 1. Engine starts hard, runs roughly or stalls at idle speed. 2. Engine runs rich (indicated by black, sooty exhaust smoke, misfiring, loss of speed and power, governor hunting, or excessive throttle opening).
  • Page 33 Fuel Shut-off Solenoid Carburetors are equipped with a fuel shut-off solenoid, which also contains the main jet. The solenoid has a spring loaded pin which retracts when the key switch is ‘‘on’’, allowing the engine to function normally. When the key switch is turned ‘‘off’’, the pin extends and prevents fuel from entering the engine.
  • Page 34 Section 5 Fuel System and Governor Float Replacement 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 Carburetor Overhaul Kit (see page 5.10) if float replacement is necessary. 1.
  • Page 35 Refer to the Parts Manual for the engine being serviced to ensure the correct repair kits and replacement parts are used. The Kohler part number is stamped on the top of the carburetor mounting flange. Section 5...
  • Page 36 Section 5 Fuel System and Governor Overhaul Kit Contains: Qty. Description Gasket, air cleaner base Gasket, carburetor Screw, throttle adjusting Gasket, chamber screw Screw, idle adjusting Float Pin, float Inlet Needle Gasket, float chamber Spring, throttle adjusting screw Spring, idle adjusting screw Gasket, passage cover Choke Repair Kit Contains: Qty.
  • Page 37 Figure 5-7. Governor Controls and Linkage (External). Adjustments General The governed speed setting is determined by the position of the throttle control. It can be variable or constant, depending on the engine application. Initial Adjustment Make this adjustment whenever the governor lever is loosened or removed from the cross shaft.
  • Page 38 Section 5 Fuel System and Governor High Idle RPM Speed Adjustment (See Figure 5-8.) 1. With the engine running, move the throttle control to fast. Use a tachometer to check the RPM speed. 2. Loosen the lock nut on the high idle adjusting screw.

  • Page 39: Section 6. Lubrication System

    Go Back Lubrication System General This engine uses a full pressure lubrication system. This system delivers oil under pressure to the crankshaft, camshaft and connecting rod bearing surfaces. In addition to lubricating the bearing surfaces, the lubrication system supplies oil to the hydraulic valve lifters.
  • Page 40 (more often under severe conditions). Refill with service class SG, SH, SJ or higher oil, as specified in the ‘‘Viscosity Grades’’ table on previous page. Always use a genuine Kohler oil filter. Use chart below to determine part number to order.
  • Page 41 3. Before removing the oil filter, clean the surrounding area to keep dirt and debris out of the engine. Remove the old filter and wipe/clean the surface where the filter mounts. 4. Reinstall the drain plug. Make sure it is tightened to 13.6 N·m (10 ft.
  • Page 42 Section 6 Lubrication System To install the switch, follow these steps: ® 1. Apply Loctite No. 592 Pipe Sealant with Teflon ® (or equivalent) to the threads of the switch. 2. Install the switch into the tapped hole in the breather cover.

