Kohler SV810-840 Service Manual
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Kohler SV810-840 Service Manual

Vertical crankshaft
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S
M
ERVICE
ANUAL
COURAGE
SV710-740
COURAGE PRO
SV810-840
V
C
ERTICAL
RANKSHAFT

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Summary of Contents for Kohler SV810-840

  • Page 1 ERVICE ANUAL COURAGE SV710-740 COURAGE PRO SV810-840 ERTICAL RANKSHAFT...

  • Page 3: 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 5: 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 6 Section 1 Safety and General Information WARNING 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 7 When ordering parts, or in any communication involving an engine, always give the Model, 1-1. An explanation of these numbers is shown in A. Model No. Courage Engine Vertical Crankshaft B. Spec. No. Engine Model Model SV710 SV715 SV720 SV730 SV735 SV740 SV810...
  • Page 8 Leaded gasoline is not recommended. 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 are not approved. Gasoline/Ether blends Methyl Tertiary Butyl Ether (MTBE) and unleaded gasoline blends (up to a maximum of 15% MTBE by volume) are approved as a fuel for Kohler engines.
  • Page 9 Have bendix starter drive serviced . Every 500 Hours Perform these maintenance procedures more frequently under extremely dusty, dirty conditions. Have a Kohler Engine Service Dealer perform these services. Storage If the engine will be out of service for two months or more, use the following storage procedure: 1.
  • Page 10 Section 1 Safety and General Information Inch equivalents shown in [ ].
  • Page 11 Section 1 Safety and General Information Inch equivalents shown in [ ]. 342.40 357.74 [13.480] [14.084] 420.81 [16.567] 466.27 [18.357] 480.92 [18.934]...
  • Page 12 Section 1 Safety and General Information SV710, SV810 ... SV715 ... SV740, SV840 ... Bore ... Stroke ... Displacement ... Compression Ratio ...9.0:1 Dry Weight ... Blower Housing and Sheet Metal M4 HI-LO Screws Torque ... Camshaft End Play (With Shim) ... Running Clearance...
  • Page 13 Connecting Rod Connecting Rod-to-Crankpin Running Clearance New... Max. Wear Limit ... Connecting Rod-to-Crankpin Side Clearance... Connecting Rod-to-Piston Pin Running Clearance... Piston Pin End I.D. New... Max. Wear Limit ... Crankcase New... Max. Wear Limit ... Breather Assembly Inner Cover Outer Cover Stud Torque ...
  • Page 14 Section 1 Safety and General Information Crankshaft (Continued) Oil Pan End Main Bearing Journal O.D. - New ... O.D. - Max. Wear Limit...40.84 mm (1.608 in.) Max. Taper ... Max. Out-of-Round ... Connecting Rod Journal O.D. - New ... O.D. - Max. Wear Limit... Max.
  • Page 15 Governor (Continued) Governor Lever Nut Torque... Ignition Spark Plug Type (Champion ® or Equivalent) ... Spark Plug Gap... Spark Plug Torque... Ignition Module Air Gap ... M8 Hex Nuts ... 5/16-18 Capscrews ... Oil Filter Piston, Piston Rings, and Piston Pin Piston-to-Piston Pin Running Clearance ...
  • Page 16 Section 1 Safety and General Information Speed Control Bracket Starter Assembly Thru Bolt Torque Mounting Screw Torque (All)... Brush Holder Mounting Screw Torque Delco-Remy Starter... Solenoid (Starter) Mounting Hardware Torque Delco-Remy Starter... Nut, Positive (+) Brush Lead Torque Delco-Remy Starter... Stator Mounting Screw Torque...
  • Page 17 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% Safety and General Information Property Class 10.9 Property Class 10.9 Section 1 Noncritical Fasteners Into Aluminum...
  • Page 18 Section 1 Safety and General Information English Fastener Torque Recommendations for Standard Applications Tightening Torque: N·m (in. lb.) + or - 20% Bolts, Screws, Nuts and Fasteners Assembled Into Cast Iron or Steel Grade 2 Size 8-32 10-24 10-32 1/4-20 1/4-28 5/16-18 5/16-24...

  • Page 19: Section 2. Tools & Aids

    Separate Tool Suppliers: Kohler Tools Contact your source Tools Description Pressure Tester Noid Light Section 2 Tools & Aids SE Tools Section 2 Tools & Aids Source/Part No.
  • Page 20 Starter Brush Holding Tool (Solenoid Shift) Tachometer (Digital Inductive) For checking operating speed (RPM) of an engine. Vacuum/Pressure Tester Alternative to a water manometer. Source/Part No. SE Tools KLR-82411 SE Tools KLR-82416 Design Technology Inc. DTI-110 Kohler 25 761 22-S...
  • Page 21 Section 2 Tools & Aids Aids Description Source/Part No. Loctite® Ultra Copper...
  • Page 22 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 23: Section 3. Troubleshooting

    Troubleshooting Guide When troubles occur, be sure to check the simple considered. For example, a starting problem could be Engine Cranks But Will Not Start 9. DSAI or DSAM mode. hose. Engine Starts But Does Not Keep Running 4. Loose wires or connections that short the kill hose.
  • Page 24 Section 3 Troubleshooting Engine Will Not Idle 7. Low compression. problem. Engine Overheats shrouds clogged. 7. DSAI or DSAM Engine Knocks 4. Internal wear or damage. Engine Loses Power 8. Low compression. 9. Exhaust restriction. 10. DSAI or DSAM Engine Uses Excessive Amount of Oil 3.
  • Page 25 • drainage. Cleaning the Engine engine parts. When such a cleaner is used, follow the manufacturer’s instructions and safety precautions carefully. the engine is reassembled and placed into operation. Basic Engine Tests Crankcase Vacuum Test crankcase when the engine is operating. Pressure the kits.
  • Page 26 Section 3 Troubleshooting No Crankcase Vacuum/Pressure in Crankcase Possible Cause 4. Restricted exhaust. Compression Test Cylinder Leakdown Test adapter hose, and a holding tool. Leakdown Test Instructions engine. the compression stroke. Hold the engine in this position while testing. The holding tool supplied is perpendicular to both the holding tool and Solution reassemble, and recheck pressure.

