Kohler CS10 Service Manual
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Kohler CS10 Service Manual

Command pro cs series 4-12 hp horizontal crankshaft engines
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S
M
ERVICE
ANUAL
C
P
CS S
OMMAND
RO
ERIES 4-12 HP
H
C
ORIZONTAL
RANKSHAFT

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Summary of Contents for Kohler CS10

  • Page 1 ERVICE ANUAL CS S OMMAND ERIES 4-12 HP ORIZONTAL RANKSHAFT...

  • Page 2: Table Of Contents

    Contents Section 1. Safety and General Information ................Section 2. Special Tools ......................Section 3. Troubleshooting ..................... Section 4. Air Cleaner and Air Intake System ................. Section 5. Fuel System and Governor ..................Section 6. Lubrication System ....................Section 7. Retractable Starter ....................Section 8.

  • Page 3: Section 1. Safety And General Information

    Section 1 Safety and General Information CS4-12 Go Back Section 1 Safety and General Information Safety Precautions To insure safe operations please read the following statements and understand their meaning. Also refer to your equipment owner's manual for other important safety information. This manual contains safety precautions which are explained below.
  • Page 4 Section 1 Safety and General Information WARNING WARNING WARNING Explosive Gas can cause fires and Carbon Monoxide can cause Explosive Fuel can cause fires and severe acid burns. severe nausea, fainting or death. severe burns. Charge battery only in a well Do not operate engine in closed or ventilated area.
  • Page 5 NOTE: CS8.5 engines have been produced in two different specification series, 92xxxx and 95xxxx. The design features of 92xxxx spec. no. engines are identical to CS10 and CS12 engines, and share the same service procedures. The 95xxxx spec. no. engines incorporate certain design differences from the 92xxxx spec.
  • Page 6 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. Figure 1-4. Oil Container Logo.
  • Page 7 Section 7 • Have combustion chamber decarbonized. ¹Perform these maintenance procedures more frequently under extremely dusty, dirty conditions. ²Have a Kohler Engine Service Dealer perform this service. Storage If the engine will be out of service for two months or...
  • Page 8 Section 1 Safety and General Information 347.00 (13.661) 30.00 373.00 (1.181) (14.685) 106.00 (4.173) 5/16-24 [qty. 5] 14 mm (.551) deep 66.00 (2.598) 162.00 (6.378) 384.25 (15.128) 321.50 (Straight PTO) (12.657) 143.00 (5.630) 100.00 162.00 (3.937) (6.378) 145.25 Spark Plug (5.719) 380.03 (14.962)
  • Page 9 11.00 (.433) dia. [qty. 2] 16.00 11.00x27 (.433x1.063) slot (.630) [qty. 2] 65.00 37.00 (2.559) (1.457) Dimensions in millimeters. 62.00 102.00 Inch equivalents shown in ( ). (2.441) (4.016) Figure 1-6. Typical Engine Dimensions CS8.5 (spec. 92xxxx), CS10, and CS12.
  • Page 10 Section 1 Safety and General Information 431.00 (16.968) 156.00 (6.142) 165.1 (6.50) 110 (4.33) 424.00 (16.693) 410.00 (16.142) 428.00 (16.850) 70.00 133.50 146.08 (5.78) (2.756) (5.256) 90.50 103.00 (3.563) (4.055) 5/16-24 18 mm (.709) deep [qty. 2] 3/8-16 18 mm (.709) deep 5/16-24 18 mm (.709) deep [qty.
  • Page 11 CS8.5 (spec. 95xxxx @ 2400 RPM) ..........16.5 N·m (12.1 ft. lb.) CS8.5 (spec. 92xxxx @ 2000 RPM) ..........19.66 N·m (14.5 ft. lb.) CS10 (@ 2000 RPM) ..............19.66 N·m (14.5 ft. lb.) CS12 (@ 2000 RPM) ..............22.6 N·m (16.7 ft. lb.) Bore CS4 ....................
  • Page 12 CS4,CS6 ..................0.6 L (0.64 U.S. qt.) CS8.5 (spec. 95xxxx) ..............1.0 L (1.1 U.S. qt.) CS8.5 (spec. 92xxxx) ..............1.1 L (1.2 U.S. qt.) CS10-12 ..................1.1 L (1.2 U.S. qt.) Fuel Tank Capacity CS4,CS6 ..................3.9 L (4.1 U.S. qt.) CS8.5 (spec.
  • Page 13 CS4,CS6 ..................0.2/0.6 mm (0.008/0.024 in.) CS8.5 (spec. 95xxxx) ..............0.2/0.6 mm (0.008/0.024 in.) CS8.5 (spec. 92xxxx) ..............0.2/0.65 mm (0.0079/0.0256 in.) CS10-12 ..................0.2/0.65 mm (0.0079/0.0256 in.) Connecting Rod-to-Piston Pin Running Clearance ........ 0.006/0.025 mm (0.0002/0.0001 in.) Piston Pin End I.D.
  • Page 14 CS4,CS6................... 52 mm (2.047 in.) CS8.5 (spec. 95xxxx) ............... 52 mm (2.047 in.) CS8.5 (spec. 92xxxx) ............... 80 mm (3.149 in.) CS10-12 ................... 80 mm (3.149 in.) Max. Wear Limit CS4,CS6................... 52.05 mm (2.0492 in.) CS8.5 (spec. 95xxxx) ............... 52.05 mm (2.0492 in.) CS8.5 (spec.
  • Page 15 CS4,CS6 ..................65 N·m (48 ft. lb.) CS8.5 (spec. 95xxxx) ..............65 N·m (48 ft. lb.) CS8.5 (spec. 92xxxx) ..............120 N·m (85 ft. lb.) CS10-12 ..................120 N·m (85 ft. lb.) Fuel Tank Fuel Tank Fastener Screws Torque ............8-12 N·m (71-106 in. lb.)
  • Page 16 CS4,CS6................... 16.002/16.013 mm (0.6300/0.6304 in.) CS8.5 (spec. 95xxxx) ............... 18.004/18.015 mm (0.7088/0.7093 in.) CS8.5 (spec. 92xxxx) ............... 20.004/20.015 mm (0.7876/0.7880 in.) CS10-12 ................... 20.004/20.015 mm (0.7876/0.7880 in.) Max. Wear Limit CS4,CS6................... 16.03 mm (0.6311 in.) CS8.5 (spec. 95xxxx) ............... 18.03 mm (0.7098 in.) CS8.5 (spec.
  • Page 17 CS4,CS6 ..................22 N·m (195 in. lb.) CS8.5 (spec. 95xxxx) ..............22 N·m (195 in. lb.) CS8.5 (spec. 92xxxx) ..............65 N·m (48 ft. lb.) CS10-12 ..................65 N·m (48 ft. lb.) Retractable Starter Mounting Screws to Blower Housing Torque CS4,CS6 ..................
  • Page 18 Section 1 Safety and General Information Throttle Control Throttle Control Lever Fastener Torque CS4,CS6 ..................7-9 N·m (62-80 in. lb.) CS8.5-12 ..................9-11 N·m (80-97 in. lb.) Valve Cover Valve Cover Fastener Torque CS4,CS6 ..................10 N·m (88 in. lb.) CS8.5-12 ..................
  • Page 19 Size Into Aluminum Model M10x1.25 17 (150) CS4, CS6 N·m = in. lb. x 0.113 M12x1.50 20 (177) CS8.5, CS10, CS12 N·m = ft. lb. x 1.356 in. lb. = N·m x 8.85 ft. lb. = N·m x 0.737 1.17...
  • Page 20 Section 1 Safety and General Information 1.18...

