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Courage SV470
Service manual
Table Of Contents - Kohler Courage SV470 Service Manual
Vertical crankshaft
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Also See for Courage SV470
:
Service manual
(133 pages)
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Owner's manual
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Owner's manual
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Table Of Contents
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
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Table of Contents
Table Of Contents
2
Safety Precautions
3
Section 1. Safety And General Information
3
Engine Identification Numbers
5
Oil Recommendations
6
Fuel Recommendations
6
Oil Type
6
Gasoline/Alcohol Blends
6
Periodic Maintenance
7
Storage
7
Typical Engine Dimensions
8
General Specifications
9
General Torque Values
15
Oil Drain Plugs Tightening Torque
15
Section 2. Tools & Aids
16
Special Tools You Can Make
19
Flywheel Holding Tool
19
Rocker Arm/Crankshaft Tool
19
Section 3. Troubleshooting
20
External Engine Inspection
21
Cleaning The Engine
21
Basic Engine Tests
22
Incorrect Vacuum In Crankcase
22
Compression Test
23
Cylinder Leakdown Test
23
Leakdown Test Instructions
23
Leakdown Test Results
23
Air Cleaner Assembly - Exploded View
24
Section 4. Air Cleaner And Air Intake System
24
Paper Element Service
25
Inspect Air Cleaner Components
25
Bushings In Air Cleaner Base
25
Air Intake/Cooling System
27
Section 5. Fuel System And Governor
28
Fuel System Troubleshooting Guide
29
Fuel Filter
29
Fuel Pump
29
Carburetor
30
Troubleshooting - Fuel System
30
Carburetor Adjustment
31
Low Idle Mixture Adjustment
32
Low Idle Speed Setting
32
Optimum Low Idle Fuel Setting
32
Welch Plug Removal
33
Carburetor - Exploded View
33
Cleaning
34
Main Fuel Jet Removal
34
Fuel Inlet Seat Removal
34
Choke Shaft Removal
34
Choke Shaft Installation
35
Welch Plug Installation
35
Carburetor Reassembly
35
Fuel Shut-Off Solenoid
36
High Altitude Operation
36
Unitized Throttle And Choke Control
36
Throttle Cable Adjustment
36
Adjusting Unitized Throttle/Choke Control
37
Typical Throttle/Choke Controls
37
Alignment Hole In Speed Control Bracket And Throttle Lever
37
Alignment Holes In Speed Control Bracket And Throttle Lever
37
High Speed (Rpm) Adjustment
38
Throttle Position For Starting Engine
38
Separate Throttle And Choke Control
39
Choke Adjustment
39
Install Separate Control Cables
39
Choke Control Installation
40
Starting An Engine Equipped With Separate Control Cables
40
Governor
41
Changing The High Speed (Rpm) On The Engines With Separate Controls
41
Setting The Low Idle Rpm
41
Governed Idle Adjustment
41
Governor Operation
42
Governor Initial Adjustment
42
Governor Gear/Flyweight Assembly
42
Tightening Governor Lever Nut
42
Early Style Governor Spring Location Chart
43
Later Style Governor Spring Location Chart
43
Check Oil Level
44
Viscosity Grades Table
44
Section 6. Lubrication System
44
Change Oil And Oil Filter
45
Removing Dipstick
45
Dipstick Seated
45
Oil Level Dipstick
45
Full-Pressure Lubrication System
46
Oil Filter
46
Oil Sentry
46
Testing Oil Pressure
47
To Install The Oil Sentry Switch
47
Spark Plug Service
48
Section 7. Electrical System And Components
48
Spark Plug Inspection
49
Electronic Cd Ignition System
50
Troubleshooting And Testing Cd Ignition Systems
51
Capacitive Discharge Ignition Module
51
Cd Ignition System Troubleshooting Guide
52
Ignition Tester
52