  • Page 27: Troubleshooting

    Section 3 Troubleshooting Leakdown Test Results ...Engine is still usable, but there is some wear present. Customer should start wear. Engine should be reconditioned or replaced.
  • Page 28 Section 3 Troubleshooting...

  • Page 29: Section 4. Air Cleaner And Air Intake System

    Air Cleaner and Air Intake System Air Cleaners General Air cleaner systems used on these engines will be either the standard size or PRO Series increased capacity (slightly taller) design. Each system uses a replaceable, high-density paper air cleaner element. Some are also equipped with an oiled-foam precleaner, which surrounds the paper element.

  • Page 30: Section 4 Air Cleaner And Air Intake System

    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 sealing surface is bent or damaged.
  • Page 31 Air Cleaner Base Disassembly/Reassembly If the air cleaner base requires removal, proceed as follows: 1. Remove the mounting screws for the fuel pump (if equipped), and the blower housing. 2. Raise or remove the blower housing for access to the air cleaner base. 3.
  • Page 32 Section 4 Air Cleaner and Air Intake System...

  • Page 33: Section 5. Fuel System And Governor

    Leaded gasoline is not recommended. Gasoline/Alcohol blends Gasohol (up to 10% ethyl alcohol, 90% unleaded gasoline by volume) is approved as a fuel for Kohler Gasoline/Ether blends volume) are approved as a fuel for Kohler engines. Section 5...
  • Page 34 Section 5 Fuel System and Governor Fuel Filter every 100 hours Fuel Line Regulations, these engines use Low Permeation requirements. Standard fuel line may not be used. Troubleshooting – Fuel System Related Causes Test 1. Check the following: a. Make sure the fuel tank contains clean, fresh, proper fuel.
  • Page 35 Fuel Pump General pumping action is created by the oscillation of positive and negative pressures within the crankcase. This a rubber hose connected between the pump and crankcase. The pumping action causes the diaphragm on the inside of the pump to pull fuel in on its downward stroke and to push it into the carburetor on its upward stroke.
  • Page 36 Section 5 Fuel System and Governor Slow Circuit: port this air fuel mixture is delivered to the idle progression chamber. From the idle progression chamber the air fuel mixture is metered through the idle port passage. At low idle when the vacuum signal is weak, the air fuel becomes great enough so the main circuit begins to work.
  • Page 37 Main Circuit: Fuel Inlet Float Valve Seat Float Valve Main Jet Figure 5-3. Main Circuit (Typical). Fuel System and Governor Idle Speed (RPM) Adjustment Screw Float Main Emulsion Hole Main Air Bleed Jet Choke Valve Bowl Vent Section 5 Fuel Mixture Keihin Carburetors...
  • Page 38 Section 5 Fuel System and Governor Troubleshooting - Carburetor Related Causes Condition or stalls at idle speed. black, sooty exhaust smoke, governor hunting, or excessive governor hunting or excessive 4. Fuel leaks from carburetor. Troubleshooting Checklist When the engine starts hard, runs roughly or stalls at low idle speed, check the following areas before gasoline.
  • Page 39 High Altitude Operation over-rich. This can cause conditions such as black, power, poor fuel economy, and poor or slow governor response. correct kit number. Fuel Shut-off Solenoid place of the bowl retaining screw. The solenoid has a spring-loaded pin that retracts when 12 volt current is applied to the lead.
  • Page 40 Section 5 Fuel System and Governor tapered to critical dimensions. Damage to the needle end and the seat in the carburetor body will result if it is forced. Low Idle Speed (RPM) Adjustment Figure 5-5. Carburetor Adjustments. Low Idle Mixture Adjustment Screw (Some Models) Idle Speed (RPM)
  • Page 41 to return to the governed idle speed. Check it with a tachometer against the equipment manufacturers recommended idle speed. (approximate) higher than the low idle speed. If on the speed control assembly to set. Governed Idle Spring Figure 5-7. Governed Idle Spring Location. Hold Throttle Lever Against Screw...
  • Page 42 Section 5 Fuel System and Governor Figure 5-11. Float and Inlet Needle. seat and carburetor body. Insert the new pivot Figure 5-12. Installing Float Assembly. hangs vertically and rests lightly against the fuel inlet needle. The inlet needle should be fully seated but the center pin of the needle (on retainer clip end) should not be depressed.
  • Page 43 Figure 5-15. Fuel Bowl Removed from Carburetor. necessary unless a Fuel Solenoid Kit (obtained separately), is also being installed. Discard all of the parts. The seat for the inlet needle is not serviceable, and should not be removed. Figure 5-16. Removing Float and Inlet Needle. removed, the main nozzle can be taken out Fuel System and Governor Figure 5-17.
  • Page 44 Section 5 Fuel System and Governor Figure 5-18. Installing Main Nozzle and Main Jet. Figure 5-19. Installing Slow Jet. Figure 5-20. Installing Plug into Slow Jet Tube. metal tang should point up, with the needle valve hanging down 5.12 Figure 5-21. Float and Inlet Needle. seat and carburetor body.
  • Page 45 Figure 5-23. Checking Float Height. bowl and transfer passage (if so equipped). See Figure 5-24. Installing Fuel Bowl O-Rings. with the four original screws. Torque the screws to 2.5 ± 0.3 N·m (23 ± 2.6 in. lb.) Figure 5-25. Installing Fuel Bowl. Fuel System and Governor carburetor.
  • Page 46 Section 5 Fuel System and Governor Choke Repair 1. Remove the carburetor from the engine. Discard the old mounting gaskets for the air cleaner and carburetor. self-relieving choke mechanism thoroughly. 4. Note the position of the spring legs and the choke plate for correct reassembly later.
  • Page 47 Figure 5-31. Choke Shaft and Spring Details. inner leg of the spring, against the formed stop within the choke lever as originally assembled. spring must still be between the formed stops of ® 11. Place a drop of the Loctite on the threads of each The larger cutout must be on the right.
  • Page 48 Section 5 Fuel System and Governor and seat. If dirty, blow out with compressed air. kit. 8. Using new gaskets, reinstall the bowl and tighten the bowl retaining screw or solenoid to 5.1-6.2 N·m (45-55 in. lb.). 9. Reinstall the carburetor on the engine, reconnect the fuel line, control linkages and air intake components.
  • Page 49 Some Models Only Figure 5-33. Typical Carburetor - Exploded View. Inspection/Repair To clean vent ports, seats etc., use a good commercially available carburetor solvent, such as Gumout™, and clean, dry compressed air to blow out internal channels and ports. Use a suitable shop rag to Carefully inspect all components and replace those that are worn or damaged.
  • Page 50 Section 5 Fuel System and Governor Always use new gaskets when servicing or reinstalling carburetors. Repair kits are available which include new gaskets and other components. Carburetor Repair Kit Float Kit Solenoid Assembly Kit Reassembly Procedure Reassembly is essentially the reverse of the disassembly procedure.
  • Page 51 Initial Adjustment carburetor. 2. Loosen the hex nut holding the governor lever to in position. 4. Insert a nail into the hole in the end of the cross counterclockwise as far as it will turn, then tighten the hex nut securely. Sensitivity Adjustment governor spring in the holes of the governor lever.
  • Page 52 Section 5 Fuel System and Governor 5.20...