  • Page 21: Section 2. Special Tools

    I.D. to slip on the capscrew and an testing crankcase vacuum. They can also be used for O.D. of approximately 1". Kohler Part No. 12 468 05-S testing exhaust back pressure and for adjusting some can be used if you don't have the right size on hand.
  • Page 22 The flywheel holding tool shown below is illustrated in template form on page 2.3, and may be fabricated locally for use in the field. The tool is not available from Kohler. Figure 2-2. Using Flywheel Holding Tool.
  • Page 23 Section 2 Template for Flywheel Holding Tool Special Tools Material needed: 9 mm or 3/8" thick steel, 25 mm or 1" wide. 14"...
  • Page 24 Section 2 Special Tools...

  • Page 25: Section 3. Troubleshooting

    Section 3 Troubleshooting CS4-12 Go Back Section 3 Troubleshooting Troubleshooting Guide Engine Will Not Crank 1. PTO drive is engaged. When troubles occur, be sure to check the simple 2. Battery (if equipped) is discharged. causes which, at first, may seem too obvious to be 3.
  • Page 26 Section 3 Troubleshooting Engine Knocks • Check the air cleaner element. Look for holes, 1. Excessive engine load. tears, cracked or damaged sealing surfaces, or 2. Low crankcase oil level. other damage that could allow unfiltered air into 3. Old/improper fuel. the engine.
  • Page 27 Pressure in the crankcase (normally caused by a clogged breather) can cause oil to be forced out at oil seals, gaskets, or other available spots. Crankcase vacuum is best measured with water manometer, Kohler Part No. 25 761 02-S, or vacuum/pressure tester, Kohler Part No. 25 761 22-S. Complete instructions are provided in the kits.
  • Page 28 Section 3 Troubleshooting b. If the flywheel end of the engine is more Kohler Part No. 25 761 05-S is a relatively simple, inexpensive leakdown tester for small engines. The accessible, you can use a breaker bar and tester includes a quick disconnect for attaching the socket on the flywheel nut/screw or a flywheel adapter hose and a holding tool.

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

    Section 4 Air Intake and Air Cleaner System CS4-12 Go Back Section 4 Air Cleaner and Air Intake System Air Cleaners General These engines are equipped with one of three air cleaner configurations; the standard dual-element air cleaner assembly, an optional heavy-duty cyclonic air cleaner assembly, or a third design which uses an oiled, solid foam element.
  • Page 30 Section 4 Air Cleaner and Air Intake System To service the precleaner perform the following steps: 1. Remove the air cleaner cover knob (standard air cleaner) or unsnap the latches (heavy-duty air cleaner), and remove the cover/housing. See Figures 4-3 and 4-4. 2.
  • Page 31 2. 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 surfaces are bent or damaged.
  • Page 32 Section 4 Air Cleaner and Air Intake System 3. When servicing the air cleaner, check the air Heavy-Duty Cyclonic Air Cleaner cleaner base, and cover/housing assembly. Make Air Cleaner Housing, Swirl/Dirt Chamber, Latch sure it is secure and not bent or damaged. On a Clips heavy-duty air cleaner, unsnap the latches and Make sure the main housing, lower swirl/dirt chamber,...
  • Page 33 Every 50 hours of operation, wash and reoil the foam remove any excess. air cleaner element (more oftern under extremely dusty, or dirty conditions). Replace the foam element with a new genuine Kohler element if deteriorated or damaged in any way.
  • Page 34 Section 4 Air Cleaner and Air Intake System Air Intake/Cooling System 5. When servicing the foam air cleaner element, clean and check the air cleaner case and outer To ensure proper cooling, make sure the grass screen, cover for damage, distortion, or an improper seal. cooling fins and other external surfaces of the engine Replace any components which are bent or are kept clean at all times.