  • Page 43: Section 7. Cooling System

    Go Back WARNING: Explosive release of fluids from pressurized cooling system can cause serious burns! When it is necessary to open cooling system at radiator cap, shut off engine and remove filler cap only when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely.
  • Page 44 Section 7 Cooling System Coolant Recommendations Use equal parts of ethylene glycol (anti-freeze) and water only. Distilled or deionized water is recommended, especially in areas where the water contains a high mineral content. Propylene glycol based anti-freeze is not recommended. This mixture will provide protection from -37º...
  • Page 45 Torque the plugs to 13.5 N·m (120 in. lb.). Some early production engines contained steel plugs. Always use brass (soft) plugs (Kohler Part. No. 66 139 01-S) when service is performed. 5. Loosen the two screws holding the overflow reservoir retainer bracket to the radiators.
  • Page 46 Section 7 Cooling System Figure 7-8. Removing Overflow Reservoir. 7. Reinstall the reservoir, inserting the two lower molded protrusions into the mounting holes in the lower support bracket. Engage the top bracket around the upper protrusion of the reservoir. Hold it in this position and torque the two screws to 7.3 N·m (65 in.
  • Page 47 Hoses and Tubes Hoses and tubes are used to connect the components within the cooling system. To guard against coolant loss and hose failure, the hoses, tubes and their connections should be checked regularly for leaks or damage. Loss of coolant can result in serious engine damage.
  • Page 48 Section 7 Cooling System High Temperature Sensor A high temperature sensor may be mounted in the intake manifold and is used to activate a warning light, audible alarm, or kill the engine (depending on the application), if the safe operating temperature is exceeded.
  • Page 49 15 psi Figure 7-12. Adapter Installed onto the Tester. 2. Pressurize the tester to 15 psi. 3. Observe the indicated pressure. It should hold steady and not decrease or leak down. If leakage is detected, the cap should be replaced. If the tester pressure is increased to 16 psi, or above, the cap should then ‘‘bleed off’’...
  • Page 50 Section 7 Cooling System...

  • Page 51: Section 8. Electrical System And Components

    The engine is equipped with the following spark plugs: Type: The standard spark plug is a Champion RC14YC (Kohler Part No. 66 132 01-S). Equivalent alternate brand plugs can also be used. Gap: 0.76 mm (0.030 in.)
  • Page 52 Section 8 Electrical System and Components Inspection Inspect each spark plug as it is removed from the cylinder head. The deposits on the tip can be an indication of the general condition of the engine and/or adverse operating conditions. Normal and fouled plugs are shown in the following photos: Normal: A plug taken from an engine operating under normal conditions will have light tan or gray colored...
  • Page 53 Overheated: Chalky, white deposits indicate very high combustion temperatures. This condition is usually accompanied by excessive gap erosion. Lean carburetor settings, an intake air leak, or incorrect spark timing are normal causes for high combustion temperatures. Battery General A 12 volt battery with a minimum of 400 cold cranking amps should be sufficient for cranking.
  • Page 54 Section 8 Electrical System and Components Electronic CD Ignition Systems Operation of CD Ignition Systems Capacitive Discharge with Fixed Timing This system consists of the following components. See Figure 8-3. • A magnet assembly which is permanently affixed to the flywheel. Kill Switch or ‘‘Off’’...
  • Page 55 Figure 8-5. Capacitive Discharge Ignition Module. Operation: As the flywheel rotates, the magnet grouping passes the input coil (L1). The corresponding magnetic field induces energy into the input coil (L1). The resultant pulse is rectified by D1 and charges capacitor C1. As the magnet assembly completes its pass, it activates the triggering device (L2), which causes the semiconductor switch (SCS) to turn on.
  • Page 56 Electrical System and Components Test Procedure for Standard CD Ignition Test 1. Test for spark on both cylinders with Kohler ignition tester, Part No. 24 455 02-S. Disconnect one spark plug lead and connect it to the post terminal of the tester. Connect the clip to a good ground, not to the spark plug.
  • Page 57 CONNECTOR LAYOUT Starter (L/R) Ground Battery (R) Key Switch Starter Ground (B) Battery Run (R) Ignition Kill (W) Key Switch Accessory (Y) Ignition Kill Connector Battery Starter Solenoid Stud Fuse Starter Solenoid Tang Starter Assembly Figure 8-6. Wiring Diagram - 15/20/25 amp Regulated Battery Charging System. Ground-To-Kill Lead (White) Light Key Switch...
  • Page 58 Section 8 Electrical System and Components Rectifier-Regulator Figure 8-8. 15/20/25 amp Stator and Rectifier-Regulator. Lighting Lead (Yellow) Diode Charging Lead (Black) Figure 8-9. 3 amp/70 Watt Stator. Connector AC Leads Lighting Stator 15 Amp Stator 3 Amp Charging Stator...
  • Page 59 Stator The stator is mounted on the crankcase behind the flywheel. Should the stator have to be replaced, follow the procedures in Section 9 - “Disassembly.” Rectifier-Regulator The rectifier-regulator is mounted inside the lower blower housing. See Figure 8-10. To replace it; remove the upper blower housing, disconnect the connector plug, remove the single mounting screw with the ground lead and lift out the rectifier-regulator.