  • Page 53: Section 6. Lubrication System

    Select the viscosity based on the air temperature at the R EC OMME NDE D S AE V IS CO SIT Y GR A D ES 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 54 Section 6 Lubrication System Checking Oil Level The importance of checking and maintaining the proper oil level in the crankcase cannot be overemphasized. Check oil BEFORE EACH USE as 1. Make sure the engine is stopped, level, and cool so the oil has had time to drain into the sump. 2.
  • Page 55 Oil Filter Figure 6-6. Oil Filter Location. type, in through the threaded center hole. Stop additional 3/4-1 turn. 10. Start the engine and check for oil leaks. Recheck oil level before placing the engine into service. level on the dipstick. Service Oil Cooler cooler.
  • Page 56 Section 6 Lubrication System ground the ignition module to stop the engine. On NOTE: Make sure the oil level is checked before each Installation Figure 6-9. Figure 6-9. Oil Sentry™ Location. 1. Apply adapter. See Figure 6-9. Testing the Switch Compressed air, a pressure regulator, pressure gauge 1.

  • Page 57: Section 7. Electrical System And Components

    Electrical System and Components This section covers the operation, service, and repair of the electrical system components. Systems and components covered in this section are: • Spark Plugs • Electric Starter Spark Plugs condition. The engine is equipped with the following spark plugs: Type: Gap:...
  • Page 58 Section 7 Electrical System and Components normal conditions will have light tan or gray colored reused. compression. Worn: gap. Replace a worn spark plug immediately. or worn piston rings, cylinder walls or valve guides. Overheated:...
  • Page 59 Battery General amps is generally recommended for starting in cold cranking requirement depends on engine size, application and starting temperatures. The cranking requirements increase as temperatures decrease and Temprature Battery Required Above 32°F (0°) 200 cca minimum 0°F to 32°F (18°C to 0°C) 250 cca minimum -5°F to 0°F (-21°C to -18°C) 300 cca minimum...
  • Page 60 Section 7 Electrical System and Components Electronic Ignition Systems is triggered. The Fixed Ignition System engine speed. which is located in the ignition modules. The ignition timing varies depending upon the engine speed with this system. This system uses a digital microprocessor that triggers the ignition modules and spark. The ignition timing varies depending upon the engine speed with this system.
  • Page 61 Kill Switch or ‘‘Off’’ Position of Key Switch Figure 7-4. Capacitive Discharge Fixed Timing Ignition System. dead center. Figure 7-5. Capacitive Discharge (CD) Ignition Module Schematic. Troubleshooting CD Ignition Systems information is provided to help you get to the root of CAUTION: High-Energy Electric Spark! wires are connected, including the spark plug leads.
  • Page 62 Section 7 Electrical System and Components wires, connections, safety interlocks, etc. associated with the ignition or electrical isolated until all testing is completed. wiring is okay, replace ignition module and retest for spark. misses or won’t run on that cylinder, try a new spark plug.
  • Page 63 Figure 7-6. DIgital Spark Advance Ignition (DSAI) System. on these engines. Use of any other tester can and all external loads are disconnected. Test 1. Isolate and Verify the Trouble is Within the Engine Ignition System harnesses from the engine and equipment are the connectors and position or insulate the kill lead terminal so it cannot touch ground.
  • Page 64 Section 7 Electrical System and Components install new spark plugs gapped at Test 3. Check for Timing Advance with a marking pen or narrow tape. See Figure that had good spark. Flywheel Screen Mark Figure 7-7. Check For Timing Advance. movement of the line on the screen relative to the good spark, repeat the test on the other cylinder.
  • Page 65 C. Digital Spark Advance Module (DSAM) equipped engines utilize an electronic capacitive discharge ignition system with electronic spark the following components: • Two electronic capacitive discharge ignition modules which mount on the engine crankcase spark advance module. spark advance module to stop the engine. •...
  • Page 66 Section 7 Electrical System and Components Figure 7-9. Digital Spark Advance Module (DSAM) Ignition System. Figure 7-10. Block Diagram - Spark Advance Module (DSAM). 7.10...
  • Page 67 Troubleshooting CD Ignition Systems information is provided to help you get to the root of CAUTION: High-Energy Electric Spark! wires are connected, including the spark plug leads. sure the ignition switch is in the RUN position. complains of hard starting, low power, excessive draw on the kill circuit.
  • Page 68 Section 7 Electrical System and Components engine runs poorly, install new spark plugs Test 3. Check For Timing Advance. with a marking pen or narrow tape. See Figure Flywheel Screen Mark Figure 7-11. Check For Timing Advance. had good spark. and watch for movement of the line on the screen cylinders had good spark, repeat the test on the other cylinder.
  • Page 69 run. 24 584 36-S Test (2-1/16 in. High) (Use Digital Ohmmeter) From No. 1 to 4 Ignition Module Resistance Table room temperature. reinstall the second mounting screw removed follows. module position. screws to hold it temporarily. centered under the module. the module.
  • Page 70 Section 7 Electrical System and Components Test 5. Test the DSAM. to the harness connection. Separate the connector indicated, check the ground circuit the harness connector terminal for a good connection and crimp to the lead. Then trace harness, key switch, etc., looking for any poor connections, or faulty circuits.
  • Page 71 DSAM ______ ______ Part No. DSAM ______ ______ ______ Part No. cycle, recheck all of the connections, check the *IMPORTANT! Figure 7-14. Select Test Number. Figure 7-15. “Pass” Indicator. Electrical System and Components ______ ______ faceplate and secure with the four screws. Battery Charging System General systems.
  • Page 72 Section 7 Electrical System and Components Figure 7-16. Wiring Diagram – Fixed Timing Ignition System. 7.16...
  • Page 73 Section 7 Electrical System and Components Figure 7-17. Wiring Diagram – DSAI Ignition System. 7.17...
  • Page 74 Section 7 Electrical System and Components Figure 7-18. Wiring Diagram – DSAM Ignition System. 7.18...