  • Page 35: Section 5. Fuel System And Governor

    Gasoline/Alcohol blends Gasohol (up to 10% ethyl alcohol, 90% unleaded Operation gasoline by volume) is approved as a fuel for Kohler The fuel from the tank is moved through the shut-off engines. Other gasoline/alcohol blends are not valve/screen filter and fuel lines by gravity.
  • Page 36 Section 5 Fuel System and Governor Fuel System Tests When the engine starts hard, or turns over but will not start, it is possible that the problem is in the fuel system. To find out if the fuel system is causing the problem, perform the following tests. Troubleshooting –...
  • Page 37 Section 5 Fuel System and Governor Troubleshooting – Carburetor Related Causes Condition Possible Cause/Probable Remedy 1. Engine starts hard, runs 1. Low idle fuel mixture/speed improperly adjusted. Adjust the low idle roughly or stalls at idle speed RPM, then adjust the low idle fuel needle. speed.
  • Page 38 Section 5 Fuel System and Governor Adjustments 3. Low Idle Speed Setting: Place the throttle control into the ‘‘idle’’ or ‘‘slow’’ position. Set the General low idle speed to 2000 RPM* (+150 RPM) by NOTE: Carburetor adjustments should be made only turning the low idle speed adjusting screw in or after the engine has warmed up.
  • Page 39 Section 5 Fuel System and Governor 1. Pilot Jet 11. Bowl Retaining 1. Pilot Jet 13. Float Pin 2. Screw Screw 2. Plug Screw Washer 14. Clip 3. Main Jet 12. Float Bowl 3. Seal 15. Needle Assembly 4. Main Nozzle 13.
  • Page 40 CS6 is 16 mm (0.63 in.). Float height for the dirty, obstructed or worn. CS8.5, CS10, and CS12 is 14.9 mm (0.59 in.). Install a float kit if the float height is incorrect. a. Remove the main jet from the side of the tower.
  • Page 41 Section 5 Fuel System and Governor d. Check components for contamination, wear, 13. Use the reverse of steps 1-5 to reinstall the or damage. See Figure 5-6. Use carburetor carburetor on the engine. cleaner to clean out any dirt or contamination. Use a float kit if the inlet needle or float is Governor damaged or worn.
  • Page 42 8 N·m (70.8 in. lb.) on CS4, CS6 spring tension and the force applied by the regulating 10 N·m (88.5 in. lb.) on CS8.5, CS10, CS12 pin will again be in equilibrium. This maintains the engine speed at a relatively constant level.
  • Page 43 Throttle Stop Screw Throttle Lever 1. Start the engine and allow it to warm up. Place the Figure 5-13. CS8.5 (spec. 92xxxx), CS10, and CS12 throttle control lever into the ‘‘fast’’ or high idle Throttle Lever/Throttle Stop Screw Details. position.
  • Page 44 Section 5 Fuel System and Governor Low Idle Speed Adjustment The recommended low idle speed is 2000 +100 RPM. The low idle speed is set by turning the low idle speed screw in or out, see Figures 5-15 and 5-16. 1.

  • Page 45: Section 6. Lubrication System

    Section 6 Lubrication System Go Back CS4-12 Section 6 Lubrication System General These engine use a splash lubrication system, supplying necessary lubrication to the crankshaft, camshaft, connecting rod and valve train components. Oil Recommendations Using the proper type and weight of oil in the crankcase is extremely important.
  • Page 46 Section 6 Lubrication System NOTE: If the engine stalls or does not start, turn the engine switch to the ‘‘on’’ position and Bring Level Up To attempt to start the engine. If the oil warning Point of Overflow light flickers for a few seconds, the engine oil is insufficient.
  • Page 47 Section 6 Lubrication System NOTE: To prevent extensive engine wear or damage, always maintain the proper oil level in the crankcase. Never operate the engine with the oil level below the low oil level. Figure 6-6. CS8.5-12 Right Oil Fill/Level Plug Location.
  • Page 48 Section 6 Lubrication System...

  • Page 49: Section 7. Retractable Starter

    Section 7 Retractable Starter CS4-12 Go Back Section 7 Retractable Starter WARNING: Spring Under Tension! Retractable starters contain a powerful, recoil spring that is under tension. Always wear safety goggles when servicing retractable starters and carefully follow instructions in this section for relieving spring tension. Pawl Repair Starter Drive Cup...
  • Page 50 Section 7 Retractable Starter 5. When all spring tension on the starter pulley is 2. Pull the starter handle out until the pawls engage the drive cup. Hold the handle in this position and released, remove the rope from the pulley. torque the screws to 5.5 N·m (48 in.
  • Page 51 4. Carefully inspect the components for wear, Center Screw cracks, and/or damage. Replace all worn or Clip damaged components. Use only genuine Kohler Starter Pawl (Dog) replacement parts as specified in the parts manuals. All components shown in Figure 7-1 are CS8.5-12 Pawl Repair Kit Contains...
  • Page 52 Section 7 Retractable Starter 1. Release spring tension and remove the handle Clip and starter rope. (Refer to ‘‘Rope Replacement’’.) Drive Plate 2. Unscrew the center screw and lift off the drive plate. The screw will be captured within plate by the clip on backside.
  • Page 53 Section 7 Retractable Starter 3. Carefully install pulley into recoil housing, engaging the spring hook with starter housing tab. See Figure 7-10. NOTE: Rotating pulley counterclockwise slightly will assist engagement. 4. Install the pawl springs (CS8.5-12 only) and pawls onto pawl studs of pulley. Figure 7-11.
  • Page 54 Section 7 Retractable Starter...

