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Magnum M12
Kohler Magnum M12 Manuals
Manuals and User Guides for Kohler Magnum M12. We have
2
Kohler Magnum M12 manuals available for free PDF download: Service Manual, Owner's Manual
Kohler Magnum M12 Service Manual (153 pages)
Single cylinder engine
Brand:
Kohler
| Category:
Engine
| Size: 5.38 MB
Table of Contents
Contents
2
General Information
3
Engine Identification Numbers
3
Safety Information
4
Oil/Fuel Recommendations
7
Oil Type
7
Check Oil Level
7
Change Oil
7
Fuel Type
8
Overall Dimensions
8
Gasoline/Alcohol Blends
8
Standard Torque Values
10
Specifications, Tolerances and Special Torque Values
10
Special Tools
15
Valve Service Tools
16
Seal and Bearing Installers
16
Tool Usage Chart
18
Bearing and Seal Installers
18
Miscellaneous Tools
18
Engine Analysis Kit (no 25 800 01)
19
Ignition System Tester
20
Water Manometer
20
Cylinder Leakdown Tester
20
Inductance Tachometer
20
Periodic Maintenance
21
Required Maintenance
21
Oil Sentry
22
Service Air Cleaner
22
Clean Air Intake/Cooling Areas
23
Precleaner
23
Paper Element
23
Inspect Air Cleaner Components
23
Check Spark Plug
24
Service Optional Reduction Gear Unit
24
Servicing Spark Plug
24
Ignition System Service
25
Check Fuel Filter
25
Service Starter Motor Drive
25
Clean Cylinder Head and Combustion Chamber
25
Check Valve-To-Tappet Clearance
26
Cylinder Head Fastener Tightening Sequence
26
Measuring Valve-To-Tappet Clearance
26
Storage
27
Troubleshooting
28
External Engine Inspection
29
Cleaning the Engine
29
Basic Engine Tests
29
No Crankcase Vacuum/Pressure in Crankcase
30
Air Cleaner Disassembly
31
Air Cleaner Assembly - Exploded View
31
Air Cleaner Reassembly/Service
32
Fuel System and Governor
33
Fuel System Operation
33
Fuel System Troubleshooting
33
Typical Fuel System
33
Fuel Tank
34
Fuel Filter
35
Fuel Pump
35
Fuel Shutoff Valve
35
Isolation Mounts
35
Carburetor
36
Carburetor Adjustment
37
Carburetor Disassembly
38
Carburetor Cleaning
38
Carburetor Inspection
38
Carburetor Repair
39
Throttle and Choke Shaft Replacement
39
To Replace Throttle and Choke Shafts
40
Disassemble Carburetor
40
Remove Choke Plate and Choke Shaft; Transfer Choke Lever
40
Remove Throttle Plate and Throttle Shaft; Transfer Throttle Lever
40
Drill Choke Shaft Bores Using a Drill Press
41
Installing Choke Shaft Bushings
41
Install Throttle Shaft Bushing
42
Installing Choke Shaft
42
Install Throttle Shaft and Throttle Plate
43
Setting Float Level
43
Setting Float Drop
43
Governor Operation
44
Centrifugal Flyweight Mechanical Governor
44
Checking Float Clearance
44
Governor Adjustment
45
Initial Governor Adjustment
45
High Speed Adjusting Screw
45
Engine Mounted Throttle and Choke Controls
46
Sensitivity Adjustment
46
Engine Mounted Throttle and Choke Controls - Exploded View
47
Engine Mounted Throttle and Choke Controls - Disassembly/Reassembly
48
Retractable Starters
50
To Remove/To Install Starter
50
Retractable Starter on Model M8
50
To Replace Starter Pawls (Dogs)
50
Exploded View - Retractable Starter for Model M8
51
Starter Pawls
51
To Replace Rope
52
Removing Handle
52
Installing Rope
52
Releasing Spring Tension
52
Starter Disassembly
53
Position of Spring and Keeper on Pulley
53
Removing Pulley from Housing
53
Starter Inspection and Service
54
Starter Reassembly
54
Retractable Starter on Models M10, M12, M14, M16 Disassembly
54
Installing Pulley and Spring into Housing
54
Exploded View - Retractable Starter for Models M10, M12, M14, M16
55
Removing Spring from Housing
57
To Replace Recoil Spring
57
Spring Reassembly
58
Installing Spring Using Seal Installer and Handle
58
Positioning New Spring/C-Ring
58
Installing Pawls, Pawl Retainer and Related Components
59
Tensioning Spring
59
Winding Rope Onto Pulley
60
Electrical Systems and Components
61
Magnum Electronic Magneto Ignition System
61
Ignition System Troubleshooting Guide
62
Ignition Module Removal
63
Ignition Module Installation
63
Ignition Tester, Testing Module Secondary
63
Setting Magnet-To-Module Air Gap
63
Kill Lead with Optional Diode
64
Spark Plug Service
64
Kill Lead/Diode Replacement
64
Diode Test
64
Spark Plug Inspection
65
Electrical System Wiring Diagram and Battery Charging Systems
