Kohler KS540 Manuals

Manuals and User Guides for Kohler KS540. We have 1 Kohler KS540 manual available for free PDF download: Service Manual

Kohler KS540 Service Manual (93 pages)

5400 series

Brand: Kohler | Category: Engine | Size: 12.64 MB

Contents
1
Safety Precautions
2
Maintenance Instructions
3
Maintenance Schedule
3
Repairs/Service Parts
3
Every 100 Hours
3
Maintenance
4
Oil Recommendations
4
Storage
4
Fuel Recommendations
4
Engine Dimensions-Flywheel Side
5
Specifications
5
Engine Dimensions-Starter Side
6
Engine Dimensions-PTO Side
7
Engine Dimensions-Oil Filter Side
8
Engine Dimensions-Valve Cover Side
9
Engine Identification Numbers
10
General Specifications
10
Torque Sequences
10
Connecting Rod Fasteners
10
Clearance Specifications
14
General Torque Values
17
English Fastener Torque Recommendations for Standard Applications
17
Metric Fastener Torque Recommendations for Standard Applications
17
Tools and Aids
18
Separate Tool Suppliers
18
Aids
20
Flywheel Holding Tool
20
Rocker Arm/Crankshaft Tool
20
Troubleshooting Guide
21
Engine Cranks but will Not Start
21
Engine Starts but Does Not Keep Running
21
Engine Starts Hard
21
Engine Loses Power
22
Engine Uses Excessive Amount of Oil
22
Oil Leaks from Oil Seals, Gaskets
22
External Engine Inspection
22
Crankcase Vacuum Test
23
To Test Crankcase Vacuum with Manometer
23
Compression Test
24
Cylinder Leakdown Test
24
Air Cleaner
25
Air Cleaner Components
25
Precleaner
25
Paper Element
25
Breather Tube
25
Air Cooling
25
Fuel System
26
Fuel Line
26
Fuel Pump
26
Auto Choke
26
Fuel System Tests
27
Carburetor
28
Typical One-Barrel Carburetor Components
28
Troubleshooting Checklist
28
Troubleshooting-Carburetor Related Causes
29
Fuel Shut-Oﬀ Solenoid
29
Carburetor Circuits
30
Carburetor Adjustments
30
Carburetor Servicing
30
Slow and MID-Range
30
High Altitude Operation
31
Smart-Choke
32
Smart-Choke Components
32
Troubleshooting Smart-Choke
33
Smart-Choke System Troubleshooting
33
Starting an Engine Equipped with Smart-Choke
34
Controls
34
Unitized Throttle and Choke Control
34
Throttle/Choke Controls Details
34
Starting Throttle Control Details
35
High Speed (RPM) Adjustment
35
Speed Control Bracket Details
35
Governed Idle Adjustment
36
Install Separate Control Cables
36
Speed Control Bracket Alignment Hole Details
36
Choke Control Installation
37
Starting an Engine Equipped with Separate Control Cables
37
Setting Low Idle RPM
37
Governor System
38
Governor Components
38
Governor Adjustments
39
Governor Sensitivity Adjustment
39
Lubrication System
40
Lubrication Components
40
Check Oil Level
40
Change Oil and Filter
40
3-Terminal Switch
41
Single-Terminal Switch
41
Oil Pressure
41
Single Terminal Oil Pressure
41
Electrical System
42
Battery Charging System
42
Fixed Ignition System
42
Ignition System Components
42
Wiring Diagram-12/15 Amp Regulated Battery Charging System
43
12/15 Amp Battery Charging Systems
47
To Test Charging System
47
Ignition System
48
Spark Plug
48
Wet Fouled
48
Electronic Ignition System Tests
49
Carbon Fouled
49
Overheated
49
Test for Spark
50
Test Ignition Module with Ohmmeter
50
Fuel Shut-Off Relay Circuit
51
Troubleshooting-Fuel Shut-Oﬀ Relay System
51
Fuel Shut-Oﬀ Relay Harness Connections
51
Engine Operates as Designed
52
Engine Cranks but will Not Start (Voltage at Yellow Wire)
52
Blade Stop Stator Brake and Fuel Shut-Off Circuit
53