  • Page 75 Stator replacement is necessary. To replace it, remove the two mounting screws and disconnect the plug. note of the terminal markings and install the plug accordingly. Electrical System and Components Tester. To Test – removed from the engine for clarity. Repeat times to determine the condition of the part.
  • Page 76 Section 7 Electrical System and Components not represent the condition of the part. Figure 7-23. the four status lights will illuminate, indicating the condition of the part. Figure 7-24. a result of an inadequate ground lead is clean and clamp is secure. 7.20 tested and the squared single end of the tandem Figure 7-25.
  • Page 77 of the four status lights will illuminate indicating the partial condition of the part. light comes on again, the part is good and DC Voltmeter Figure 7-27. Connections for Testing Charging System. 15 & 25 amp Battery Charging Systems Electrical System and Components a result of an inadequate ground lead location is clean and the clamp is secure.
  • Page 78 Section 7 Electrical System and Components Problem voltmeter. No Charge to Battery voltmeter. across stator leads using an ohmmeter. resistance from each stator lead to ground using an ohmmeter. Battery Continuously Charges at High Rate Electric Starting Motors These engines may use either an inertia drive or following.
  • Page 79 condition is corrected. Problem Possible Fault Battery Starter Wiring Does Not Energize Starter Switch or Solenoid Battery Brushes Starter Energizes but Turns Slowly Transmission Engine Operation - Inertia Drive Starters cranks the engine. than the starter armature and drive pinion. This moves the drive pinion out of mesh with the ring removed from the starter, the armature stops rotating and the drive pinion is held in the retracted position...
  • Page 80 Section 7 Electrical System and Components Dust Cover Retaining Ring Spring Retainer Anti-Drift Spring Drive Pinion Drive Nut (Collar) Drive End Cap Armature Frame Commutator End Cap with Brushes Figure 7-28. Inertia Drive Electric Starter. Drive Service the inside that snaps over a lip on the front drive pinion clockwise until it reaches the extended position, grasp the tip of the dust cover with a pliers or vise grip and pull it free from the...
  • Page 81 the collar over the inner halves to hold them in position. Figure 7-31. Assembling Inner Half of Removal Tool Around Armature Shaft and Retaining Ring. The resistance against the center screw will tell you when the retaining ring has popped out of Figure 7-32.
  • Page 82 Section 7 Electrical System and Components Figure 7-34. Assembling Larger Inner Half Around Spring Retainer. around the retaining ring. Stop turning when tool. Starter Disassembly instructions for servicing the drive. frame. End Cap/Brush Replacement installation is performed, the end of the armature commutator.
  • Page 83 Figure 7-37. Installing and Torquing Thru Bolts. drive components following the instructions for servicing the starter drive. Solenoid Shift Electric Starters also, so it is not repeated here. Operation – Solenoid Shift Starter solenoid moves the drive pinion out onto the drive the starter solenoid is deactivated, the drive lever with the ring gear into the retracted position.
  • Page 84 Section 7 Electrical System and Components Figure 7-40. Solenoid Removed from Starter. Figure 7-41. Removing Plunger. Figure 7-42. Removing Thru Bolts. and locking caps. Remove the thrust washer from 7.28 Figure 7-43. Removing Commutator End Plate Assembly. Figure 7-44. Starter Frame Removed. Figure 7-45.
  • Page 85 Figure 7-46. Armature and Lever Removed. Figure 7-47. Retaining Ring Detail. Electrical System and Components Save the stop collar. Figure 7-48. Removing Retaining Ring. armature. Do not soak the armature or use solvent or use compressed air. Section 7 7.29...
  • Page 86 Section 7 Electrical System and Components Collar Ring Stop Drive Armature Washer Tube Figure 7-49. Delco-Remy Starter. Inspection Drive Pinion mechanism for nicks, or irregularities which could cause seal damage. housing and rotating the pinion. The pinion should rotate in one direction only. Brushes and Springs 7.30 Wear limit length:...
  • Page 87 Commutator O.D. Mica Insulation Figure 7-51. Commutator Mica Inspection. commutator, and check for continuity. See Figure Insulation Check Continuity Check Armature Coil Figure 7-52. Checking Armature. segments and the commutator segments. See shorting. Shift Fork and contact areas are not excessively worn, cracked or Electrical System and Components Brush Replacement replacement is necessary.
  • Page 88 Section 7 Electrical System and Components Starter Service 52 357 02-S other starter parts for wear or damage as required. Starter Reassembly 52 357 02-S pliers to compress it in the groove. c. Slide the stop collar up and lock it into place, so the recess surrounds the retainer in the outward on the armature splines against the retainer to help seat the collar around the...
  • Page 89 grommet, into the matching recess of the drive end cap. The molded recesses in the grommet Figure 7-58. Installing Backup Washer and Grommet. notch with the corresponding section in the cutout, if it was removed previously. See Figure Figure 7-59. Installing Frame and Drain Tube. Electrical System and Components Figure 7-60.
  • Page 90 Section 7 Electrical System and Components Figure 7-62. Removing Retaining Clips. Figure 7-63. Brush Installation Tool with Extension. end housing, and carefully place the tool into place around the commutator, install the 7.34 Figure 7-64. Installing Brush Holder Assembly using Tool with Extension. the corresponding slot in the grommet of the holder mounting screws to 2.5-3.3 N·m Figure 7-65.
  • Page 91 Figure 7-66. Torquing Brush Holder Screws. the drive lever, and install the spring into the through the holes in the drive end cap. Use these to hold the solenoid gasket in position, then mount the solenoid. Torque the screws to to the solenoid and secure with the hex nut.
  • Page 92 Section 7 Electrical System and Components Test 2. Solenoid Pull-In Coil/Contact Continuity Test. connect the two ohmmeter leads to the two large post indicate continuity, if no continuity is indicated the 12 volt Test Leads Momentary Connection Only Figure 7-69. Testing Pull-In Coil/Solenoid Contact Continuity.

