Kohler Courage SV470 Service Manual
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Kohler Courage SV470 Service Manual

Vertical crankshaft
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S
M
M M
ERVICE
E
ANUAL
COURAGE
SV470-SV620
V
C
ERTICAL
RANKSHAFT

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Summary of Contents for Kohler Courage SV470

  • Page 1 ERVICE ANUAL COURAGE SV470-SV620 ERTICAL RANKSHAFT...

  • Page 2: Table Of Contents

    Section 1. Safety and General Information ... Section 2. Tools & Aids ... Section 3. Troubleshooting ... Section 4. Air Cleaner and Air Intake System ... Section 5. Fuel System and Governor... Section 6. Lubrication System ... Section 7. Electrical System and Components ... Section 8.

  • Page 3: Section 1. Safety And General Information

    Safety and General Information Safety Precautions To ensure safe operation 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 and severe burns. engine is hot or running. Explosive Fuel! its vapors can explode if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied engine is hot or running, since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition.
  • Page 5 When ordering parts, or in any communication involving an engine, always give the Model, A. Model No. Courage Vertical Shaft Engine Numerical Designation B. Spec. No. Engine Model Model SV470 SV480 SV530 SV540 SV590 SV600 SV610 SV620 C. Serial No.

  • Page 6: Fuel Recommendations

    Gasoline/Alcohol Blends gasoline by volume) is approved as a fuel for Kohler and E85 are not to be used and not approved. Any failures resulting from use of these fuels will not be warranted.
  • Page 7 Have valve lash checked/adjusted . Every 500 Hours ¹Perform these maintenance procedures more frequently under extremely dusty, dirty conditions. ²Have a Kohler Engine Service Dealer perform this service. Storage more, use the following storage procedure: still warm from operation. See Change Oil and 3.
  • Page 8 Section 1 Safety and General Information Dimensions in millimeters. Inch equivalents shown in (). VALVE COVER VIEW Figure 1-4. Typical Engine Dimensions.
  • Page 9 Bore ... 89 mm (3.50 in.) Stroke... Displacement Dry Weight... 35.8 kg (79 lb.) Air Cleaner Base Blower Housing and Sheet Metal Cam Lever Cam Gears End Play ... Carburetor to assembly, EXCEPT for air cleaner base thread forming screw - install dry. Safety and General Information Section 1...
  • Page 10 Section 1 Safety and General Information Closure Plate Balance Weight Guide Channel Width New... Connecting Rod New... Piston Pin End I.D. New... Crankcase New... Oil Drain Plug Torque ... Crankshaft End Play (free) ... New... New... Max. Taper ... PTO End Main Bearing Journal O.D. Max.
  • Page 11 Crankshaft (Continued) New... Max. Taper ... New... Balance Weight New... Balance Weight Pin O.D. New... New ... New... New... New... Balance Weight Screw Torque ... Safety and General Information Section 1...
  • Page 12 Section 1 Safety and General Information Cylinder Bore ... 89.073 mm (3.507 in.) Max. Taper ... Cylinder Head ... 0.8 mm (0.003 in.) Electric Starter Thru Bolt Torque ... 3.3-3.9 N·m (30-35 in. lb.) Mounting Nut Torque ... Fan/Flywheel Governor New...
  • Page 13 Ignition (Continued) Spark Plug Torque... Oil Filter Oil Filter Pad Pipe Plug Oil Pump Mounting Screw Torque... Pump Gears-to-Crankcase Side Clearance... Oil Sentry™ Pressure Switch Torque... Piston, Piston Rings, and Piston Pin New... Piston Pin O.D. New... New Bore Used Bore (max.)... 0.77 mm (0.030 in.) New ...
  • Page 14 Section 1 Safety and General Information Piston, Piston Rings, and Piston Pin (Continued) New ... New ... Mounting Screw Torque... Speed Control Stator Stator Mounting Screw Torque ... Throttle/Choke Controls Valve Cover Valves and Valve Lifters ... 8.9 mm (0.350 in.) ...
  • Page 15 Valves and Valve Lifters (Continued) New... New... New... General Torque Values Metric Fastener Torque Recommendations for Standard Applications Tightening Torque: N·m (in. lb.) + or - 10% Size Tightening Torque: N·m (ft. lb.) + or - 10% Oil Drain Plugs Tightening Torque: N•m (English) Size Into Cast Iron –...