  • Page 55: Section 8. Electrical System And Components

    NGK spark plug is RN14YC The service replacement is Wire Gauge Champion ® RC14YC (Kohler Part No. 66 132 01-S). Equivalent alternate Spark Plug brand spark plugs can also be used. Gap: 0.76 mm (0.030 in.) Thread Size:...
  • Page 56 Section 8 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 57 Section 8 Electrical System and Components Operation As the flywheel rotates and the magnet assembly moves past the ignition module, a low voltage is induced in the primary windings of the module. When the primary voltage is precisely at its peak, the module induces a high voltage in its secondary windings.
  • Page 58 If it still will not start, check other possible causes Kohler Part No. 25 455 01-S. Attach tester (fuel, compression, etc.). If tester does not fire, spring clip to a good ground, not to the spark plug.
  • Page 59 Section 8 Electrical System and Components Problem Test Conclusion 6. Resistance of the ignition module should be 6. Set an ohmmeter to the Rx1K or Rx10K scale and zero. Connect one ohmmeter lead to the 13.5-18.0 K ohms. kill lead (black/white) terminal and connect the other lead into the spark plug cap.
  • Page 60 Model No. Spec. No. Figure No. Page No. CS10S 931509 CS6T 911501 CS10ST 931510 CS6T 911502 CS10TG 931511 CS6T 911503 CS10 931512 CS6TR 911504 CS6TP 911505 Model No. Spec. No. Figure No. Page No. CS6TG 911506 CS6TG 911510 CS12T 941501...
  • Page 61 Section 8 Electrical System and Components Wiring Color Codes Ignition Module Black Blue Spark Plug Yellow Ground White Brown Green Gray Black w/ White Stripe Red w/ White Stripe White w/ Blue Stripe Green w/ Red Stripe Stop Green w/ Yellow Stripe Switch Blue w/ White Stripe Blue w/ Red Stripe...
  • Page 62 Section 8 Electrical System and Components Warning Unit Stop Switch Ground Oil Sentry Light Oil Sentry Wire Lead Gauge Ignition Module Ground Ground Spark Plug Stator Ground Ground Figure 8-6. Main Switch Wire Color Warning B B B Start Unit Ground Oil Sentry Fuse (15 A)
  • Page 63 Section 8 Electrical System and Components Main Switch Wire Color Warning Start Unit Ground Oil Sentry Fuse (15 A) Light Wire Lead Engine Ground Ignition Module Oil Sentry Ground Gauge Stator Starter Spark Ground Ground Solenoid Plug Battery Ground Rectifier-Regulator Starter Motor Ground...
  • Page 64 Section 8 Electrical System and Components Main Switch Wire Color Warning Start Unit R RW Ground Ground Rectifier Oil Sentry Light Wire Lead Ignition Module Fuse Oil Sentry Gauge Starter Solenoid Spark Ground Ground Ground Plug Ground Ground Battery Starter Motor Ground Ground Figure 8-10.
  • Page 65 Section 8 Electrical System and Components Warning Unit Stop Switch Engine Ground Ground Ground Oil Sentry Light Oil Sentry Gauge Ignition Module Ground Spark Plug Stator Ground Ground Figure 8-12. Main Switch Wire Color Warning Start Unit R RW Engine Ground Oil Sentry Ground...
  • Page 66 Section 8 Electrical System and Components Warning Stop Unit Switch Engine Ground Ground Ground Oil Sentry Gauge Ignition Module Oil Sentry Gauge Stator Spark Plug Ground Ground Ground Rectifier Figure 8-14. Rectifier Assembly Oil Warning Unit Oil Sentry Main Switch Rectifier-Regulator Light R RB Y LR...
  • Page 67 Section 8 Electrical System and Components NOTE: Observe the following guidelines to avoid 18 amp Rectifier-Regulator damage to the electrical system and The 18 amp rectifier-regulators contain a 6-terminal components. plug-in configuration, illustrated in Figure 8-16. The upper center terminal is the control or ‘‘monitor’’ •...
  • Page 68 Section 8 Electrical System and Components Rectified Only (Non-Regulated) Systems Some engines are equipped with a 3 or 18 amp rectified, non-regulated charging system. The rectifier is connected to the engine with a matching wiring harness. Grounded through the wiring harness, the rectifier module is secured to the equipment with a single mounting screw.
  • Page 69 Section 8 Electrical System and Components Troubleshooting Guide Battery Charging System NOTE: Zero ohmmeters on each scale to ensure accurate readings. Voltage tests should be made with engine running at 3600 RPM - no load. Battery must be fully charged. Check the specific gravity of battery. If low, recharge or replace battery as necessary.
  • Page 70 Section 8 Electrical System and Components Battery 2. Keep the cables, terminals, and external surfaces of the battery clean. A build-up of corrosive acid or grime on the external surfaces can cause the General battery to self-discharge. Self-discharge occurs A 12 volt battery (not furnished) with a minimum rapidly when moisture is present.
  • Page 71 Section 8 Electrical System and Components Electric Starting Motors NOTE: If the engine develops sufficient speed to disengage the starter but does not keep Electric start engines in this series will use either an running (a false start), the engine rotation inertia drive, or a solenoid shift starter.
  • Page 72 Section 8 Electrical System and Components Troubleshooting Guide – Electric Starting System Problem Test Conclusion 1. Test battery on unit. 1. a. Battery voltage should be at least 12 volts If low charge battery. a. Connect a DC voltmeter across the b.
  • Page 73 2. Push back the spring holder (collar) to expose the retaining ring on the armature shaft, which secures the drive components. Remove the retaining ring using either of the Kohler retaining ring removal tools. Figure 8-22. Inertia Drive Starter. Operation When power is applied to the starter, the armature rotates.
  • Page 74 Section 8 Electrical System and Components 3. Remove the spring holder (collar), spring and 8. Install a new retaining ring into the groove of the drive pinion assembly from the armature shaft. armature shaft. Squeeze it with a pliers to compress it into the groove.
  • Page 75 Section 8 Electrical System and Components 3. Scribe or mark a small line from the starter frame to each end cap to serve as match marks for reassembly later. See Figure 8-29. Figure 8-31. Removing End Cap with Brush Plate. 6.
  • Page 76 Section 8 Electrical System and Components 2. Inspect both the springs and brushes for wear, fatigue, or damage. Measure the length of each brush. The minimum length for each brush must be 9 mm (0.350 in.). See Figure 8-33. Replace the brush plate assembly if the condition of parts Depth: is out of specification or questionable.
  • Page 77 Section 8 Electrical System and Components Starter Reassembly 1. Position the thrust washer in the recess inside the drive end cap. Install cover gasket on housing flange if removed previously. Figure 8-39. Installing Frame. 4. With the brushes and brush springs in place on brush plate, align the tabs and install the brush plate in commutator end cap.
  • Page 78 Section 8 Electrical System and Components 5. Assemble the end cap assembly to the starter, inserting the commutator below the brushes and gently guiding the end of the armature shaft into the bushing within the end cap, against the brush spring tension.
  • Page 79 Section 8 Electrical System and Components Solenoid Shift Electric Starter The following subsection covers the solenoid shift electric starter. Much of the information in the proceeding subsection relates to this type starter also, so it is not repeated here. A Nippendenso solenoid shift starter is used. Operation (Solenoid Shift Starter) When power is applied to the starter, the electric solenoid moves the drive pinion out onto the drive shaft and into mesh with the flywheel ring gear.
  • Page 80 Section 8 Electrical System and Components Starter Disassembly 8. Pull outward on the pivot portion of the drive lever, 1. Remove flange nut and disconnect the braided and remove the drive lever and armature from the wire from lower main solenoid terminal. drive end cap.
  • Page 81 Electrical System and Components Brush Replacement The brushes in the starter are part of the starter frame. The brush kit, Kohler Part No. 52 221 01-S, contains four replacement brushes and springs. If replacement is necessary, all four brushes should be replaced.
  • Page 82 Section 8 Electrical System and Components 7. Mount the brush holder to rear of starter frame. Install the four brushes into the corresponding slots. Then carefully work (set) each of the four brush springs into position behind the brushes. Slide the rubber insulating grommet onto the small corresponding plastic tab on frame.
  • Page 83 Section 8 Electrical System and Components 14. Connect the braided (brush) lead to lower main solenoid terminal and secure with the loose hex. flange nut. See Figure 8-59. Figure 8-57. Installing End Cap. 12. Install and tighten the two thru bolts. Figure 8-59.
  • Page 84 Section 8 Electrical System and Components 8.30...