  • Page 93: Section 8. Disassembly

    Section 8 Disassembly Section 8 Disassembly WARNING: Accidental Starts! Disabling engine. Accidental starting can cause severe injury or death. Before working on the engine or equipment, Disconnect Spark Plug Leads Typical Disassembly Sequence Figure 8-1. Disconnect Spark Plug Leads. Shut Off Fuel Supply Drain Oil From Crankcase and Remove Oil Filter...
  • Page 94 Section 8 Disassembly Oil Fill Cap/Dipstick Drain Plug Figure 8-2. Removing Oil Fill Cap/Dipstick. Figure 8-3. Removing Oil Filter. Adapter Nipple Figure 8-4. Removing Oil Filter Adapter. Mounting Screws Figure 8-5. Removing Oil Cooler From Blower Housing. Oil Feed Tube Figure 8-6.
  • Page 95 Remove Fuel Pump (Equipped Models) WARNING: Explosive Fuel! Outlet Line Clip Figure 8-7. Removing Pulse Pump. Remove Blower Housing and Outer Four Locations Two in Front (Not Shown) Figure 8-8. Blower Housing Mounting Screws. Fuel Pump Mounting Screws Pulse Figure 8-9. Removing Blower Housing. Hose Outer Remove Throttle Controls...
  • Page 96 Section 8 Disassembly Mounting Locations Figure 8-11. Control Bracket Mounting Locations. Dampening Spring Governor Spring Figure 8-12. Disconnecting Linkage and Governor Springs. Remove External Governor Controls Figure 8-13. Removing Governor Lever. Remove Air Cleaner and Carburetor WARNING: Explosive Fuel! Choke Linkage from the engine.
  • Page 97 Figure 8-15. Removing Air Cleaner Assembly. Figure 8-16. Removing Air Cleaner Element. Figure 8-17. Removing Carburetor. Remove Electric Starter Motor Figure 8-18. Removing Electric Starter Motor. Figure 8-19. Removing Oil Fill Tube. Section 8 Disassembly...
  • Page 98 Section 8 Disassembly (# 2) Side Lifting Strap Mounting Screws Remove Ignition Modules Standard (Fixed) Timing Ignition Module (Single Lead) shown DSAM or SMART-SPARK™ Ignition Module (Two-Leads) Figure 8-21. Removing Ignition Modules. Regulator Intake Manifold Mounting Locations Figure 8-22. Intake Manifold Mounting Locations.
  • Page 99 Figure 8-24. Removing B+ Lead from Terminal Plug. Remove Spark Plugs Figure 8-25. Removing Spark Plug. Remove Valve Covers and Cylinder Heads Plug Figure 8-26. Removing Valve Covers. Section 8 Disassembly...
  • Page 100 Section 8 Disassembly Figure 8-27. Loosening Pivot Screws (End Adjustment Style Shown). Figure 8-28. Removing Cylinder Head Screws (Center Pivot Adjustment Style Shown). Figure 8-29. Removing Cylinder Head and Gasket. Figure 8-30. Match Marks on Cylinder Barrel and Heads. Disassemble Cylinder Heads End Adjustment Style Components Head Screws...
  • Page 101 Figure 8-32. Removing Valves with Valve Spring Compressor. • • • • • • (intake valve – some models) Spring Valve Figure 8-33. Valve Components. Figure 8-34. Intake Valve Stem Seal* (Some Models). Remove Grass Screen, Fan, and Flywheel Retainer Keepers Figure 8-35.
  • Page 102 Section 8 Disassembly Figure 8-36. Removing Fan and Flywheel Mounting Hardware. Holding Tool Figure 8-37. Removing Flywheel. 8.10 Figure 8-38. Removing Key. Remove Backing Plate and Stator Figure 8-39. Removing Backing Plate. Puller Figure 8-40. Removing Stator.
  • Page 103 Remove Outer Breather Assembly Figure 8-41. Removing Outer Breather Cover. Stud Retainer Breather Reed Figure 8-42. Removing Stud, Retainer, and Breather Reed. Remove Oil Pan Assembly Figure 8-43. Removing Oil Pan Screws. Figure 8-44. Removing Oil Pan. Governor Assembly Oil Pump Assembly Section 8 Disassembly Splitting Tab...
  • Page 104 Section 8 Disassembly Remove Camshaft and Valve Tappets Shim Camshaft Figure 8-45. Removing Camshaft. Figure 8-46. Removing Valve Tappets. Remove Governor Cross Shaft 8.12 Retainer Washer Figure 8-47. Removing Governor Cross Shaft Retainer. Governor Shaft Washer Figure 8-48. Removing Governor Cross Shaft.
  • Page 105 Remove Connecting Rods with Pistons and Rings Figure 8-49. Removing Connecting Rod End Cap. Figure 8-50. Removing Connecting Rod and Piston Assembly. Remove Crankshaft Figure 8-51. Removing Crankshaft. Remove Inner Breather Assembly Screw Drainback Hole Cover Gasket Filter Inner Breather Chamber Figure 8-52.
  • Page 106 Section 8 Disassembly Remove Flywheel and PTO End Oil Seals Crankcase Seal Oil Pan Seal Figure 8-53. Removing Oil Seals. 8.14...