  • Page 60: Troubleshooting Guide

    Section 8 Electrical System and Components Troubleshooting Guide 15/20/25 amp Battery Charging Systems If it is difficult to keep the battery charged, or the battery overcharges, the problem is usually with the charging system or the battery. NOTE: Always zero ohmmeter on each scale before testing to ensure accurate readings. Voltage tests should be made with the engine running at 3600 RPM - no load.
  • Page 61 Troubleshooting Guide 3 amp Battery Charging System with 70 Watt Lighting Stator NOTE: Zero ohmmeters on each scale to ensure accurate readings. Voltage tests should be made with engine running at 3000 RPM - no load. Battery must be fully charged. Problem 1.
  • Page 62 Section 8 Electrical System and Components Solenoid Shift Electric Starters The following subsection covers the solenoid shift style electric starters. Some of the information in the preceding subsection relates also to this style of starter, so it is not repeated here. A Nippendenso or Delco-Remy solenoid shift starter may be used.
  • Page 63 Delco-Remy Starters Figure 8-12. Starter Disassembly 1. Remove the hex. nut and disconnect the positive (+) brush lead/bracket from the solenoid terminal. 2. Remove the three screws securing the solenoid to the starter. Remove the solenoid and plunger spring from the drive end cap. See Figure 8-13 and 8-14.
  • Page 64 Section 8 Electrical System and Components 5. Remove the commutator end plate assembly, containing the brush holder, brushes, springs, and locking caps. Remove the thrust washer from inside the commutator end. See Figure 8-17. Figure 8-17. Removing Commutator End Plate Assembly.
  • Page 65 11. Remove the retainer from the armature shaft. Save the stop collar. NOTE: Do not reuse the old retainer. Figure 8-22. Removing Retaining Ring. Collar Armature Washer Figure 8-23. Delco-Remy Starter. Electrical System and Components 12. Remove the drive pinion assembly from the armature.
  • Page 66 Brush Replacement 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.”...
  • Page 67 Starter Service Clean the drive lever and armature shaft. Apply Kohler electric starter drive lubricant Part No. 52 357 02-S to the lever and shaft (Versilube G322L or Mobil Temp SHC 32).
  • Page 68 5. Lubricate the fork end and center pivot of the drive lever with drive lubricant (Kohler Part No. 52 357 02-S). Position the fork end into the space between the captured washer and the rear of the pinion.
  • Page 69 10. Starter reassembly when replacing the Brushes/ Brush Holder Assembly: a. Hold the starter assembly vertically on the end housing, and carefully position the assembled brush holder assembly with the supplied protective tube, against the end of the commutator/armature. The mounting screw holes in the metal clips must be “up/out.”...
  • Page 70 Section 8 Electrical System and Components 11. Install the end cap onto armature and frame, aligning the thin raised rib in the end cap with the corresponding slot in the grommet of the positive (+) brush lead. 12. Install the two thru bolts, and the two brush holder mounting screws.
  • Page 71 Starter Assembly Figure 8-44. Nippendenso Solenoid Shift Starter. Operation – Solenoid Shift Starter When power is applied to the starter the electric solenoid moves the drive pinion out onto the drive shaft and into mesh with the flywheel ring gear. When the pinion reaches the end of the drive shaft it rotates the flywheel and cranks the engine.
  • Page 72 Service may be necessary more frequently under dusty or dirty conditions. Starter Reassembly 1. Apply new drive lubricant (Kohler Part No. 52 357 02-S) to the armature shaft splines and Plastic drive lever. Install the pinion onto the splines.