  • Page 85: Section 9. Disassembly

    Section 9 Disassembly CS4-12 Go Back Section 9 Disassembly WARNING: Accidental Starts! Disabling engine. Accidental starting can cause severe injury or death. Before working on the engine or equipment, disable the engine as follows: 1) Disconnect the spark plug lead(s). 2) Disconnect negative (-) battery cable from battery.
  • Page 86 Section 9 Disassembly Turn Fuel Shut-Off Valve to ‘‘Off’’ Position Figure 9-4. Removing Muffler. Figure 9-2. Fuel Shut-Off Valve. 3. Remove the exhaust gasket from the outlet. Drain Oil From Crankcase Remove Air Cleaner Assembly 1. Remove one of the oil drain plugs and one of the Remove the air cleaner components from the air oil fill caps.
  • Page 87 (blower housing mounted valves). See Figure 9-10. Figure 9-6. CS8.5 (spec. 92xxxx), CS10, and CS12 Air Cleaner Base. Figure 9-9. Disconnecting Fuel Line on CS4, CS6, CS8.5 (spec. 92xxxx), CS10, and CS12.
  • Page 88 1. Carefully lift up and unhook the choke link and spring from the choke lever on the carburetor (CS8.5, CS10, and CS12 only). The choke link may stay connected on CS4 and CS6 engines. Figure 9-14. Removing Governor Lever and Linkage.
  • Page 89 Section 9 Disassembly Remove Carburetor WARNING: Gasoline may be present in the carburetor and fuel system. Gasoline is extremely flammable, and its vapors can explode if ignited. Keep sparks, open flames and other sources of ignition away from the engine. 1.
  • Page 90 Figure 9-21. Cover Panel Mounting Screws. Not on CS8.5 (spec. 95xxxx) Figure 9-19. CS8.5 (spec. 92xxxx), CS10, and CS12 Blower Housing Screws. Figure 9-22. CS8.5 (spec. 92xxxx), CS10, and CS12 Upper Right-Hand Mounting Screw.
  • Page 91 Figures 9-24 and 9-25. Disconnect the rectifier- regulator lead connections if used. Figure 9-26. CS4, CS6 Right Tank Bracket Mounting Details. Figure 9-24. CS8.5 (spec. 92xxxx), CS10, and CS12 Ground Lead Location. Figure 9-27. CS8.5 (spec. 92xxxx), CS10, and CS12 Right Tank Mounting Bracket Details.
  • Page 92 Section 9 Disassembly 4. Remove the two electric starter mounting bolts. See Figures 9-29 and 9-30. Figure 9-31. CS8.5 (spec. 92xxxx), CS10, CS12 with Electric Starter Assembly Removed. Figure 9-29. Removing Starter Mounting Bolts on CS8.5 (spec. 92xxxx), CS10, and CS12.
  • Page 93 2. Remove the valve cover and gasket from the cylinder head. See Figure 9-38. The breather assembly is inside the valve cover. Figure 9-35. CS8.5 (spec. 92xxxx), CS10, and CS12 Left Side Tank Mounting Bracket Details. Remove Valve Cover/Breather, Air Shroud, Cylinder Head Assembly, and Push Rods 1.
  • Page 94 (2), push rods, and cylinder head gasket. NOTE:Mark the push rods so they will be reinstalled in the same location. Figure 9-42. CS8.5 (spec. 92xxxx), CS10, and CS12 Removing Rocker Arms and Spark Plug. 3. Using a valve spring compressor, remove the Figure 9-40.
  • Page 95 Section 9 Disassembly Figure 9-43. Disassembling Valve Assemblies. Figure 9-45. Removing Carburetor Mounting Studs. 4. Remove and replace the intake valve stem seal whenever the cylinder head is serviced or Remove Flywheel diassembled. See Figure 9-44. NOTE: Whenever possible, an impact wrench should be used to loosen the flywheel retaining nut.
  • Page 96 Section 9 Disassembly Remove Ignition Module 1. Remove the two hex. flange screws securing the ignition module to the crankcase. See Figure 9-50. Figure 9-47. Removing Flywheel Nut Using Holding Tool. 2. Remove the flywheel from the crankshaft using a Figure 9-50.
  • Page 97 Section 9 Disassembly 2. Remove the four hex. flange shoulder screws securing the stator to the crankcase. Remove the stator and pull the wires through the opening in the casting. See Figure 9-52 Figure 9-54. Removing Reduction Housing Screws on CS8.5-CS12. 3.
  • Page 98 Section 9 Disassembly 4. Remove the screw and washer securing the crankshaft sprocket/gear. Figure 9-59. Removing Sprockets and Chain on CS4, CS6. Figure 9-57. Removing Screw from Crankshaft on CS4, CS6. Figure 9-60. Thrust Washer Behind Crank Sprocket on CS4, CS6. Figure 9-58.
  • Page 99 Section 9 Disassembly 6. Check the reduction system bearings for wear or excessive play. See Figure 9-62. If bearing removal is required, use an internal bearing puller to remove the housing bearings. An arbor press should be used for removal of the others. Figure 9-64.
  • Page 100 An arbor press should be used for removal of the others. 6:1 Reduction Assemblies, CS8.5, CS10, and CS12 1. Remove any drive coupling and the key from the reduction assembly output shaft. Clean the shaft and keyway of any burrs/damage.
  • Page 101 Section 9 Disassembly 5. Remove the counter gear from the closure plate. Remove the screw and washer securing the crank gear and slide the gear off of the crankshaft splines. See Figure 9-72. Pry/Tap Pry/Tap Pads Pads Figure 9-74. CS4, CS6 Closure Plate Mounting Screws.
  • Page 102 Section 9 Disassembly Figure 9-76. Separating Closure Plate From Figure 9-78. Removing Governor Gear. Crankcase. 6. Remove the crankshaft seal. See Figure 9-79. Steps 3-7 should be performed only if further disassembly or servicing in the respective areas is necessary. 3.