  • Page 107: 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: Section 4: Air Cleaner and Intake System Section 5: Carburetor &...
  • Page 108 Move the hone up and down ridges. Check the size frequently. NOTE: Kohler pistons are custom-machined to exacting tolerances. When over-sizing a cylinder, it should be machined exactly 0.25 mm (0.010 in.) over the new diameter...
  • Page 109 1). Inspection and Reconditioning Flywheel Inspection Inspect the ring gear for cracks or damage. Kohler does not provide ring gears as a serviceable part. Cylinder Head and Valves Inspection and Service and the corresponding top surface of the crankcase, using a surface plate or piece of glass and feeler gauge as shown in Figure 9-3.
  • Page 110 Section 9 Inspection and Reconditioning EXHAUST VALVE Dimension Seat Angle 89° 36.987/37.013 mm (1.4562/1.4572 in.) Insert O.D. 4 mm (0.1575 in.) Guide Depth 7.038/7.058 mm (0.2771/0.2779 in.) Guide I.D. 33.37/33.63 mm (1.3138/1.3240 in.) 45° Valve Face Angle 1.5 mm (0.0591 in.) Valve Margin (Min.) 6.982/7.000 mm (0.2749/0.2756 in.) Valve Stem Diameter...
  • Page 111 Normal: can be reconditioned and reused if the face and margin are in good shape. If a valve is worn to where the margin is less than 1/32" do not reuse it. The valve shown was in operation for almost 1000 hours under controlled test conditions.
  • Page 112 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 gasoline. 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 113 Valve Guides not guide the valve in a straight line. This may result in burnt 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 of the guide.
  • Page 114 Section 9 Inspection and Reconditioning Ring failure is usually indicated by excessive oil consumption and blue exhaust smoke. When rings fail, oil is allowed to enter the combustion chamber consumption can also occur when the piston ring end gap is incorrect because the ring cannot properly conform to the cylinder wall under this condition.
  • Page 115 Replacement pistons are available in STD bore size, and 0.25 mm (0.010 in.) oversize. Replacement pistons include new piston ring sets and new piston pins. Replacement ring sets are also available separately for STD, and 0.25 mm (0.010 in.) oversize pistons. Always use new piston rings when installing pistons.
  • Page 116 Replace tappet(s) if condition is lobe(s) should also be checked for wear or damage. Compression Whenever tappets are replaced, apply a liberal coating Ring of Kohler lubricant 25 357 14-S to the base of each new tappet before it is installed. Center Compression Ring Rails Figure 9-11.
  • Page 117 Governor Assembly (Internal) Inspection Inspect the governor gear teeth. Replace the gear if it is worn, chipped, or if any teeth are missing. Inspect the governor weights. They should move freely in the governor gear. Disassembly The governor gear must be replaced once it is removed from the oil pan.
  • Page 118 Section 9 Inspection and Reconditioning Figure 9-15. Removing Oil Pump Mounting Screws. 3. The outer Gerotor gear is typically held captive in the oil pump housing. If the gear becomes separated, see Step 1 under Reassembly for proper reinstallation. NOTE: The relief valve is sealed as part the oil pump housing and not serviceable.
  • Page 119 Figure 9-19. Oil Pump Torque Sequence. a. Start fastener 1 into hole, apply only minimal torque to position the pump. b. Torque fastener 2 to full value. c. Torque fastener 1 to full value. freedom of movement. Make sure there is no binding.
  • Page 120 Section 9 Inspection and Reconditioning 9.14...