  • Page 73: Section 9. Disassembly

    Go Back 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(s). 2) Disconnect negative (-) battery cable from battery. General Clean all parts thoroughly as the engine is disassembled.
  • Page 74 Section 9 Disassembly Shut Off Fuel Supply Drain Oil From Crankcase and Remove Oil Filter 1. Remove the dipstick and one of the oil drain plugs. See Figures 9-2 and 9-3. Figure 9-2. Removing Oil Fill Cap/Dipstick. Oil Drain Plug Oil Drain Plug Filter Figure 9-3.
  • Page 75 Drain the coolant into a suitable container. Early production units contained steel plugs, remove only when the cylinders are cool. Replace with brass (soft) plugs on reassembly, Kohler Part No. 66 139 01-S. Figure 9-9. Location of Coolant Drain Plugs.
  • Page 76 Section 9 Disassembly 2. Disconnect the fuel lines at the inlet of the carburetor, and the in-line fuel filter. See Figure 9-11. Figure 9-11. Removing Fuel Line at Carburetor. 3. Remove the two hex. flange screws securing the fuel pump to the blower housing and remove the pump and lines as an assembly.
  • Page 77 Remove Carburetor 1. Disconnect the fuel solenoid leads (most models) from the wiring harness. 2. Disconnect the dampening spring and throttle linkage from the governor arm. Remove the black bushing, and clip it back onto the linkage, so it does not get lost. See Figure 9-15. Figure 9-15.
  • Page 78 Section 9 Disassembly 4. Remove the throttle control bracket, governor lever, and governor spring as an assembly. See Figure 9-19. Figure 9-19. Removing Main Bracket and Governor Lever. Remove Electric Starter 1. Disconnect the leads from the starter. 2. Remove the two starter motor mounting screws. See Figure 9-20.
  • Page 79 Figure 9-23. Location of Four Screws Securing Blocking Plates. Remove Overflow Reservoir 1. Remove the reservoir cap from the reservoir. 2. Loosen the two screws holding the overflow reservoir retainer bracket to the radiators. See Figure 9-24. 3. Carefully lift the bracket up slightly to unhook the locking tab, and remove the reservoir from under the bracket.
  • Page 80 Section 9 Disassembly 3. Slide the ignition module onto the contoured section of the flywheel. Disconnect the lead and remove the module from the engine. Note: On modules containing 90º terminals, the leads must be removed by pulling to the side.
  • Page 81 Remove Radiators and Cooling System 1. Remove the hex. nut from the center mounting stud, located between the two radiators and through the main support bracket. See Figure 9-31. Figure 9-31. Removing Center Mounting Nut. 2. Cut the metal tie strap from around the lower hose/tube assembly, secured to the blower housing.
  • Page 82 Section 9 Disassembly Figure 9-36. Lower Hose Removed. 6. Lift the entire cooling system, with the radiators, hoses, and supporting brackets attached, off the engine. See Figure 9-37. Further disassembly may be performed as required. When disassembly of hose connections is necessary, the use of a rubber lubricant on the inside of hoses will make installation easier.
  • Page 83 Figure 9-40. Removing B+ Charging Lead from Connector. 4. Remove the stator and rectifier-regulator. Remove Cam Pulley and Coolant Pump Belt 1. Remove the hex. flange screw and flat washer, securing the cogged drive pulley to the camshaft. See Figure 9-41. Figure 9-41.