Testing Cd Ignition Module Secondary
52
Battery Charging
53
Battery Maintenance
53
Battery Test
53
Electrical Systems Wiring Diagrams And Battery Charging Systems
53
3 Amp/70 Watt Stator
54
3 Amp Regulated Battery Charging System/70 Watt Lighting
54
Troubleshooting Guide 3 Amp Battery Charging System With 70 Watt Lighting Stator
55
Troubleshooting Guide 3 Amp/70 Watt Braking Stator
56
Battery Charging System 9 Or 15 Amp
58
9 Or 15 Amp Stator And Rectifier-Regulator
59
Proper Connection To Test 9 Or 15 Amp Charging System
59
Troubleshooting Guide 9 Or 15 Amp Regulated Battery Charging System
60
Troubleshooting Guide - Starting Difficulties
61
Electric Starters
61
Starting Motor Precautions
61
Starter Removal And Installation
62
Retaining Ring Installation
63
Starter Disassembly
63
Brush Replacement
64
Commutator Service
64
Starter Reassembly
64
Installing Brush Carrier Using Staples
65
Torquing Thru Bolts
65
Assembled Starter
65
Typical Disassembly Sequence
66
Drain Oil From Crankcase And Remove Oil Filter
66
Oil Drain Location, Oil Filter, And Oil Fill Cap/Dipstick
66
Section 8. Disassembly
66
Remove Muffler
67
Remove Rectifier-Regulator
67
Remove Oil Sentry Pressure Switch
67
Remove Blower Housing
67
Remove Air Cleaner
68
Remove External Governor Components, Carburetor, And Fuel Pump
68
Removing Electric Starter
68
Removing Air Cleaner Cover
68
Disconnecting Fuel Line From Carburetor
69
Disconnecting Pulse Line From Fitting
69
Removing Heat Deflector Screw And Ground Lead
69
Disconnecting Fuel Solenoid Lead
69
Removing Speed Control Bracket From Closure Plate
70
Disconnecting Governor Spring
70
Removing Governor Lever
70
Removing Heat Deflector
70
Remove Ignition Module
71
Remove Grass Screen, Fan, And Flywheel
71
Removing Insert (Some Models)
71
Removing Lead From Clip
71
Remove The Stator
72
Remove The Valve Cover And Cylinder Head
72
Removing Fan And Flywheel Mounting Hardware
72
Removing Flywheel Using Puller
72
Loosening Adjustment Set Screw And Nut
73
Removing Cylinder Head Bolts And Washer
73
Removing Cylinder Head And Gasket
73
Removing Drain Back Check Ball From Crankcase
73
Disassemble Cylinder Head
74
Remove Closure Plate
74
Removing Spark Plug
74
Disassembling Rocker Arm Components
74
Disassemble Closure Plate
75
Remove Cam Gears, Cam Shafts, And Oil Pump
75
Closure Plate And Gasket Removed From Crankcase
75
Removing Governor Gear
75
Removing Cam Levers
76
Removing Exhaust Side Cam Shaft And Slotted Thrust Washer
76
Removing Drain Back Tube
76
Outlet Seal Styles
76
Remove Connecting Rod And Piston
77
Intake Cam Shaft And Oil Pump Assembly
77
Separating Oil Pump Assembly From Intake Side Cam Shaft
77
Removing Connecting Rod Cap
77
Remove Piston From Connecting Rod
78
Remove Piston Rings
78
Remove Crankshaft And Balance Weight Assembly
78
Balance Weight Disassembly
79
Removing Crank Gear Key
79
Removing Balance Weight Screw And Guide Pin
79
Remove Governor Cross Shaft
80
Remove Pto And Flywheel Side Oil Seals
80
Disassembled Balance Weight
80
Removing Hitch Pin And Washer
80
Automatic Compression Release (Acr)
81
Section 9. Inspection And Reconditioning
81
Cam Gears
82
Crankshaft And Crank Gear
82
Crankcase
82
Measuring Piston-To-Bore Clearance
83
Balance Weight Assembly
83
Clean Cylinder Bore After Honing
83
Balance Weight-To-Eccentric Clearance
84
Measuring Balance Weight To Crankshaft Clearance
84
Measuring Balance Weight Guide Pin And Guide Shoe-To-Closure Plate Guide Channel Running Clearance
84
Flywheel Inspection
85
Measuring Guide Pin O.d.