66
Manual Start Engines: Optional 70 Watt Lighting
67
Troubleshooting Guide: 70 Watt Lighting Stator
67
Electric Start Engine: 1.25 Amp or 3 Amp Unregulated Charging System, Optional 70 Watt Lighting
68
Wiring Diagram - Electric Start Engine/1,25 Amp or 3 Amp Unregulated Battery Charging System/70 Watt Lighting
68
1.25 Amp or 3 Amp Stator /70 Watt Lighting Stator
68
Troubleshooting Guide: 1,25 Amp Battery Charging System
69
Troubleshooting Guide: 3 Amp Battery Charging System with 70 Watt Lighting Stator
70
Electric Start Engines: 15 Amp Regulated Charging System
71
Amp Stator and Rectifier Regulator
71
Troubleshooting Guide: 15 Amp Battery Charging System
72
Electric Start Engines: 25 Amp Regulated Charging System
73
25 Amp Stator and Rectifier Regulator
73
Troubleshooting Guide: 25 Amp Battery Charging System
74
Keyswitch
75
Battery Test
75
Battery Charging, Maintenance
75
Checking Battery Voltage
75
Battery Testing
76
Solenoid Testing
76
Electric Starter
76
Electric Starter Operation
77
Bendix Drive Electric Starter
77
Electric Starter Troubleshooting Guide
78
Starter Removal and Installation
78
Starter Drive Service
78
Commutator End Cap with Brushes
79
Commutator Service Reassembly
79
Starter Assembly Match Marks
79
Oil Sentry , Oil Level Monitor Operation
80
Float Switch Removal
80
Float Switch Installation/Removal
81
Float Switch Test
83
Automatic Compression Release - Operation
85
Automatic Compression Release - Starting Position
85
Automatic Compression Release - Running Position
85
Benefits
86
Compression Testing
86
Inspection and Service
86
Disassembly Procedure
87
Disconnect Spark Plug Lead Drain Oil from Crankcase
87
Remove Air Cleaner
87
Removing Spark Plug Lead, Oil Drain Plug and Air Cleaner Cover
87
Remove Muffler
88
Removing Choke Linkage, Throttle Linkage and Carburetor
88
Removing Air Cleaner Element
88
Removing Air Cleaner Base
88
Remove Fuel Pump
89
Removing Fuel Pump, External Governor Components, and Throttle and Choke Controls
89
Remove External Governor Components, and Throttle and Choke Controls
89
Remove Retractable Starter
90
Remove Electric Starter and Solenoid
90
Remove Fuel Tank
90
Removing Starter from Bearing Plate
90
Remove Cylinder Head Baffle, Blower Housing and Side Air Baffles
91
Remove Breather Assembly
91
Removing Cylinder Head Baffle, Blower Housing and Breather Cover
91
Removing Fuel Tank Bracket from Crankcase
91
Remove Spark Plug and Cylinder Head
92
Remove Ignition Module and Air Baffle
92
Remove Drive Cup or Rope Start, Pulley, Grass Screen, Flywheel and Fan
92
Rope Start Models
93
Electric Start Models
93
Retractable Start Models
93
Remove Valves
94
Remove Stator
94
Remove Oil Pan
94
Remove Connecting Rod and Piston
95
Remove Piston Rings
95
Remove Piston from Connecting Rod
95
Remove Crankshaft and Bearing Plate
95
Remove Camshaft and Tappets
96
Remove Governor Gear and Cross Shaft
96
Remove Oil Seals
97
Remove Bearings
97
Model M10, M12, M14, M16 Disassembly
98
Disconnect Spark Plug Lead
98
Drain Oil from Crankcase
98
Remove Rectifier-Regulator
99
Remove Choke Linkage, Throttle Linkage and Carburetor
99
Remove External Governor Components and Throttle and Choke Controls
100
Remove Breather
100
Remove Fuel Pump, Remove Retractable Starter
100
Remove Fuel Tank and Solenoid
101
Remove Oil Fill/Dipstick Tube
101
Remove Electric Starter
101
Removing Starter Tail Brace and Starter
102
Removing Carburetor Side Air Baffle
102
Remove Drive Cup or Rope Start Pulley, Grass Screen, Flywheel and Fan
103
Removing Flywheel Fastener
103
Removing Fan from Flywheel
104
Remove Stator, Valves, Oil Pan
105
Remove Balance Gears
107
Removing Bearing Plate Using a Puller
107
Removing Tappets
107
Remove Governor Gear, Cross Shaft
108
Remove Oil Seals, Bearings
108
Removing Balance Gears, Governor Gear and Cross Shaft
108
Inspection and Repair/Reconditioning
109
Flywheel Inspection
109
Cylinder Head Inspection
109
Checking Cylinder Head Flatness
109
Cylinder Block Inspection and Reconditioning
110
Honing
110
Cylinder Bore Crosshatch after Honing
110
Measuring Cylinder Bore
110
Valves Inspection and Service
111
Measuring Piston-To-Bore Clearance
111
Measuring Piston Diameter