  • Page 84 Section 9 Disassembly 2. Loosen and unscrew the hex. cap section, securing the transfer tube to the 90° fitting in the crankcase. See Figure 9-44. Support the fitting with a wrench, if possible, when loosening the hex. cap section. NOTE: The 90° fitting in the crankcase, which the transfer tube is connected to, is sealed and installed at the factory in a specific position.
  • Page 85 2. Remove the two No. 1 side intake manifold mounting screws securing the ground leads and clip for the wiring harness. Note the locations of the clip and ground leads. See Figure 9-48. Figure 9-48. Removing No. 1 Side Intake Manifold Screws with the Ground Leads.
  • Page 86 Section 9 Disassembly Remove Intake Manifold, Temperature Sensor, and Thermostat 1. Remove the four remaining hex. flange screws securing the intake manifold to the cylinder heads. See Figure 9-52. Figure 9-52. Removing Remaining Intake Manifold Screws. 2. Separate the intake manifold from the cylinder heads and remove it, by shifting it toward the crankshaft, until the carburetor studs clear the lower blower housing.
  • Page 87 Figure 9-56. Removing Dipstick Tube Assembly. ™ Remove Oil Sentry (If So Equipped) ™ 1. Remove the Oil Sentry switch, from the breather cover. See Figure 9-57. Figure 9-57. Removing Oil Sentry Remove Breather Cover 1. Remove the four hex. flange screws securing the breather cover to the crankcase.
  • Page 88 Section 9 Disassembly Remove Spark Plugs 1. Remove the spark plug from each cylinder head using a spark plug socket. See Figure 9-61. Figure 9-61. Removing Spark Plug(s). Remove Valve Covers 1. Remove the four hex. flange screws securing each of the valve covers. Note the differences between the covers, and the lengths of the screws, for proper installation later.
  • Page 89 Figure 9-65. Removing Hex. Flange Nuts and Washers from Studs. 5. Carefully remove the cylinder heads, and head gaskets. See Figure 9-66. NOTE: It is not necessary to remove the cylinder studs from the crankcase unless replacement is intended. If studs are removed for any reason, discard the old stud(s), do not reuse/reinstall.
  • Page 90 Section 9 Disassembly 3. With the keepers taken out, the following items can be removed (see Figures 9-70 and 9-71): • valve spring retainers • valve springs • valve spring caps • intake and exhaust valves • valve stem seals (intake valve only) NOTE: These engines use a valve stem seal on the intake valves.
  • Page 91 Oil Pump Assembly The oil pump is mounted in the oil pan. If service is required, refer to the service procedures under ‘‘Oil Pump Assembly’’ in Section 10. Remove Camshaft 1. Remove the camshaft and shim. See Figure 9-74. Figure 9-74. Removing Camshaft and Shim. Remove Governor Cross Shaft 1.
  • Page 92 Section 9 Disassembly 2. Carefully remove the connecting rod and piston assembly from the cylinder bore. See Figure 9-78. NOTE: The cylinders are numbered on the crankcase. Use the numbers to mark each end cap, connecting rod, and piston for reassembly. Do not mix end caps and connecting rods.