  • Page 121: Section 10. Reassembly

    General NOTE: Make sure the engine is assembled using Typical Reassembly Sequence Section 10 Reassembly Install Flywheel End Oil Seal Figure 10-1. Seal Bore of Crankcase. Section 10 Reassembly 10.1...
  • Page 122 Section 10 Reassembly Figure 10-2. Installing Oil Seal in Crankcase. Install Breather Filter and Inner Cover Cover Drainback Hole Figure 10-3. Installing Breather Filter and Cover. 10.7 N·m (95 in. lb.) 7.3 N·m (65 in. lb.) 10.2 Drainback Hole (Must Be Open) Figure 10-4.
  • Page 123 Figure 10-6. Setting Governor Shaft Endplay. Install Crankshaft Figure 10-7. Installing Crankshaft in Crankcase. Install Connecting Rods with Pistons and Rings Flywheel Cylinder #1 Side Figure 10-8. Proper Piston Connecting Rod Orientation. Section 10 Reassembly Side Cylinder #2 10.3...
  • Page 124 Section 10 Reassembly Figure 10-9. Installing Piston Assembly Using Ring Compressor Tool. 11.3 N·m (100 in. lb.) Connecting Rod End Cap Figure 10-10. Installing Connecting Rod End Cap. 10.4 Figure 10-11. Torquing Connecting Rod End Cap. Install Valve Tappets and Camshaft Figure 10-12.
  • Page 125 Figure 10-13. Installing Valve Tappets. Figure 10-14. Apply Camshaft Lubricant to Cam Lobes. Governor Cross Shaft Figure 10-15. Aligning Crankshaft and Camshaft Timing Marks. Determining Camshaft End Play Figure 10-16. Checking Camshaft End Play. 0.076/0.127 mm (0.003/0.005 in. Section 10 Reassembly Timing Marks...
  • Page 126 Section 10 Reassembly White: Blue: Red: Yellow: Green: Gray: Black: Figure 10-17. Change Shim to Obtain Correct End Play. Oil Pump Assembly Governor Assembly 10.6 Install Oil Seal in Oil Pan Figure 10-18. Oil Seal Depth in Oil Pan. Install Oil Transfer Tubes and Filter Adapter Figure 10-19.
  • Page 127 Transfer Tube With O-Ring Figure 10-20. Installing Oil Pump Outlet Tube. Figure 10-21. Installing Oil Feed Tube. Oil Pump Outlet Figure 10-22. Oil Filter Adapter and O-Ring. Alignment Figure 10-23. Installing Nipple and Adapter. Figure 10-24. Torquing Nipple. Section 10 Reassembly Adapter O-Ring...
  • Page 128 Section 10 Reassembly Install Oil Pan Assembly Figure 10-25. Oil Pan Sealant Pattern. (216 in. lb) 10.8 Figure 10-26. Oil Pan Fastener Torque Sequence. Figure 10-27. Torquing Oil Pan Fasteners. Install Breather Reed and Outer Cover 6.2 N·m (55 in. lb.) 4.0 N·m (35 in.
  • Page 129 25 597 07-S Figure 10-29. Sealant Applied to Breather Cover. lb.) Outer Cover Sealant Sealing Washer Figure 10-30. Installed Breather Cover and RTV Details. ® Sealant Bead Figure 10-31. Breather Cover and Breather Hose Installation. Install Stator and Backing Plate 1.3 N·m (11.5 in.
  • Page 130 Section 10 Reassembly 7.3 N·m (65 in. lb.) Mounting Screws Figure 10-33. Installing Backing Plate. Install Flywheel and Fan WARNING: Damaging Crankshaft and Flywheel Can Cause Personal Injury! causes extensive engine damage, but can also cause personal 10.10 Figure 10-34. Clean and Dry Taper of Crankshaft, Install Key.
  • Page 131 Figure 10-36. Installing Flywheel. Figure 10-37. Installing Fan and Mounting Hardware to Flywheel. Flywheel Holding Tool Figure 10-38. Torquing Flywheel Fastener. Install Grass Screen Screw Heavy Washer Figure 10-39. Installing Grass Screen. Washer Section 10 Reassembly 10.11...
  • Page 132 Section 10 Reassembly Assemble and Install Cylinder Heads Valve Stem Seals Intake Valve Stem Seal (Some Models Only) Figure 10-40. Intake Valve Seal Location. Spring Valve Figure 10-41. Valve Components. 10.12 Figure 10-42. Installing Valves with Valve Spring Compressor. Gasket (Printing Up) Figure 10-43.
  • Page 133 Figure 10-44. Match Marks Location. Figure 10-45. Torquing Cylinder Head Fasteners. 22.6 N·m (200 in. lb.) (370 in. lb.) Match Marks Figure 10-46. Cylinder Head Fastener Torque Sequence. 41.8 N·m Figure 10-47. Loosing Nut and Backing Off Adjuster. (100 in. lb.) Section 10 Reassembly Adjuster...
  • Page 134 Section 10 Reassembly Figure 10-48. Torquing Rocker Arm Screws. Install Push Rods and Seat in Tappets Figure 10-49. Installed Push Rods. Adjust Valve Clearance 10.14 End Adjustment Style Turning Adjuster Center Pivot Adjustment Style Turning Adjuster Figure 10-50. Turning Adjusters In to Retain Push Rods.