  • Page 103 Section 9 Disassembly Remove Balance Shaft (If So Equipped) 1. Pull the balance shaft out of the crankcase. Figure 9-83. Removing Connecting Rod Bolts. NOTE: If a carbon ridge is present at the top of the Figure 9-81. Removing Balance Shaft. cylinder bore, use a ridge reamer to remove it, before attempting to remove the piston.
  • Page 104 Section 9 Disassembly Remove Crankshaft 1. Carefully remove the crankshaft from the crankcase. Figure 9-87. Removing Governor Cross Shaft with Inner Washer. Remove Flywheel End Main Bearing and Figure 9-85. Removing Crankshaft. Oil Seal 1. Remove the front oil seal from the crankcase. Remove Governor Cross Shaft See Figure 9-88.
  • Page 105 Section 9 Disassembly 2. Remove the front main bearing from the crankcase using an arbor press. See Figure 9-89. Figure 9-89. Removing Main Bearing with Press. Remove Balance Shaft Bearing 1. Remove the balance shaft bearing using an internal bearing puller. 9.21...
  • Page 106 Section 9 Disassembly 9.22...
  • Page 107 Section 10 Internal Components CS4-12 Go Back Section 10 Internal Components 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 their own sections: Air Cleaner, Section 4 Carburetor &...
  • Page 108 26.9 +0.05 mm 26.68 +0.05 mm be replaced. Check the condition and operation of the (1.06 +0.002 in.) (1.05 +0.002 in.) ACR mechanism. See Figure 10-2. CS8.5, CS10, 32.55 +0.05 mm 32.55 +0.05 mm CS12 (1.28 +0.002 in.) (1.28 +0.002 in.) 10.2...
  • Page 109 (0.87 +0.002 in.) (0.87 +0.002 in.) pickup. Slight score marks can be cleaned with crocus cloth soaked in oil. If wear limits, as stated in CS8.5, CS10, 26.08 +0.05 mm 26.08 +0.05 mm “Specifications and Tolerances” are exceeded, it will be CS12 (1.03 +0.002 in.)
  • Page 110 Section 10 Internal Components 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.) of desired size and then use finish stones (220-280 grit) and polish to final size.
  • Page 111 Replace the flywheel, the crankshaft, and the key if flywheel key is sheared or the keyway damaged. Inspect the ring gear for wear, cracks, or damage. Kohler does not provide ring gears as a serviceable part. Replace the flywheel if the ring gear is damaged. 10.5...
  • Page 112 Section 10 Internal Components Cylinder Head and Valves Inspection and Service Carefully inspect the valve mechanism parts. Inspect the valve springs and related hardware for excessive wear or distortion. Check the valves and valve seat area for evidence of deep pitting, cracks, or distortion. Check clearance of the valve stems in guides.
  • Page 113 Section 10 Internal Components CS8.5, CS10, CS12 Valve Specifications Dimension Intake Exhaust Head Diameter 32.0 mm (1.26 in.) 27.0 mm (1.06 in.) Stem Diameter 5.948/5.963 mm 5.940/5.955 mm (0.2342/0.2348 in.) (0.2339/0.2344 in.) Length 88.1 mm (3.47 in.) 87.9 mm (3.46 in.) Face/Seat Width 0.7/0.9 mm (0.0276/0.0354 in.)
  • Page 114 Section 10 Internal Components Leakage: A poor grind on face or seat of valve will Gum: Gum deposits usually result from using stale gasoline. Gum is a prevalent cause of valve sticking. allow leakage resulting in a burned valve on one side only.
  • Page 115 Section 10 Internal Components Valve Seat Cover (Typical) Pilot Overheating: An exhaust valve subject to overheating Figure 10-11. Standard Valve Seat Cutter. will have a dark dicoloration in the area above the valve guide. Worn guides and faulty valve springs may Lapping Valves cause this condition.
  • Page 116 Section 10 Internal Components Pistons and Rings Inspection Scuffing and scoring of pistons and cylinder walls occurs when internal temperatures approach the melting point of the piston. Temperatures high enough to do this are created by friction, which is usually attributed to improper lubrication, and/or overheating of the engine.
  • Page 117 Section 10 Internal Components Replacement pistons are available in STD bore size, 4. After installing the new rings on the piston, check and in 0.25 mm (0.010 in.) and 0.50 mm (0.20 in.) piston-to-ring side clearance. Maximum oversizes. Replacement pistons include new piston recommended side clearance is: ring sets and new piston pins.
  • Page 118 Section 10 Internal Components Install Piston Rings 2. Middle Compression Ring: Locate and identify the compression ring with the ‘‘R’’ marking. Using a To install piston rings, proceed as follows: piston ring expander, install this ring in the middle groove with the ‘‘R’’ up towards the top of the NOTE: Rings must be installed correctly.
  • Page 119 See Figure 10-19. Figure 10-20. Governor Shaft Position Details. Exposed Shaft Length–A CS4, CS6 29.2 +0.2 mm (1.149 +0.007 in.) CS8.5, CS10, 36.0 +0.6 mm (1.417 +0.023 in.) CS12 Figure 10-19. Governor Gear Removal. 10.13...
  • Page 120 Section 10 Internal Components Governor Reassembly 1. Install one thrust washer onto the governor shaft, followed by the governor gear/flyweight assembly. 2. Start the retaining clip over the end of the shaft. 3. Raise the gear up on the shaft sufficiently to install the other thrust washer and governor regulating pin under the outer ‘‘fingers’’...
  • Page 121 Section 10 Internal Components Figure 10-25. Inspect for Binding. Figure 10-27. CS8.5-12 Oil Passage. 5. Check to see that the closure plate/oil passages to the reduction assembly are open and not restricted. See Figures 10-26 and 10-27. Figure 10-26. CS4, CS6 Oil Passage. 10.15...
  • Page 122 Section 10 Internal Components 10.16...