111
Valve Spring Free Height
111
Valve Details
112
Valve Guides
114
Install Valve Guide
114
Valve Seat Inserts
114
Reaming Valve Guide
114
Remove Valve Seat Insert
115
Install Valve Seat Insert
115
Pulling Valve Seat Insert
115
Piston and Rings Identification
116
Piston and Rings Inspection
116
Piston and Rings Service
117
Common Types of Piston and Ring Damage
117
Intall Piston Rings
118
Measuring Piston Ring Side Clearance/End Gap
118
Posi-Lock Connecting Rods
119
Piston Ring Installation
119
Magnum M8 Posi-Lock Connecting Rods
119
Piston Ring Inspection and Service
120
Balance Gears and Stub Shafts
120
Governor Gear
120
Camshaft and Crankshaft Inspection and Service
120
Crankpin Fillets
121
Model M8 Reassembly
122
Install Rear Bearing
122
Install Governor Gear and Cross Shaft
122
Install Tappets and Camshaft
123
Installing Governor Gear
123
Measuring Camshaft End Play
123
Install Crankshaft
124
Install Bearing Plate
124
Install Fuel Line and Wiring Harness
124
Install Front Bearing
124
Install Oil Seals
125
Install Piston to Connecting Rod
125
Install Piston Rings
125
Install Piston/Connecting Rod
126
Install Oil Pan
126
Installing Pistons
126
Install Valves
127
Install Stator
128
Install Fan, Flywheel, Grass Screen and Drive Cup or Rope Start Pulley
128
Install Fan to Flywheel
128
Install Ignition Module and Air Baffle
129
Installing Ignition Module
129
Install Cylinder Head and Spark Plug
130
Install Side Air Baffles, Blower Housing and Cylinder Head Baffle
130
Installing Breather Components
130
Cylinder Head Fastener Torque Sequence
130
Install Fuel Tank and Brackets
131
Installing Blower Housing, Keyswitch Panel and Side Air Baffle
131
Installing Fuel Tank Bracket to Crankcase
131
Install Solenoid and Electric Starter
132
Install Retractable Starter
132
Installing Starter and Starter Tail Brace
132
Installing Fuel Tank
132
Install External Governor Components, and Throttle and Choke Controls
133
Install Fuel Pump
133
Install Carburetor, Throttle Linkage and Choke Linkage
133
Install Rectifier-Regulator
134
Installing Carburetor, Throttle Linkage and Choke Linkage
134
Adjusting Governor Arm/Cross Shaft
134
Install Muffler
135
Install Air Cleaner
135
Prepare the Engine for Operation
136
Install Air Cleaner Cover, Oil Drain and Spark Plug
136
Models M10, M12, M14, M16 Reassembly
137
Installing Tappets, Governor Gear and Cross Shaft
138
Install Balance Gears (on Engines so Equipped)
139
Install Crankshaft (on Engines Without Balance Gears)
139
Installing Balance Gears, Camshaft Pin and Cup Plug
139
Install Crankshaft (on Engines with Balance Gears)
140
Aligning Crankshaft and Camshaft Timing Marks, Balance Gears
140
Installing Balance Gear Timing Tool, Aligning Crankshaft and Camshaft Timing Marks
140
Install Front Bearing, Fuel Line and Wiring Harness
141
Timing Marks on Balance Gear and Crankshaft
141
Checking Crankshaft and Balance Gear Alignment
141
Install Bearing Plate, Oil Seals
142
Installing Wiring Harness and Bearing Plate
142
Measuring Crankshaft End Play
142
Installing Oil Seals Using Sleeve
142
Install Piston Rings, Install Piston to Connecting Rod
143
Install Oil Pans, Valves
144
Install Stator, Fan, Flywheel, Grass Screen and Drive Cup or Rope Start Pulley
145
Retractable Start, Electric Start, Rope Start
146
Install Cylinder Head and Spark Plug, Side Air Baffles, Blower Housing and Cylinder Head Baffle
147
Install Electric Starter, Fuel Tank
148
Install Retractable Starter, Fuel Pump
149
Install Breather Assembly, External Governor Components and Throttle and Choke Controls
150
Install Rectifier-Regulator, Muffler
151
Install Air Cleaner, Prepare the Engine for Operation
152
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Kohler Magnum M12 Owner's Manual (9 pages)
8/10/12/14/16 HP
Brand:
Kohler
| Category:
Engine
| Size: 1.68 MB
Table of Contents
Checking Oil
2
Pre-Start Checklist
3
Operating Instructions
3
Maintenance Instructions
4
Ignition System
4
Cooling System
4
Air Cleaner
4
Spark Plug
5
Battery Charging
5
Fuel Filter
5
Carburetor Adjustments
6
Troubleshooting
7
Parts Ordering
7
Major Repair
7
Model Designation
7
Specifications
8
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