  • Page 16: Section 2. Tools & Aids

    Separate Tool Suppliers: Kohler Tools Contact your source Tools Description Balance Gear Timing Tool (K & M Series) Pressure Tester Noid Light Section 2 Tools & Aids SE Tools Section 2 Tools & Aids Source/Part No.
  • Page 17 For checking operating speed (RPM) of an engine. Vacuum/Pressure Tester Alternative to a water manometer. Valve Guide Reamer (K & M Series) For sizing valve guides after installation. Source/Part No. SE Tools KLR-82411 SE Tools KLR-82416 Design Technology Inc. DTI-110 Kohler 25 761 22-S SE Tools KLR-11843...
  • Page 18 Section 2 Tools & Aids Aids Description Source/Part No. Loctite® Ultra Copper...
  • Page 19 Section 2 Tools & Aids Special Tools You Can Make Flywheel Holding Tool Figure 2-1. Flywheel Holding Tool. Rocker Arm/Crankshaft Tool Figure 2-2. Rocker Arm/Crankshaft Tool.

  • Page 20: Section 3. Troubleshooting

    Troubleshooting Guide When troubles occur, be sure to check the simple considered. For example, a starting problem could be below. Use these to help locate the possible cause(s). Engine Cranks But Will Not Start 5. Spark plug lead disconnected. 10. Choke not closing. Engine Starts But Does Not Keep Running 4.
  • Page 21 Section 3 Troubleshooting Engine Overheats shrouds clogged. Engine Knocks 4. Internal wear or damage. Engine Loses Power 8. Low compression. 9. Exhaust restriction. Engine Uses Excessive Amount of Oil 3. Worn or broken piston rings. Oil Leaks from Oil Seals, Gaskets 2.
  • Page 22 the engine is reassembled and placed into operation. Basic Engine Tests Crankcase Vacuum Test crankcase when the engine is operating. Pressure testers. Be sure the pinch clamp is installed on the hose and use the tapered adapters to connect manometer is at the “0” line. Make sure the pinch clamp is closed.
  • Page 23 Section 3 Troubleshooting Compression Test These engines are equipped with an automatic leakdown test described below. Cylinder Leakdown Test Leakdown Test Instructions will need to hold the engine in this position while testing. The holding tool supplied with Gauge reading in low (green) zone ... Gauge reading in high (red) zone...

  • Page 24: Section 4. Air Cleaner And Air Intake System

    Air Cleaner and Air Intake System Air Cleaner These engines are equipped with a replaceable, high density, paper air cleaner element. Some engines also have an oiled, foam precleaner, located in the outer air cleaner cover. See Figure 4-1. Air Cleaner Base Figure 4-1.
  • Page 25 Do not wash the paper element or use pressurized air, as this will damage the element. Replace a dirty, bent, or damaged element with a genuine Kohler element. Handle new elements carefully; do not use if the rubber seal is damaged.
  • Page 26 Figure 4-3. Breather Hose. Disassembly The following procedure is for complete disassembly of all air cleaner components. As the removal of the governor adjustment, steps 3 and 4 should only be performed if required. Detailed photos are provided in Sections 5, 8, and 10 for the various individual steps.
  • Page 27 Section 4 Air Cleaner and Air Intake System Air Intake/Cooling System Clean Air Intake/Cooling Areas To ensure proper cooling, make sure the grass screen, are kept clean at all times. Annually or every 100 hours under extremely dusty, dirty conditions), remove the blower housing and any other cooling shrouds.