  • Page 93: Section 10. Inspection And Reconditioning

    Go Back 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 & External Governor, Section 5 Ignition, Charging &...
  • Page 94 Procedure to Install New Plug: 1. Use a single cylinder camshaft pin Kohler Part No. 47 380 09-S as a driver and tap the plug into the plug bore until it seats at the bottom of the bore.
  • Page 95 Crankcase These engines contain a cast-iron cylinder liner that may be reconditioned as follows: Inspection and Service Check all gasket surfaces to make sure they are free of gasket fragments. Gasket surfaces must also be free of deep scratches or nicks. Check the cylinder bore for scoring.
  • Page 96 Replace the flywheel, the crankshaft, and the key if flywheel key is sheared or the keyway is damaged. Inspect the ring gear for cracks or damage. Kohler does not provide ring gears as a serviceable part. Replace the flywheel if the ring gear is damaged.
  • Page 97 Exhaust Valve Dimension Seat Angle Insert O.D. Guide Depth Guide I.D. Valve Head Diameter Valve Face Angle Valve Margin (Min.) Valve Stem Diameter Figure 10-5. Valve Details. Normal: Even after long hours of operation a valve can be reconditioned and reused if the face and margin are in good shape.
  • Page 98 Section 10 Inspection and Reconditioning Leakage: A poor grind on face or seat of valve will allow leakage resulting in a burned valve on one side only. Stem Corrosion: Moisture in fuel or from condensation are the most common causes of valve stem corrosion. Condensation occurs from improper preservation during storage and when engine is repeatedly stopped before it has a chance to reach normal operating temperatures.
  • Page 99 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 excessive oil consumption. To check valve guide-to-valve stem clearance, thoroughly clean the valve guide and, using a split-ball gauge, measure the inside diameter.
  • Page 100 Section 10 Inspection and Reconditioning Pistons and Rings Inspection Scuffing and scoring of pistons and cylinder walls occurs when internal temperatures approach the welding point of the piston. Temperatures high enough to do this are created by friction, which is usually attributed to improper lubrication, and/or overheating of the engine.
  • Page 101 Replacement pistons are available in STD bore size, 0.08 mm (0.03 in.), 0.25 mm (0.010 in.), and 0.50 mm (0.20 in.) oversizes. Replacement pistons include new piston ring sets and new piston pins. Service replacement piston ring sets are also available separately for STD, 0.08 mm (0.03 in.), 0.25 mm (0.010 in.), and 0.50 mm (0.020 in.) oversized pistons.
  • Page 102 Section 10 Inspection and Reconditioning Install Piston Rings To install piston rings, proceed as follows: NOTE: Rings must be installed correctly. Ring installation instructions are usually included with new ring sets. Follow instructions carefully. Use a piston ring expander to install rings (see Figure 10-10).
  • Page 103 NOTE: The governor gear is held onto the shaft by small molded tabs in the gear. When the gear is removed from the shaft, these tabs are destroyed and the gear must be replaced. Therefore, remove the gear only if absolutely necessary.
  • Page 104 Section 10 Inspection and Reconditioning 2.0 mm (0.0787 in.) Governor Cross Shaft Seal Figure 10-15. Installing Cross Shaft Oil Seal. Figure 10-16. Governor Shaft Seal Installation. Figure 10-17. Governor Shaft Seal Position. 10.12 Water Pump The water/coolant pump consists of a sealed impeller assembly, which includes the outer cover and a cogged drive pulley.