Stator Brake and Fuel Shut-Oﬀ Relay Harness Connections
53
Troubleshooting-Stator Brake System
54
To Test for Dead Battery
54
To Test Engine that will Crank but will Not Start
54
Troubleshooting-Starting Difficulties
55
Inertia Drive Electric Starters
55
Starter System
55
Starter System
56
Inertia Drive Starter Tests
56
Before Starting
56
Test 1 Conclusions
56
Emission Compliant Systems
57
Evaporative Emission Compliant System
57
Carbon Canister System
57
Secondary Emission Compliant System
58
Secondary Air Induction System
58
Remove Inlet Screen
59
Inlet Components
59
Disassembly/Inspection and Service
60
External Engine Components
60
Disconnect Spark Plug Lead
61
Turn Oﬀ Fuel Supply
61
Drain Oil from Crankcase and Remove Oil Filter
61
Remove Air Cleaner
61
Standard Choke
62
Remove External Governor Components
63
Remove Oil Fill/Dipstick Tube
63
Remove Oil Sentry Pressure Switch
63
Remove Wiring Harness
63
Remove Debris Screen, Fan, and Flywheel
64
Flywheel Inspection
64
Remove Stator
65
Remove Electric Starter
65
Remove Cylinder Head Baffle
65
Remove Valve Cover
65
Remove Cylinder Head
66
Inspection and Service
67
Valve Details
67
Valve Guides
67
Exhaust Valve
67
Valve Seat Inserts
68
Lapping Valves
68
Remove Breather
68
Remove Closure Plate
68
Governor Gear Inspection
69
Remove Governor Gear and Oil Passage Cover
69
Governor Shaft Inspection
69
Remove Governor Shaft
69
Remove Camshaft
70
Automatic Compression Release (ACR)
70
Remove Balance Shafts
70
Remove Connecting Rod and Piston
71
Piston and Rings Inspection
71
Remove Piston from Connecting Rod
71
Remove Piston Rings
71
Piston and Rings
72
Piston and Rings Components and Details
72
Install New Piston Rings
72
Piston Ring Orientation
72
Remove Crankshaft
73
Remove Oil Pump Assembly
73
Crankshaft and Crankshaft Gear Inspection and Service
73
Oil Pump Inspection
73
Remove Cam Levers
74
Remove Governor Cross Shaft
74
Remove Oil Baffle
74
Crankcase
74
Honing
75
Clean Cylinder Bore after Honing
75
Measuring Piston-To-Bore Clearance Piston Detail
75
Install PTO Side Oil Seal
76
PTO Seal Depth Details
76
Install Oil Baffle
76
Install Governor Cross Shaft
76
Install Cam Levers
77
Install Oil Pump and Oil Pump Housing Assembly
77
Install Crankshaft and Crankshaft Gear
77
Install Piston to Connecting Rod
78
Connecting Rod Fastener Torque Sequence
78
Install Balance Shafts
78
Balance Shaft 1 Timing Mark Detail
78
Install Camshaft
79
Install Flywheel Side Oil Seal
79
Oil Seal Depth Details
79
Closure Plate Sealant Pattern on Crankcase
79
Install Breather
80
Breather Cover Sealant Pattern
80
Sealant Bead on Closure Plate
80
Install Cylinder Head
81
Assemble Cylinder Head
81
Cylinder Head Torque Sequence
81
Install Rocker Arms and Push Rods
81
Valve Cover Sealant Pattern
82
Valve Cover Torque Sequence
82
Install Spark Plug
82
Install Cylinder Head Baffle
82
Install Stator
83
Install Fan and Flywheel
83
Install Wiring Harness
83
Install Ignition Module
84
Install Rectifier-Regulator
84
Install Oil Sentry or Pipe Plug
84
Install Oil Fill Tube
84
Install Intake Manifold
85
Install Carburetor
85
Connect Wire Controls
86
Mounting Speed Control Bracket
86
Governor Spring Detail
86
Reassembly
88
Install Blower Housing
88
Install Fixed Guard
88
Install Fuel Pump
88

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Kohler KS540 Service Manual (93 pages)

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