  • Page 28: Section 5. Fuel System And Governor

    Fuel System and Governor Section 5 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 including E20 failures resulting from use of these fuels will not be warranted.
  • Page 29 Section 5 Fuel System and Governor Fuel System Troubleshooting Guide Test proper fuel. the tip. the fuel pump. the carburetor. Fuel Filter Replacement is recommended annually or every 100 hours Fuel Pump Some engines are equipped with an optional pulse Operation The fuel pump has two internal chambers separated by a diaphragm.
  • Page 30 Figure 5-1. Pulse Fuel Pump. Carburetor have a low idle speed adjustment screw, and either needle. Figure 5-2. Carburetor. WARNING: Explosive Fuel Fuel System and Governor Troubleshooting – Fuel System If engine troubles are experienced that appear to be adjusting or disassembling the carburetor. gasoline.
  • Page 31 Section 5 Fuel System and Governor Condition 1. Engine starts hard, runs roughly or stalls at idle speed. 2. Engine runs rich. (Indicated governor hunting, or excessive governor hunting, or excessive Carburetor Adjustment NOTE: Carburetor adjustments should be made only The carburetor is designed to deliver the correct conditions.
  • Page 32 Low Idle Mixture Adjustment* NOTE: possible) or a limiter cap on the idle fuel adjustment needle. Step 2 can only be performed within the limits allowed by the cap. minutes to warm up. The engine must be warm before doing step 2. into the idle or slow position.
  • Page 33 Section 5 Fuel System and Governor Disassembly Throttle Plate Screw(s) Throttle Plate Low Idle Speed Adjusting Screw and Spring Low Idle Fuel Adjusting Needle and Spring with Limiter Cap Fuel Shut-off Solenoid Figure 5-5. Carburetor - Exploded View. fuel inlet needle. Do not adjustment needle if it has a limiter cap.
  • Page 34 Tool No. KO1018 Do Not Allow Tip to Strike Carburetor Body Pierce Plug with Tip Welch Plug Figure 5-6. Removing Welch Plug. Main Fuel Jet Removal The main jet is pressed into the side of the tower portion of the body. Removal is not recommended, case the removal instructions will be included in the Fuel Inlet Seat Removal The fuel inlet seat is pressed into the carburetor body,...
  • Page 35 Section 5 Fuel System and Governor installed. The cleaner may damage these components. Inspection Carefully inspect all components and replace those that are worn or damaged. other wear or damage. for wear or damage. • Inspect the fuel inlet needle and seat for wear or damage.
  • Page 36 Figure 5-10. Installing Float and Fuel Inlet Needle. solenoid. Torque the bowl retaining screw to 5.1-6.2 N·m (45-55 in. lb.). Fuel Shut-off Solenoid solenoid installed in place of the bowl retaining screw solenoid, verify that the correct shutdown procedure the engine must be running between half and full the carburetor body to the air cleaner base mounting screw is properly connected.
  • Page 37 Section 5 Fuel System and Governor into the fast or high speed position. The actuating Choke Adjustment Screw Figure 5-13. Adjusting Unitized Throttle/Choke Control. travel past the fast position. This will Warm Engine Cold Engine Figure 5-14. Typical Throttle/Choke Controls. Early Models: Early models use a single alignment hole to set the engine RPM.
  • Page 38 Starting an Engine Equipped with Unitized Throttle and Choke Control fast/choke on position. Figure 5-17. Throttle Position for Starting Engine. soon as the engine starts. for more than 10 seconds at a time. If the engine does not start, allow a these guidelines can burn out the starter motor.
  • Page 39 Section 5 Fuel System and Governor Figure 5-18. Adjusting High Speed (RPM). readjust if necessary. 11.0 N·m (95 in. lb.). Into used hole – 7.5 N·m (65 in. lb.). follows). Choke Adjustment This procedure must follow the High Speed Adjustment just described. If not already completed, control lever to the low idle (slow) position, then out until it no longer moves.
  • Page 40 Alignment Hole Figure 5-20. Alignment Hole in Speed Control Bracket and Throttle Lever. (Early Models) Later Models: instead of one. Based upon the intended high must be made matching the hole in the control lever with the appropriate alignment hole. Use lever with the appropriate hole in the control clamp securely.
  • Page 41 Section 5 Fuel System and Governor Changing the High Speed (RPM) on the Engines with Separate Controls (Increase or Decrease RPM) matches the intended high speed RPM operating Figure 5-22. Adjusting High Speed (RPM). To increase the RPM: Move the speed control RPM: a tachometer.
  • Page 42 NOTE: Flyweights must be installed perpendicular to the nylon gear as shown. Improper Flyweights Nylon Gear Figure 5-24. Governor Gear/Flyweight Assembly. Operation As the governor gear rotates, centrifugal force causes regulating pin to move outward. governor lever is clamped on the protruding end of fast position, the tension of the governor spring holds (the governor gear assembly is rotating), the force tension and the force applied by the regulating pin are...
  • Page 43 Section 5 Fuel System and Governor Governor Sensitivity Adjustment Governor sensitivity is adjusted by repositioning the governor spring in the holes in the governor lever. If speed surging occurs with a change in load, the governor is set too sensitive. If a big drop in speed occurs when a normal load is applied, the governor should be set for greater sensitivity.