85
Measuring Guide Shoe Hole I.d.
85
Cylinder Head And Valves Inspection And Service
86
Valve Guides
89
Valve Seat Inserts
89
Lapping Valves
89
Pistons And Rings
89
Common Types Of Piston And Ring Damage
90
Install Piston Rings
91
Top And Middle Compression Ring End Gap
91
Connecting Rods
92
Oil Pump Assembly And Pressure Relief Valve
92
Closure Plate And Passage Cover
92
Governor Gear And Shaft
93
Governor Shaft Press Depth
93
Typical Reassembly Sequence
94
Install Pto Side Oil Seal
94
Section 10. Reassembly
94
Install Governor Cross Shaft
95
Install Oil Pump Assembly And Intake Cam Shaft
95
Pto Seal Depth Details
95
Assembled Intake Cam Shaft Details
96
Gerotor Gears Installed In Oil Pump
96
Pump Outlet Seals
96
Oil Pump Outlet Styles
96
Install Crankshaft And Balance Weight
97
Checking Outlet Seal Passage Opening
97
Torquing Oil Pump Mounting Screws
97
Installing Drain Back Tube
97
Assembling Balance Weight To Crankshaft
98
Installing Crank Gear Key
98
Installing Crankshaft Assembly
98
Install Piston And Connecting Rod
100
Direction Arrow On Piston
100
Install Cam Levers
101
Install The Exhaust Cam Shaft And Cam Gear
101
Drive Pin Locations For Exhaust Cam Shaft
101
Install Intake Cam On Cam Shaft
102
Install Crank Gear
102
Hooking Acr Spring Onto Exhaust Cam Gear
102
Install Flywheel Side Oil Seal
103
Install Closure Plate Gasket, Closure Plate, And Wiring Harness
103
Assemble Cylinder Head
104
Install Cylinder Head
104
Closure Plate Fastener Torque Sequence
104
Installing Drain Back Check Ball
104
Install Rocker Arms And Push Rods
105
Installing Cylinder Head Fasteners
105
Installing Guide Plates And Rocker Arm Pivot Studs
105
Install Valve Cover
106
Valve Clearance Specifications
106
Adjusting Valve Clearance
106
Locking Adjustment Nut Set Screw
106
Install Stator And Wiring Harness
107
Install Pipe Plug Or Fitting And Pulse Line For Fuel Pump
107
Install Fan And Flywheel
108
Torquing Flywheel
108
Install Electric Starter
109
Install Ignition Module
109
Install New Spark Plug
110
Install Heat Deflector, Carburetor, Linkage And Air Cleaner Cleaner Base
110
Inserting Alignment Pin
111
Installing Carburetor Assembly With Linkages
111
Securing Ground Lead
111
Fuel Solenoid Lead Secured With Tie Strap
111
Install And Adjust Governor Lever
113
Mounting Speed Control Bracket
113
Install Fuel Pump
114
Install Rectifier-Regulator
114
Install Blower Housing And Flywheel Screen
114
Install Oil Sentry Or Pipe Plug
115
Install Air Cleaner Element, Precleaner, And Air Cleaner Cover
116
Install Muffler
116
Install Drain Plug, Oil Filter, And Oil
117
Prepare The Engine For Operation
117
Testing The Engine
117
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Table of Contents
Troubleshooting
Section 3. Troubleshooting
20
Fuel System Troubleshooting Guide
29
Carburetor
30
Troubleshooting and Testing CD Ignition Systems
51
CD Ignition System Troubleshooting Guide
52
Troubleshooting Guide 3 Amp Battery Charging System With 70 Watt Lighting Stator
55
Troubleshooting Guide 3 Amp/70 Watt Braking Stator
56
Troubleshooting Guide 9 or 15 amp Regulated Battery Charging System
60
Troubleshooting Guide - Starting Difficulties
61
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This manual is also suitable for:
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Courage sv610
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