  • Page 123: Section 11. Reassembly

    Section 11 Reassembly CS4-12 Go Back Section 11 Reassembly General 20. Install carburetor. 21. Install air cleaner base and element. NOTE: Make sure the engine is assembled using all 22. Adjust/Set governor. specified torque values, tightening 23. Install fuel tank and fuel tank support. sequences, and clearances.

  • Page 124: Install Governor Cross Shaft

    Section 11 Reassembly Figure 11-2. Installing Bearing in Closure Plate. Figure 11-4. Installing Governor Shaft. 3. Use a seal driver and install the crankshaft oil seals (manufacturer’s numbers visible) into crankcase and closure plate. Seals should be installed to a depth of 2 mm (0.080 in.) below outer surface.
  • Page 125 Section 11 Reassembly Install Connecting Rod with Piston and Rings 1. If the piston and/or connecting rod has been changed or removed, make sure the following is correct before installing. Figure 11-6. CS4, CS6. Installing Hitch Pin. Figure 11-9. a. The locating mark on piston is down. See Figure 11-10.
  • Page 126 Section 11 Reassembly b. The connecting rod offset is down and oil hole is in the 3 o’clock position. Match marks should align as shown with dipper down. See Figure 11-11. Oil Hole Match Marks Figure 11-13. Installing Piston Using a Ring Dipper Compressor.
  • Page 127 Section 11 Reassembly 3. Rotate the crankshaft to TDC so the timing mark 2. Install the balance shaft, aligning the timing mark (dimple) on crankgear (smaller gear) is in the 4 (hole) with the timing mark (dimple) on the larger o’clock position.

  • Page 128: Install Closure Plate Assembly

    Section 11 Reassembly 2. Install shield for lead and secure with the M6x1.0 hex. flange screw. Torque all three screws to 10 N·m (88.5 in. lb.). See Figure 11-19. Dowel Dowel Figure 11-21. CS8.5-12. Internal Details. 3. Install the closure plate to the crankcase. Carefully seat the ends of the camshaft and balance shaft Figure 11-19.
  • Page 129 Section 11 Reassembly Torque Screws to 30 N·m (265 in. lb.) Figure 11-23. CS8.5-12. Closure Plate Torque Figure 11-25. CS8.5-12. Installing Bearing. Sequence. 2. Install a new oil seal into the cover to a depth of Install Reduction System (If So Equipped) 2 mm (0.08 in.).
  • Page 130 Secure with the flat washer and hex. flange screw. See Figure 11-32. Torque the screw to: CS8.5 (spec. 92xxxx), CS10, CS12: 60-70 N·m (44-51 ft. lb.) CS8.5 (spec. 95xxxx): 22 N·m (195 in. lb.) Figure 11-29. CS4, CS6. Installing Wave Washer.
  • Page 131 Section 11 Reassembly Install the counter gear into the pre-oiled bearing boss in the closure plate, engaging teeth with gear on crankshaft. Install the output shaft/gear assembly into the corresponding pre-oiled bearing boss in the closure plate. See Figure 11-33. Figure 11-35.
  • Page 132 Section 11 Reassembly Description C Oil seal installation depth Bolt Chain Case Cover Gasket 2 mm (0.08 in.) Dowel Pin Oil Seal Bearing Washer Bolt/Washer Shaft 2 Idle Sprocket Chain Washer Straight Key D Tightening sequence A 22 N·m (195 in. lb.) B 10 N·m (88 in.
  • Page 133 Section 11 Reassembly 6:1 Reduction Assemblies 5. Install the reduction housing to the closure plate CS4 and CS6 as shown and secure with the four hex. flange 1. If any bearings were removed, press the new screws. Torque the screws to 20-24 N·m bearing(s) into the housing or cover, so the (177-212 in.
  • Page 134 Section 11 Reassembly 7. Install a new gasket (dry) onto the housing and attach the cover with the four mounting screws, so the Oil Fill and Oil Level port locations are positioned exactly as shown. Torque the screws to 20-24 N·m (177-212 in. lb.). Figure 11-46.
  • Page 135 Section 11 Reassembly 3. Slide the crankshaft gear onto the splines of the crankshaft. Secure with the flat washer and hex. flange screw. Torque the screw to 20-24 N·m (177-212 in. lb.). Figure 11-50. Installing Output Shaft Assembly. 6. Reinstall the two dowel pins into their respective locations in the closure plate.

  • Page 136: Install Flywheel

    Section 11 Reassembly 2. Route the stator leads along the formed channel and out through the hole in the crankcase casting. 3. Install the protective wire shield over the channel and secure in place with the M6x1.0 screw. Torque screw to 10 N·m (88.5 in. lb.). See Figure 11-56.