  • Page 44: Section 6. Lubrication System

    R E C O M M E N D E D S A E V I S C O S I T Y G R A D E S 10W-30 5W-20, 5W-30 Kohler 10W-30 °F -20 °C -30 TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE * Use of synthetic oil having 5W-20 or 5W-30 rating is acceptable, up to 4°C (40°F)
  • Page 45 Section 6 Lubrication System Figure 6-3. Removing Dipstick. Figure 6-4. Dipstick Seated. 4. Remove the dipstick and check the oil level. The oil level should be up to, but not over the ‘‘F’’ mark on the dipstick. See Figure 6-5. Operating Range Figure 6-5.
  • Page 46 an additional 3/4 to 1 turn. 8. Fill the crankcase with new oil of the proper type, to the “F” mark on the dipstick. into place. 10. Test run the engine to check for leaks. Stop the engine, allow a minute for the oil to drain down, and recheck the level on the dipstick.
  • Page 47 Section 6 Lubrication System applications, the pressure switch can be used to ground the ignition module to stop the engine. NOTE: Oil Sentry ™ is not a substitute for checking the oil level BEFORE EACH USE. Make sure the oil level is maintained up to the ‘‘F’’ mark on the dipstick.

  • Page 48: Section 7. Electrical System And Components

    Electrical System and Components This section covers the operation, service, and repair of the electrical system and electrical system components. charging systems, electric starter, and optional Oil Sentry WARNING: Electrical Shock Never touch electrical wires or components while the engine is running. They can be sources of electrical shock. Spark Plug by a spark plug that is in poor condition or has an The engine is equipped with the following spark plug:...
  • Page 49 Section 7 Electrical System and Components Inspection Inspect the spark plug as soon as it is removed from the cylinder head. The deposits on the tip are an indication of the general condition of the piston rings, valves, and carburetor. Normal and fouled plugs are shown in the following photos.
  • Page 50 Electronic CD Ignition System Air Gap 0.203/0.305 mm (0.008-0.012 in.) Flywheel Kill Switch or Off Position of Key Switch Figure 7-2. Electronic CD Ignition System. These engines are equipped with a dependable electronic, capacitive discharge (CD) ignition system. The system consists of the following components: •...
  • Page 51 Section 7 Electrical System and Components Figure 7-3. Capacitive Discharge Ignition Module. Operation by a diode (D1) and charges a high-voltage capacitor (C1). As the magnet completes its pass, it induces current in a small triggering coil (L2), which turns on the semiconductor switch (SCS).

