Kohler Courage SV735 Manuals

Manuals and User Guides for Kohler Courage SV735. We have 6 Kohler Courage SV735 manuals available for free PDF download: Service Manual, Owner's Manual

Kohler Courage SV735 Service Manual (85 pages)

Brand: Kohler | Category: Engine | Size: 4.33 MB

Contents
1
Safety Precautions
2
Maintenance Instructions
3
Maintenance Schedule
3
Repairs/Service Parts
3
Maintenance
4
Oil Recommendations
4
Storage
4
Fuel Recommendations
4
Engine Dimensions
5
Specifications
5
Engine Identification Numbers
7
General Specifications
7
Torque Specifications
7
Crankcase
7
Intake Manifold
8
Oil Filter
8
Oil Pan
8
Oil Pump
8
Oil Sentry
9
Solenoid (Starter)
9
Speed Control Bracket
9
Starter Assembly
9
Clearance Specifications
9
Clearance Specifications
10
Crankshaft
10
Cylinder Bore
10
Cylinder Head
10
Piston, Piston Rings, and Piston Pin
11
Piston-To-Piston Pin Running Clearance
11
Valves and Valve Tappets
12
General Torque Values
13
English Fastener Torque Recommendations for Standard Applications
13
Metric Fastener Torque Recommendations for Standard Applications
13
Tools and Aids
14
Separate Tool Suppliers
14
Flywheel Holding Tool
16
Rocker Arm/Crankshaft Tool
16
Troubleshooting Guide
17
Engine Cranks but will Not Start
17
Engine will Not Crank
17
Engine Runs but Misses
17
Engine Loses Power
18
Engine Uses Excessive Amount of Oil
18
Oil Leaks from Oil Seals, Gaskets
18
External Engine Inspection
18
Crankcase Vacuum Test
19
To Test Crankcase Vacuum with Manometer
19
To Test Crankcase Vacuum with Vacuum/Pressure Gauge
19
Compression Test
20
Cylinder Leakdown Test
20
Air Cleaner
21
Air Cleaner Components
21
Paper Element
21
Air Cleaner Base
21
Breather Tube
21
Air Cooling
21
Performance
22
Fuel Pump Replacement
22
Fuel System Tests
22
Carburetor
23
Keihin One-Barrel Carburetor Components
23
Nikki One-Barrel Carburetor Components
23
Walbro One-Barrel Carburetor Components
24
Troubleshooting Checklist
24
Troubleshooting-Carburetor Related Causes
25
Fuel Shut-Off Solenoid
25
Carburetor Circuits
25
Float
25
Slow and MID-Range
26
Low Idle Fuel Adjustment
26
Optimum Low Idle Fuel Setting
26
Carburetor Adjustments
26
Carburetor Servicing
27
High Altitude Operation
27
Unitized Throttle and Choke Control
28
Governor/Throttle Control Connections
28
Throttle Cable Adjustment
29
Starting an Engine Equipped with Unitized Throttle and Choke Control
29
Governor System
30
Governor Components
30
Governor Adjustments
30
Lubrication System
31
Lubrication Components
31
Check Oil Level
31
Change Oil and Filter
31
Installation
32
Spark Plugs
33
Spark Plug Component and Details
33
Wet Fouled
33
Service
33
Electrical System
33
Carbon Fouled
34
Electronic Ignition Systems
34
Overheated
34
Battery Size Recommendations
34
Fixed Ignition System
35
Wiring Diagram-Electronic CD Fixed Ignition Timing System Diagram
35
Digital Spark Advance Ignition (DSAI) Ignition System
36
Wiring Diagram-Digital Spark Advance Ignition (DSAI) System
36
Digital Spark Advance Module (DSAM) Ignition System
37
Wiring Diagram-Digital Spark Advance Module (DSAM) Ignition System
37
Electronic Ignition Systems Tests
38
Test for Spark
38
Test Timing Advance (DSAI and DSAM Only)
39
Test Ignition Modules and Connections (DSAI Only)
39
Test Ignition Modules and Connections (DSAM Only)
39
Test DSAM
41
To Test DSAM Using Spark Advance Module (SAM)
42
Electrical System
43
Battery Charging System
43
12/15/25 Amp Regulated Charging System
43
12/15/25 Amp Battery Charging Systems
44
Troubleshooting-Starting Difficulties
45
Starter System
45
Inertia Drive Electric Starters
46
Inertia Drive Electric Starter Components
46
Drive Service
46
Retaining Ring Installation
46
Starter Disassembly
47
End Cap/Brush Replacement
47
Commutator Service
47
Solenoid Shift Starter Components
47
Starter System
48
Inspection
48
Drive Pinion
48
Brush Replacement
48
Starter Reassembly
49
Solenoid Tests
50
To Test Solenoid Hold-In Coil
50
To Test Solenoid Pull-In Coil/Plunger
50
Emission Compliant Systems
51
Evaporative Emission Compliant System
51
Carbon Canister System
51
Secondary Emission Compliant System
52
Twin Secondary Air Induction System
52
Single Secondary Air Induction System
52
Remove Inlet Screen
53
Inlet Components
53
Disassembly/Inspection and Service
54
External Engine Components
54
Disconnect Spark Plug Leads
55
Drain Oil from Crankcase and Remove Oil Filter
55
Remove Blower Housing and Outer Bafﬂ es
55
Remove Throttle Controls
55
Remove Air Cleaner and Carburetor
56
Remove Ignition Modules
56
Remove Intake Manifold and Rectiﬁ Er-Regulator
56
Remove Electric Starter Motor
56
Cylinder Head Components
57
Remove Spark Plugs
57
Remove Valve Covers and Cylinder Heads
57
Remove Cylinder Heads
57
Disassemble Cylinder Heads
58
Inspection and Service
58
Valve Details
58
Exhaust Insert
58
Lapping Valves
59
Valve Guides
59
Intake Valve Stem Seal
59
Valve Seat Inserts
59
Flywheel/Ignition/Breather Components
60
Remove Debris Screen, Fan, and Flywheel
60
Remove Backing Plate and Stator
60
Remove Outer Breather Assembly
60
Crankshaft/Governor Gear/Oil Pump Components
61
Remove Oil Pan Assembly
62
Governor Assembly
62
Oil Pump Assembly (Style A)
62
Governor Shaft Component and Details
62
Oil Pump Assembly (Style B)
63
Remove Camshaft and Valve Tappets
63
Camshaft Inspection and Service
63
Remove Governor Cross Shaft
63
Connecting Rods/Piston/Breather Components
64
Piston and Rings
64
Piston and Rings Components and Details
64
Remove Connecting Rods with Pistons and Rings
64
Piston Style B
65
Install New Piston Rings
65
Piston Style a
65
Remove Crankshaft
66
Remove Inner Breather Assembly
66
Remove Flywheel and PTO End Oil Seals
66
Honing
66
Clean Cylinder Bore after Honing
67
Measuring Piston-To-Bore Clearance Piston Detail
67
Install Flywheel End Oil Seal
68
Install Breather Filter and Inner Cover
68
Install Governor Cross Shaft
68
Install Crankshaft
70
Install Connecting Rods with Pistons and Rings
70
Install Valve Tappets and Camshaft
70
Oil Pump Assembly
70
Install Oil Seal in Oil Pan
71
Install Oil Pan Assembly
71
Oil Seal Component and Detail
71
Sealant Pattern
71
Install Breather Reed and Outer Cover
72
Breather Cover Sealant
72
Install Stator and Backing Plate
72
Install Flywheel and Fan
73
Install Ignition Modules
73
DSAI Ignition System
73
Fixed or DSAM Ignition System
73
Assemble and Install Cylinder Heads
74
Assemble Cylinder Heads
74
Adjust Valve Clearance
75
Adjusters Retaining Push Rods
75
Install Cylinder Heads
75
Install Rocker Arms
75
Install Valve Covers
76
Stamped Steel Valve Cover Torque Sequence
76
Install Spark Plugs
76
Stamped Steel Valve Cover RTV Sealant
76
Install Intake Manifold
78
Install Carburetor
78
Install External Governor Controls
78
Install Rectiﬁ Er-Regulator
78
Throttle and Choke Components
79
Install Throttle and Choke Controls
79
Governor Lever Hole Position
79
Install Air Cleaner Element
79
Install Blower Housing
80
Install Fuel Pump
80
Install Muffler
80
Install Oil Filter and Fill Crankcase with Oil
80