  • Page 105: Section 11. Reassembly

    Go Back General NOTE: Make sure the engine is assembled using all specified torque values, tightening sequences, and clearances. Failure to observe specifications could cause severe engine wear or damage. Always use new gaskets, seals, and O-Rings. Make sure all traces of any cleaner are removed before the engine is assembled and placed into operation.
  • Page 106 Section 11 Reassembly Figure 11-1. Installing Flywheel End Oil Seal in Crankcase. The camshaft seal should be installed to a depth of 1-1.5 mm (.039-.059 in.) below the top of the seal bore. See Figure 11-2. Do not bottom the seal in the bore or the oil passage may be obstructed.
  • Page 107 Cylinder #1 Figure 11-5. Proper Piston Connecting Rod Orientation. 1. Stagger the piston rings in the grooves. The end gaps of the top two rings should be 180° apart and perpendicular to the rail end gaps, which should also be 180° apart. 2.
  • Page 108 Section 11 Reassembly Figure 11-8. Assembly of Nylon Washer, Retainer, and Setting the End play. Install Camshaft 1. Inspect the edges of the keyway in the end of camshaft and make sure they are not nicked or burred. Wrap this end using cellophane tape, so the keyway is covered, to protect the seal from being cut when the camshaft is installed.
  • Page 109 Determining Camshaft End Play 1. Install the shim removed during disassembly onto the camshaft. 2. Position the camshaft end play checking tool on the camshaft. See Figure 11-12. Figure 11-12. Checking Camshaft End Play. 3. Apply pressure on the end play tool, pushing the camshaft toward the crankshaft.
  • Page 110 Section 11 Reassembly 3. Install the O-Ring in groove as shown. See Figure 11-14. Apply a 1.5 mm (1/16 in.) bead of sealant to the sealing surface of the oil pan. See Figure 11-15 for the sealant pattern. Figure 11-14. Installing O-Ring in Groove of Oil Pan.
  • Page 111 Apply Loctite ® No. 272 Figure 11-17. Applying Loctite to New Stud. 2. Tighten two nuts together on the shorter threaded section. 3. Thread the end of the stud with the Loctite the crankcase, until an exposed stud height of 75 mm (2.952 in.) is obtained.
  • Page 112 Section 11 Reassembly Assemble Cylinder Heads 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.
  • Page 113 # 1 Cylinder Head # 2 Cylinder Head Figure 11-24. Cylinder Head Torque Sequence. Figure 11-25. Torquing Cylinder Heads. 6. Note the mark or tag identifying each push rod. Lightly apply assembly lubricant or grease to the ends of the push rods and install. Make sure that each push rod ball seats in its respective hydraulic lifter socket.
  • Page 114 Section 11 Reassembly 9. Mount a dial indicator to touch the top of the valve retainer, of the valve to be set. See Figure 11-27. NOTE: At this time, the valve will not be completely seated. Do not rotate the crankshaft.
  • Page 115 Shim Figure 11-30. Installing Shim(s). 14. Reassemble the rocker arm and pivot assembly to the head and seat the push rod. See Figure 11-30. Torque the fastener; 11.3 N·m (100 in. lb.) for a hex. flange screw, or 17.3 N·m (153 in. lb.) for a lock nut.
  • Page 116 Section 11 Reassembly Figure 11-33. Depressing To Bottom Limit of Lifter Plunger Travel. 10. With the lifter still compressed, slowly tighten the rocker arm fastener (clockwise) until the free end of the rocker arm just makes contact with the end of the valve. See Figure 11-34. Figure 11-34.
  • Page 117 Torque the plugs to 36.7 N·m (325 in. lb.). NOTE: Early production engines contained steel drain plugs. If encountered, replace with later production brass (soft) plugs, Kohler Part No. 66 139 01-S. 5/04 Section 11 Reassembly ®...
  • Page 118 Figure 11-43. Installing Dipstick Tube Assembly. 2. Insert a new metal tie strap (Kohler Part No. 66 454 01-S) through the slotted opening in lower blower housing, as shown in Figure 11-44. This will restrain the lower hose/tube assembly.
  • Page 119 Figure 11-44. Tie Strap in Lower Blower Housing. 3. Set the lower blower housing down into position on the crankcase, and align the eight mounting screw locations. Insert the mounting tab of the oil fill/dipstick tube into the corresponding blower housing slot from the bottom.
  • Page 120 Section 11 Reassembly Figure 11-48. Torquing Thermostat Housing Screws. 4. Check that the gasket surfaces of the intake manifold and cylinder heads are clean and free of any nicks or damage. 5. Install new intake manifold gaskets onto the port surfaces of the cylinder heads.
  • Page 121 from the crankshaft. Orient the parts as shown in Figure 11-54 while tightening. Torque the six intake manifold mounting screws in two stages; initially to 7.4 N·m (66 in. lb.) then to 9.9 N·m (88 in. lb.) in the sequence shown in Figure 11-55. Figure 11-52.