  • Page 52: Section 8. Disassembly

    CD Ignition System Troubleshooting Guide The following guide will help locate and correct ignition system problems. Problem 1. Make sure the spark plug lead is connected to the spark plug. 2. Check the condition of spark plug. Make sure gap is set to 0.76 mm (0.030 in.). 3.
  • Page 53 Section 7 Electrical System and Components Battery of 250 cold cranking amps is recommended. The actual cold cranking amp requirement depends on engine size, application and starting temperatures. As temperatures decrease, cranking requirements operating instructions of the equipment this engine Battery Charging WARNING: Explosive Gases! Battery Maintenance...
  • Page 54 Lighting Lead (Yellow) Lighting Stator Charging Lead (Black) Figure 7-7. 3 Amp/70 Watt Stator. Optional Oil Sentry Switch (Indicator Light) Ground-To- Kill Lead Key Switch Optional Oil Sentry Shutdown Optional Fuse Starter Solenoid Battery Figure 7-8. 3 amp Regulated Battery Charging System/70 Watt Lighting. Electrical System and Components 3 Amp Charging...
  • Page 55 Section 7 Electrical System and Components Troubleshooting Guide 3 Amp Battery Charging System With 70 Watt Lighting Stator NOTE: Zero ohmmeteres on each scale to ensure accurate readings. Voltage tests should be made with engine Problem using a DC voltmeter. With engine running in the fast position, measure AC voltage across stator leads using an AC voltmeter.
  • Page 56 Troubleshooting Guide 3 Amp/70 Watt Braking Stator NOTE: Zero ohmmeteres on each scale to ensure accurate readings. Voltage tests should be made with engine Problem terminals using a DC voltmeter. With engine running in the fast position, measure AC voltage across stator leads using an AC voltmeter.
  • Page 57 Section 7 Electrical System and Components Troubleshooting Guide 3 amp/70 Watt Braking Stator (Continued) Problem 1. Make sure lights are not burned out. 2. Disconnect the braking lead (green) from the wiring harness. Lights measure voltage from braking lead to ground using an AC voltmeter.
  • Page 58 Battery Charging System 9 or 15 amp Ground-to-Kill Lead Key Switch Optional Fuse Battery Starter Solenoid Figure 7-9. Regulated Battery Charging System, 9 or 15 amp. Electrical System and Components White Flywheel Regulator Violet Green Green Engine Connector Optional Oil Sentry™ Indicator Light Optional Oil Sentry™...
  • Page 59 Section 7 Electrical System and Components 9 or 15 Amp Stator DC Volt Meter Flywheel Stator Ammeter Battery Figure 7-11. Proper Connection to Test 9 or 15 amp Charging System. 7.12...
  • Page 60 Troubleshooting Guide 9 or 15 amp Regulated Battery Charging System NOTE: Zero ohmmeters on each scale to ensure accurate readings. Voltage tests should be made with engine Problem key switch, or other accessible connection. Disconnect it from switch or connection. Connect an ammeter from loose end of B+ DC voltmeter from loose end of B+ lead to With engine running in the fast position, read...
  • Page 61 Section 7 Electrical System and Components Electric Starters These engines use inertia drive starting motors. Operation When power is applied to the starter, the armature rotates. As the armature rotates, the drive pinion cranks the engine. than the starter armature and drive pinion. This moves the drive pinion out of mesh with the ring gear and into the retracted position.
  • Page 62 5. Remove the drive components, and drive nut to the sequence. If the splines are dirty, clean them with solvent. Relubricate as necessary with Kohler bendix starter lubricant (See Section 2). Reinstall or replace the drive components, assembling them in the same sequence as they were removed.
  • Page 63 Section 7 Electrical System and Components Retaining Ring Installation 1. Position the retaining ring in the groove in one of the inner halves. Assemble the other half over the top and slide on the outer collar. 2. Be certain the drive components are installed in the retaining ring inside is resting on the end of slight pressure toward the starter.
  • Page 64 Brush Replacement from the positive (+) brush lead stud. 2. Remove the thru bolts and captured hex nuts. 3. Remove the commutator end cap, then pull the brush carrier assembly out of the frame. See Figure 7-17. Figure 7-17. Removing Brush Carrier Assembly. Commutator Service Clean the commutator with a coarse, lint free cloth.
  • Page 65 Section 7 Electrical System and Components 5. Hold the brush holder assembly with the positive brush lead stud up. Align the molded sections with the corresponding cutouts in the starter frame and slide the brush carrier assembly into place. The commutator will push the carton staples out as the brush assembly is inserted.