Kohler Courage SV735 Service Manual (150 pages)

VERTICAL CRANKSHAFT

Brand: Kohler | Category: Engine | Size: 5.57 MB

Kohler Courage SV735 Service Manual (76 pages)

Engine

Brand: Kohler | Category: Engine | Size: 4.24 MB

Kohler Courage SV735 Owner's Manual (21 pages)

VERTICAL CRANKSHAFT

Brand: Kohler | Category: Engine | Size: 0.51 MB

Safety Precautions
2
California Proposition 65 Warning
2
Oil Recommendations
4
Fuel Recommendations
4
General Recommendations
5
Engine Identification Numbers
5
Cold Weather Starting Hints
6
Maintenance Instructions
7
Change Oil and Oil Filter
8
Service Precleaner and Air Cleaner Element
9
Clean Air Intake/Cooling Areas
10
Troubleshooting
13
Parts Ordering
14
Major Repair
14
Model Designation
14

Kohler Courage SV735 Owner's Manual (21 pages)

VERTICAL CRANKSHAFT

Brand: Kohler | Category: Engine | Size: 0.37 MB

Safety Precautions
2
California Proposition 65 Warning
2
Oil Recommendations
4
Fuel Recommendations
4
Cold Weather Starting Hints
6
Maintenance Instructions
7
Change Oil and Oil Filter
8
Service Precleaner and Air Cleaner Element
9
Clean Air Intake/Cooling Areas
10
Troubleshooting
13
Major Repair
14
Model Designation
14
Parts Ordering
14

Kohler Courage SV735 Owner's Manual (8 pages)

Brand: Kohler | Category: Engine | Size: 0.58 MB

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