  • Page 122 Section 11 Reassembly NOTE: A mark or dot of paint applied to top of pulley indicating the keyway location will make installation easier. 2. If the fitting for the by-pass hose in the water pump was removed previously, apply pipe sealant with Teflon ®...
  • Page 123 1) Place a new ferrule/compression ring in the 90° fitting of crankcase and loosely install the hex. cap section onto the threads of the fitting. See Figure 11-62. Figure 11-62. Installing Ferrule and Hex. Cap onto Fitting. 2) Insert the plain end of the transfer tube through the hex.
  • Page 124 Section 11 Reassembly NOTE: When installation is complete, the tangs of the two hose clamps must be down toward the crankcase, away from the flywheel and below the adjacent flange of the lower blower housing. See Figure 11-66. Figure 11-66. Tang Orientation of Clamps. 9.
  • Page 125 12. Attach the by-pass hose to the fitting on the water pump and secure with the hose clamp. The tangs of the clamp should point outward. Completed installation should look as shown in Figure 11-70. Figure 11-70. By-pass Hose Installation. Install Stator and Rectifier-Regulator 1.
  • Page 126 Section 11 Reassembly 3. Place the small sleeve spacer onto the stud, in the center of the intake manifold. If the stud was removed from the manifold, apply Loctite to the lower set of threads and install until stud bottoms, or an exposed height of 32 mm (1.26 in.) is obtained.
  • Page 127 8. Lift the by-pass hose and secure it within the metal clip under the main support bracket. See Figure 11-78. Figure 11-78. Seating By-pass Hose. Install Electric Starter 1. Position the starter mounting plate onto the crankcase so that the cutout is at the bottom, and the offset is toward the dipstick tube.
  • Page 128 Section 11 Reassembly Install Ignition Modules and Flywheel 1. Route the spark plug leads of the ignition modules, out through the corresponding cutouts in the lower blower housing assembly. 2. Route the white kill leads from the wiring harness and connect them to the ‘‘kill’’ tabs of the ignition modules.
  • Page 129 3. Lower the flywheel down into position on crankshaft and make sure the ring gear section is below the legs of the ignition modules. See Figure 11-85. Figure 11-85. Lowering the Flywheel into Position. 4. Install the hex. flange screw and washer. 5.
  • Page 130 Section 11 Reassembly 7. Rotate the flywheel back and forth checking for clearance between the magnet and ignition modules. Make sure the magnet does not strike the modules. Recheck the gap with a feeler gauge and readjust if necessary. Final Air Gap: 0.28/0.33 mm (0.011/0.013 in.).
  • Page 131 Checking Valve Train 1. Rotate engine to check for free operation of the valve train. Check the clearance between valve spring coils at full lift. Minimum allowable clearance is 0.25 mm (0.01 in.). If engine seems tight or spring coils do not have proper clearance, repeat the valve lash adjustment procedure.
  • Page 132 Section 11 Reassembly 3. Install the carburetor as an assembly, onto the carburetor studs. See Figure 11-94. Carefully lift up on the lower blower housing, directly above the carburetor, and slide the carburetor into place against the gasket and manifold. Figure 11-94.
  • Page 133 Install Throttle Controls 1. Connect the choke linkage from the carburetor into the choke actuator lever on the speed control bracket assembly. See Figure 11-97. Washer, flat (3) Nut, Spring, M5x0.8 Choke Lock Return Figure 11-97. Throttle/Choke Control Bracket and Governor Lever Detail. 2.
  • Page 134 Section 11 Reassembly Install Fuel Pump 1. Mount the fuel pump, with the lines attached, onto the blower housing, using the two hex. flange screws. Torque the screws to 2.3 N·m (20 in. lb.). See Figure 11-99. Figure 11-99. Fuel Pump Mounting. 2.
  • Page 135 Figure 11-102. Rechecking Governor Linkage Adjustment. 4. After adjustment is correct, reinstall the black bushing and linkage into the governor lever. Install Muffler 1. Install the muffler or exhaust system to the exhaust port studs. Torque hex. flange nuts to 24.4 N·m (216 in. lb.). See Figure 11-103. Figure 11-103.
  • Page 136 2. Set up the engine on a test stand. Install an oil pressure gauge (Kohler Part No. 25 761 06-S is recommended). Start the engine and check to be certain that oil pressure (20 psi or more) is present.
  • Page 137 ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044 FOR SALES AND SERVICE INFORMATION IN U.S. AND CANADA, CALL 1-800-544-2444 FORM NO.: TP-2509 ISSUED: 9/01 REVISED: 5/04 MAILED: 6/04 LITHO IN U.S.A.

This manual is also suitable for:

Aegis 1500Aegis tp-2509Aegis lv560Aegis lv675sAegis lv560sAegis lv625s

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