  • Page 66 WARNING: Accidental Starts! Disabling engine. Accidental starting can cause severe injury or death. Before working on the engine or The following sequence is suggested for complete engine disassembly. This procedure can be varied to accommodate options or special equipment. Clean all parts thoroughly as the engine is disassembled.
  • Page 67 Section 8 Disassembly Remove Oil Sentry Pressure Switch ™ (On Models So Equipped) 1. Disconnect the lead from the Oil Sentry™ pressure switch. 2. Remove the pressure switch from the center passage or adapter elbow in the closure plate. See Figure 8-2.
  • Page 68 Figure 8-6. Removing Electric Starter. Remove Air Cleaner 1. Loosen the two knobs and remove the air cleaner Figure 8-7. Removing Air Cleaner Cover. 2. Remove the precleaner (if so equipped), and the air cleaner element with the formed rubber seal. Figure 8-8.
  • Page 69 Section 8 Disassembly If a fuel pump is used, disconnect the pulse line Figure 8-11. Disconnecting Fuel Line from Carburetor. Figure 8-12. Disconnecting Pulse Line from Fitting. special washer, which also secures the ground Ground Lead. 3. If the carburetor uses a fuel solenoid, carefully cut the plastic tie strap and disconnect the fuel solenoid lead from the wiring harness.
  • Page 70 5. Mark the mounted position of the speed control screws securing the speed control bracket to the closure plate. Note or mark the governor spring hole for correct installation later. Unhook the governor spring, then remove the control bracket Figure 8-16. Removing Speed Control Bracket from Closure Plate.
  • Page 71 Section 8 Disassembly 8. Remove the insert from the intake port (some Insert Figure 8-20. Removing Insert (Some Models). Remove Ignition Module 1. Disconnect the kill lead from the ignition module. module. 3. Remove the RFI sheathed spark plug lead with from retaining clip, if so equipped.
  • Page 72 Figure 8-24. Removing Fan and Flywheel Mounting Hardware. NOTE: Always use a puller to remove the could be cracked or damaged. Figure 8-25. Removing Flywheel Using Puller. Remove the Stator 1. Remove the two screws securing the stator to the NOTE: To disconnect the B+ or stator leads from the wiring harness connector, insert a blade, and bend down the locking tang...
  • Page 73 Section 8 Disassembly 3. Loosen the inner set screws (T15 TORX) and the push rods and mark them, so they can be Figure 8-29. Loosening Adjustment Set Screw and Nut. cylinder head. Note the thick washer used on the screw closest to the exhaust port. See Figure Washer Figure 8-30.
  • Page 74 Disassemble Cylinder Head NOTE: Before disassembly, mark all valve train components that will be reused, to assure they are reassembled on the same side. Figure 8-33. Removing Spark Plug. arms from the pivot studs. 3. Remove the rocker arm pivot studs and push rod Figure 8-34.
  • Page 75 Section 8 Disassembly 3. Remove the closure plate assembly and gasket. 4. If the wiring harness needs to be separated from the closure plate, pry open the clamps and pull out through the slot. Figure 8-37. Closure Plate and Gasket Removed from Crankcase.
  • Page 76 2. Remove the screws securing the cam levers to the for proper reassembly. NOTE: Cam Gear assemblies may contain either two or four rivets. The four rivet design is shown Figure 8-41. Removing Cam Levers. Figure 8-42. Removing Exhaust Side Cam Shaft and Slotted Thrust Washer.
  • Page 77 Section 8 Disassembly 5. Remove the two screws securing the oil pump a drain back tube is used, it may be unhooked and removed separately or together with oil remove the assembly from the crankcase cavity. A small rubber oil pump outlet seal on the outlet of the oil pump may become dislodged during removal.
  • Page 78 Remove Piston from Connecting Rod 1. Remove the wrist pin retainer and wrist pin. Separate the piston from the connecting rod. See Figure 8-50. Separating Piston from Connecting Rod. Remove Piston Rings 1. Remove the top and center compression rings 2.
  • Page 79 Section 8 Disassembly Balance Weight Disassembly If necessary, the balance weight assembly can be required. carefully remove the key from the keyway. See Figure 8-54. Removing Crank Gear Key. 2. Remove the guide shoe from the guide pin on No. 3618005213) link from the guide pin on the PTO side of the assembly ( the two balance weight halves together on the...
  • Page 80 4. Mark the weights for proper reassembly and Figure 8-57. Disassembled Balance Weight (Guide Shoe Design Before Serial No. 3618005213). Figure 8-58. Disassembled Balance Weight (Control Link Design After Serial No. 3618005223). Remove Governor Cross Shaft 1. Remove the hitch pin and washer located on the Figure 8-59.