  • Page 137: Install Ignition Module

    CS4, CS6, CS8.5 (spec. 95xxxx): installed properly. 65 N·m (48 ft. lb.) CS8.5 (spec. 92xxxx), CS10, CS12: 1. Install the woodruff key into the keyway of the 120 N·m (88 ft. lb.) crankshaft. Make sure that the key is properly seated and parallel with taper of shaft.
  • Page 138 Section 11 Reassembly Assemble Cylinder Head 3. Route the ignition module lead as shown in Figure 11-61 or 11-62. 1. Lubricate all the valve train components with engine oil. Pay particular attention to the lip of the 4. Rotate the flywheel in a clockwise direction until valve stem seal, valve stems and valve guides.
  • Page 139 Torque the studs to: CS4, CS6, CS8.5 (spec. 95xxxx): 4-5 N·m (35-44 in. lb.) CS8.5 (spec. 92xxxx), CS10, CS12: 12-19 N·m (106-168 in. lb.) Install Cylinder Head 1. Check to make sure there are no nicks or burrs on the sealing surfaces of the cylinder head or crankcase.
  • Page 140 2. CS4, CS6, CS8.5 (spec. 95xxxx): Install the push rod guide plate, aligning the holes for the rocker CS8.5 (spec. 92xxxx), CS10, CS12: Install the rocker arms and adjuster assemblies into their arm studs. Screw in the rocker arm studs and original locations.
  • Page 141 Section 11 Reassembly Figure 11-72. CS8.5 (spec. 92xxxx), CS10, CS12. Figure 11-74. CS8.5 (spec. 92xxxx), CS10, CS12. Adjusting Valve to Rocker Arm Clearance. 4. Adjust the valve tappet clearance as follows: d. Hold the adjuster from turning and tighten the a.

  • Page 142: Install Valve Cover

    Section 11 Reassembly Install Valve Cover 1. Install a new valve cover gasket onto the cylinder head. 2. Install the valve cover assembly. CS4, CS6, CS8.5 (spec. 95xxxx): Install the four hex. flange screws and torque to 10-12 N·m (88-106 in. lb.). Figure 11-76.
  • Page 143 Section 11 Reassembly Figure 11-80. CS8.5-12. Torquing Screws. Figure 11-82. CS8.5 (spec. 92xxxx), CS10, CS12. Mounting Left Fuel Tank Support. Install Fuel Tank Supports (If So 2. Assemble the right fuel tank support and attached Equipped), Throttle Lever, Wiring electrical components* to the crankcase bosses.
  • Page 144 Section 11 Reassembly Figure 11-84. CS8.5-12. Mounting Right Fuel Tank Figure 11-85. CS8.5-12. Ground Lead Location. Support. Install Governor Lever, Throttle Link, CS8.5 (spec. 95xxxx): Align and mount the Throttle and Governor Springs throttle control bracket to the top of the crankcase 1.
  • Page 145 CS10 CS12 all except ‘‘G’’ models CS12 60HZ Figure 11-87. CS8.5 (spec. 92xxxx), CS10, CS12. CS12 50HZ Governor Lever Installation. Figure 11-90. CS8.5 (spec. 92xxxx), CS10, CS12. Spring Hole Position. 3. Connect the throttle link and the shorter end of...
  • Page 146 30 N·m (265 in. lb.). Leave the three cover panel screws out at this time. Figure 11-94. CS8.5 (spec. 92xxxx), CS10, CS12. Reconnect Solenoid/Wiring Harness Lead. CS8.5 (spec. 92xxxx), CS10, CS12 1. Align and mount the electric starter motor to the crankcase.
  • Page 147 See Figures 11-96, 11-97, and 11-98. Torque the screws to 7 N·m (62 in. lb.). Figure 11-98. CS8.5 (spec. 92xxxx), CS10, CS12. Blower Housing Installed. 3. Attach the electric starter cover panel (if so equipped) to the right tank support with the three phillips head screws and one flange nut.

  • Page 148: Install Carburetor

    Section 11 Reassembly Install Carburetor 1. Install a new carburetor spacer gasket onto the carburetor studs, followed by the carburetor spacer and another spacer gasket. See Figure 11-100. Figure 11-102. CS8.5-12. Assembling Linkage. 3. CS8.5-12: Connect ‘‘Z’’ end of choke link and dampening spring to choke lever on blower housing or control bracket.

  • Page 149: Install Air Cleaner Base And Element

    Section 11 Reassembly Install Air Cleaner Base and Element 1. Install the air cleaner base gasket onto the mounting studs. Attach the breather hose onto the air cleaner base connection port. Then install the air cleaner base onto the studs. Connect the opposite end of the breather hose to the valve cover.
  • Page 150 Secure with the four M6 hex. flange screws and a flat washer [CS8.5 (spec. 92xxxx), CS10, CS12 only] under each screw head. Torque the screws to 8-12 N·m (71-106 in. lb.). 3. Connect the fuel line to the shut-off valve and secure with the clamp.

  • Page 151: Install Outer Air Cleaner Cover

    Section 11 Reassembly Figure 11-112. CS8.5 (spec. 95xxxx) Installing Fuel Figure 11-114. CS8.5 (spec. 95xxxx). Mounting Tank Support. Shut-Off Valve. 2. Install the fuel tank assembly, with the fuel line 5. Connect the fuel line to the outlet of the shut-off connected to the outlet fitting, into the fuel tank valve and the carburetor inlet.

  • Page 152: Install Muffler

    Section 11 Reassembly Prepare the Engine for Operation The engine is now reassembled. Before starting or operating the engine be sure to do the following: 1. Make sure all hardware is properly torqued. 2. Make sure the oil drain plugs and oil sentry control unit are tightened securely.
  • Page 153 Section 11 Reassembly Figure 11-118. CS4, CS6. High Speed Stop Screw. Figure 11-120. CS8.5 (spec. 95xxxx). High Speed Stop Screw. Figure 11-119. CS8.5 (spec. 92xxxx), CS10, CS12. High Speed Stop Screw. 11.31...
  • Page 154 FORM NO.: TP-2503-A ISSUED: 12/99 REVISED: 8/00 MAILED: 9/00 ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044 LITHO IN U.S.A.

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