  • Page 135 Turn Adjustment Screw and Lock with Nut Feeler Gauge Figure 10-51. Adjusting Valve Clearance and Tightening Locking Nut (End Adjustment Style). Feeler Gauge Turn Adjuster and Lock Setscrew Figure 10-52. Adjusting Valve Clearance (Center Pivot Adjustment Style). counterclockwise and align clearance is 0.25 mm (0.010 in.) Check Assembly Important:...
  • Page 136 Section 10 Reassembly Install Spark Plugs ® Figure 10-54. Installing Spark Plugs. Install Ignition Modules 10.16 24.4/29.8 N·m Figure 10-55. Setting Ignition Module Gap. 0.280/0.330 mm (0.011/0.013 in.) Install Intake Manifold Feeler "Kill Tab" (Fixed Gauge Timing Module) 4.0-6.2 N·m (35-55 in. lb.) 7.4 N·m (66 in.
  • Page 137 Clip Figure 10-56. Installing Intake Manifold with Wiring Harness. Figure 10-57. Intake Manifold Torque Sequence. Mounting Screws Figure 10-58. Sealant Applied to Terminals. Figure 10-59. Connecting Kill Leads on Fixed Ignition Modules. Figure 10-60. Connect Leads on DSAM Ignition Modules. Section 10 Reassembly 10.17...
  • Page 138 Section 10 Reassembly Models) B+ Terminal Lead Plug Figure 10-61. Connecting B+ Lead to Plug. Connector Install the Inner and Outer Cylinder 10.18 Outer Cylinder 4.0 N·m (35 in. lb.) 7.3 N·m (65 in. lb.) Regulator Mounting Screw Locations 6.2 N·m (55 in. lb.) 10.7 N·m (95 in.
  • Page 139 Figure 10-65. SAM Mounting. Install Carburetor WARNING: Explosive Fuel! Figure 10-66. Installing Carburetor, Throttle Linkage and Governor Lever. Fuel Solenoid Lead Ground Lead Figure 10-67. Connecting Fuel Solenoid and Ground Lead. Install External Governor Controls Figure 10-68. Installing Governor Lever to Cross Shaft.
  • Page 140 Section 10 Reassembly Figure 10-69. Linkage Details. 6.2-7.3 N·m (55-65 in. lb.) Figure 10-70. Installing Air Cleaner Base and Gasket. 10.20 Breather Hose and Clamp Connection Port Figure 10-71. Connecting Breather Hose. 6.8 N·m (60 in. lb.) Mounting Locations Move/Rotate Figure 10-72.
  • Page 141 Install Air Cleaner Element Figure 10-73. Installing Air Cleaner Element. Install Throttle and Choke Controls Choke Linkage Choke Actuating Lever Figure 10-74. Connecting Choke Linkage. 10.7 N·m (95 in. lb.) 7.3 N·m (65 in. lb.) Latch Figure 10-75. Throttle/Choke Control Bracket Mounting Detail.
  • Page 142 Section 10 Reassembly Governor Lever Figure 10-77. Governor Lever and Hole Position/ RPM Chart. Figure 10-78. Throttle/Choke Control Bracket and Governor Lever Detail. 10.22 Governor Lever and Hole Position/RPM Chart High Idle 2900 3300 Governor Lever Governor Spring Hole No. Color Code Black Orange...
  • Page 143 Install Electric Starter Motor and Oil Fill/ Dipstick Tube (135 in. lb.) Figure 10-79. Installing Starter, Lift Bracket, and Oil Fill/Dipstick Tube. 4.0 N·m (35 in. lb.) Install Blower Housing Blower Housing Mounting Screw Locations 15.3 N·m HI-LO Screws Figure 10-80. Blower Housing Mounting Details. Install Fuel Pump WARNING: Explosive Fuel! 2.3 N·m (20 in.
  • Page 144 Section 10 Reassembly Figure 10-81. Installing Pulse Hose. Outlet Hose Clip Pulse Hose Figure 10-82. Fuel Pump Details. 10.24 (88 in. lb.) (216 in. lb.), (150 in. lb.). Install Oil Filter and Fill Crankcase with Oil 13.6 N·m (120 in. lb.) Inlet Hose Figure 10-83.
  • Page 145 Figure 10-84. Installing New Oil Filter. Do not Oil Fill Cap/ Dipstick Oil Fill Tube Figure 10-85. Oil Fill Cap/Dipstick and Oil Fill Tube. Oil Fill Cap/ Dipstick 10 oz. Oil Fill Tube Incorrect Figure 10-86. Oil Fill Cap and Oil Fill Tube Threads. Operating Range Figure 10-87.
  • Page 146 Section 10 Reassembly Prepare the Engine for Operation Testing the Engine 10.26...

  • Page 147: Section 11. Emission Compliance Systems

    Emission Compliance Systems Evaporative Emission Compliance System Operation: Maintenance: Fuel Tank Cap Fuel Tank Figure 11-1. Carbon Canister System Diagram. Emission Compliance Systems Section 11 Carbon Canister Roll Over Valve (ROV) Canister Breather Filter Section 11 To Carburetor 11.1...

  • Page 148: Section 11 Emission Compliance Systems

    Section 11 Emission Compliance Systems Secondary Emission Compliance System Operation: Maintenance: Hose To Exhaust Manifold Inlet Screen Figure 11-2. Secondary Air Induction System Diagram. 11.2 Hose To Exhaust Manifold Secondary Air Valve Assembly Secondary Air Valve Assembly Hose To Carburetor...
  • Page 150 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-2574-A ISSUED: 1/06 REVISED: 12/07 LITHO IN U.S.A.

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