  • Page 81: Section 9. Inspection And Reconditioning

    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 and External Governor, Section 5 Ignition, Charging and Electric Starter, Section 7 Clean all parts thoroughly.
  • Page 82 Section 9 Inspection and Reconditioning Reducing the compression at cranking speeds results practical for the applications in which these engines are used. 2. ACR eliminates kickback during starting, so a spark retard/advance mechanism is no longer required. the opened exhaust valve and does not hamper starting.
  • Page 83 3. When the bore is within 0.064 mm (0.0025 in.) of desired size, remove the coarse stones and replace with burnishing stones. Continue with the burnishing stones until within 0.013 mm (0.0005 in.) crosshatch should be observed if honing is done correctly.
  • Page 84 Section 9 Inspection and Reconditioning Balance Weight-to-Eccentric Clearance Before the balance weight assembly is reassembled to eccentrics must be accurately checked. Failure to maintain the required clearances will result in vibration or engine failure. NOTE: Do not use a feeler gauge to measure balance weight-to-eccentric clearance.
  • Page 85 3. Use an outside micrometer again and measure the O.D. of the balance weight guide pin. See Figure 9-8. Figure 9-8. Measuring Guide Pin O.D. 4. Use a split ball gauge or dial calipers and measure the I.D. of the corresponding hole in the guide shoe.
  • Page 86 Section 9 Inspection and Reconditioning Cylinder Head and Valves Inspection and Service Carefully inspect the valve mechanism parts. Inspect the valve springs and related hardware for excessive wear Exhaust Valve E Dimension Seat Angle Guide Depth Guide I.D. Valve Face Angle Valve Margin (Min.) Valve Stem Diameter Figure 9-10.
  • Page 87 removal, clean the valve heads, faces, and stems with a power wire brush. Then, carefully inspect each valve for defects such as warped head, excessive corrosion, or worn stem end. Replace valves found to be in bad condition. A normal valve and valves in bad condition are shown in the accompanying illustrations. Normal: can be reconditioned and reused if the face and margin are in good shape.
  • Page 88 Section 9 Inspection and Reconditioning Excessive Combustion Temperatures: The white deposits seen here indicate very high combustion temperatures, usually due to a lean fuel mixture. Gum: Gum deposits usually result from using stale season. Gum is a prevalent cause of valve sticking. The cure is to ream the valve guides and clean or replace the valves, depending on their condition.
  • Page 89 Valve Guides not guide the valve in a straight line. This may result in burned 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 90 Section 9 Inspection and Reconditioning When cylinder temperatures get too high, lacquer and varnish collect on pistons causing rings to stick which results in rapid wear. A worn ring usually takes on a shiny or bright appearance. Scratches on rings and pistons are caused by abrasive material such as carbon, dirt, or pieces of hard metal.
  • Page 91 Some important points to remember when servicing piston rings: 1. If the cylinder bore is within the wear limits (refer to Section 1) and the old piston is within wear may be reused. 2. Remove old rings and clean up grooves. Never reuse old rings.

  • Page 92: Section 10. Reassembly

    Section 9 Inspection and Reconditioning expander and then the rails. Make sure the ends of the expander are not overlapped. 2. Compression Ring (Center Groove): Install the center ring using a piston ring installation tool. ring is installed. 3. Compression Ring (Top Groove): Install the top ring using a piston ring installation tool.
  • Page 93 Governor Gear and Shaft Inspection Inspect the governor gear teeth. Look for any evidence of worn, chipped, or cracked teeth. If one or more of these problems is noted, replace the governor gear. which are damaged when the gear is removed. Never worn.
  • Page 94 The following sequence is suggested for complete engine reassembly. This procedure assumes that all components are new or have been reconditioned, and all component subassembly work has been completed. This procedure may be varied to accommodate options or special equipment. NOTE: Make sure the engine is assembled using sequences, and clearances.
  • Page 95 Section 10 Reassembly Figure 10-2. PTO Seal Depth Details. Install Governor Cross Shaft 1. Place the thin thrust washer onto the governor Thin Washer Governor Shaft Figure 10-3. Installing Governor Cross Shaft. the outside as far as it will go. Secure by inserting the hitch pin in the machined groove.
  • Page 96 Figure 10-6. Assembled Intake Cam Shaft Details. 2. 3 mm Diameter Pin 3. Oil Pump Assembly 4. 2.5 mm Diameter Pin 5. #1 Hole Location 6. #2 Hole Location 2. If it was removed, install and center the longer, 3 mm diameter drive pin into the upper hole (See 3.
  • Page 97 Section 10 Reassembly crankcase boss. Seat the rubber oil pump outlet seal into the machined pocket. If an open style outlet seal is used, check to make sure the small feed hole is open and aligned with the lower main bearing oil feed hole. Use a 3/32” allen Push the steel sleeves in the pump housing down Install the two M5 mounting screws.
  • Page 98 Guide Pin Figure 10-14. Assembling Balance Weight to Crankshaft (Guide Shoe Design). Engines Serial No. 3618005223 and Above: c. Align the weights and insert the balance weight screw, through the mounting holes guide pin outside the weight on the PTO side. Hold the guide pin with a wrench or Torx bit, and torque the screw to 11.3 N·m (100 in.
  • Page 99 Section 10 Reassembly Figure 10-18. Installed Guide Shoe (Above Serial No. 3618005223). 3. Make sure pivot pin on boss in lower section of crankcase is clean and free of any nicks, or surface irregularities. Apply a small amount of grease to O.D. 4.
  • Page 100 Install Piston and Connecting Rod NOTE: Proper orientation of the piston/connecting rod inside the engine is extremely important. Improper orientation can cause extensive wear or damage. 1. Stagger the piston rings in the grooves until the end gaps are 120° apart. Lubricate the cylinder piston, and rings with engine oil.
  • Page 101 Section 10 Reassembly Install Cam Levers 1. Install the two cam levers as shown in Figure face up. Secure each cam lever using an M6 hex 7.5 N·m (65 in. lb.). Lubricate the dimple and oil. Intake Cam Follower Dimple Figure 10-25.
  • Page 102 Figure 10-28. Spring Installed on ACR Weight. Figure 10-29. Hooking ACR Spring onto Exhaust Cam Gear. on the cam gear is in the 8 o’clock position. Install Figure 10-30. Installing Exhaust Cam Gear. Install Intake Cam on Cam Shaft slot with the upper drive pin. Rotate the gear and the 4 o’clock position.
  • Page 103 Section 10 Reassembly Install Flywheel Side Oil Seal 1. Lubricate the outside diameter and lip of the and install the oil seal. Using a seal driver, drive the seal to a depth of 5 mm (0.196 in.) in the seal Figure 10-33.
  • Page 104 Figure 10-36. Closure Plate Fastener Torque Sequence. Assemble Cylinder Head Prior to assembly, lubricate all the components with engine oil, including the tips of the valve stems and valve guides. Using a valve spring compressor, install the following items in the order listed. See Figure •...
  • Page 105 Section 10 Reassembly Figure 10-40. Installing Cylinder Head Fasteners. 6. Using the torque sequence shown in Figure stages; initially to 20.5 N·m (180 in. lb.), and 41.0 N·m (360 in. lb.). Figure 10-41. Cylinder Head Fastener Torque Sequence. Install Rocker Arms and Push Rods NOTE: Installation and seating of the push rods into the cam lever recesses during this sequence is critical.
  • Page 106 and rocker arm. Tighten the adjustment nut with a wrench until a slight drag is felt on the feeler gauge. Hold the nut in that position and (50 in. lb.). To prevent damage to the nut, torque the Torx screw only. Perform the adjustment Intake Valve 0.127 mm (0.005 in.) Exhaust Valve 0.178 mm (0.007 in.)
  • Page 107 Section 10 Reassembly Install Stator and Wiring Harness Install Stator 1. Position the stator onto the mounting bosses so that the leads lay in the channel and recess of the captured when the blower housing is installed. If a clamp was used to retain the leads, remove and install the clamp.
  • Page 108 Install Fan and Flywheel WARNING: Damaging Crankshaft and Flywheel can Cause Personal Injury! dry and completely free of lubricants. The to be over stressed and damaged when the become cracked or damaged if the key is not properly installed. not use any type of bar or wedge between the parts could become cracked or damaged.
  • Page 109 Section 10 Reassembly Install Electric Starter 1. Install the electric starter to the closure plate sure the wires are clear of any moving parts and torque the hex nuts to 3.6 N·m (32 in. lb.). See Figure 10-52. Installing Electric Starter. Install Ignition Module from the ignition module bosses.
  • Page 110 Figure 10-55. Tightening Clip around Sheathing. Install New Spark Plug ® 2. Set the gap to 0.76 mm (0.030 in.). 3. Install the spark plug and torque it to 24-30 N·m Figure 10-56. Installing Spark Plug. and Air Cleaner Base 1.
  • Page 111 Section 10 Reassembly 4. Models with one screw and one mounting stud only: Insert a 3/16” diameter rod, approximately 4” long, into the open mounting hole in the heat damage the threads. Temporary Alignment Pin Figure 10-59. Inserting Alignment Pin. 5.
  • Page 112 9. Install the air cleaner base. that the two metal spacers are in the air cleaner base mounting holes and install pin. Make sure the upper mounting tab is positioned above the closure plate boss. See Tab on Top of Closure Plate Figure 10-64.
  • Page 113 Section 10 Reassembly Install and Adjust Governor Lever 1. Install the governor lever* onto the governor *NOTE: It is recommended that a new governor lever be installed whenever removal is performed. Figure 10-68. Governor Lever Installed on Shaft. 2. Move the governor lever toward the carburetor, hold in this position.
  • Page 114 Install Fuel Pump (If Equipped) speed control bracket with the two M5 screws. Torque the screws to 6.5 N·m (55 in. lb.) into new 4.0 N·m (35 in. lb.) into used Figure 10-72. Fuel Pump Mounting Bracket. Secure with the two M6 screws. Torque the screws to 9.5 N·m (84 in.
  • Page 115 Section 10 Reassembly Notch Figure 10-76. Installing Blower Housing Screws. 3. Snap the grass screen onto the cooling fan. See Figure 10-77. Installing Grass Screen. Install Oil Sentry™ or Pipe Plug 1. Apply pipe plug or adapter. Install and tighten into the pipe plug to 4.5-5.0 N·m (40-45 in.
  • Page 116 Install Air Cleaner Element, Precleaner, and Air Cleaner Cover 1. Install the air cleaner element with the pleated side “out.” Seat the rubber seal onto all the edges Figure 10-80. Installing Air Cleaner Element. upper section of the air cleaner cover. See Figure Figure 10-81.
  • Page 117 Section 10 Reassembly Install Drain Plug, Oil Filter, and Oil 1. Install the oil drain plug and torque to 14 N·m (125 in. lb.). with the open end up. Pour new oil of the proper type, in through the threaded center hole. Stop threads.
  • Page 118 FOR SALES AND SERVICE INFORMATION IN U.S. AND CANADA, CALL 1-800-544-2444 KohlerEngines.com ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044 FORM NO.: TP-2548-A ISSUED: 9/03 REVISED: 10/07 LITHO IN U.S.A.

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