Kohler Courage SV470 Service Manual
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Kohler Courage SV470 Service Manual

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Brian Francis Murray
January 29, 2025

What Torque setting for the Valve cover gasket with a new cork seal

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1 comments:
Mr. Anderson
February 10, 2025

The torque setting for the valve cover gasket on a Kohler Courage SV470 with a new as-cast hole is 11.0 N·m (95 in. lb.).

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Summary of Contents for Kohler Courage SV470

  • Page 3: Table Of Contents

    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

    Section 1 Safety and General Information Section 1 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.
  • Page 6 Section 1 Safety and General Information WARNING WARNING WARNING Explosive Gas can cause fires and Explosive Fuel can cause fires Carbon Monoxide can cause severe acid burns. and severe burns. severe nausea, fainting or death. Charge battery only in a well Do not fill the fuel tank while the Avoid inhaling exhaust fumes, and ventilated area.
  • Page 7 Section 1 Safety and General Information Engine Identification Numbers When ordering parts, or in any communication involving an engine, always give the Model, Specification, and Serial Numbers of the engine. The engine identification numbers appear on a decal affixed to the engine shrouding. See Figure 1-1. An explanation of these numbers is shown in Figure 1-2.

  • Page 8: Oil Recommendations

    Gasohol (up to 10% ethyl alcohol, 90% unleaded service class and SAE viscosity grade. See Figure 1-3. gasoline by volume) is approved as a fuel for Kohler engines. Other gasoline/alcohol blends including E20 and E85 are not to be used and not approved. Any failures resulting from use of these fuels will not be warranted.

  • Page 9: Periodic Maintenance

    1) Disconnect the spark plug lead(s). 2) Disconnect negative (-) battery cable from battery. Maintenance Schedule Normal maintenance, replacement or repair of emission control devices and systems may be performed by any repair establishment or individual; however, warranty repairs must be performed by a Kohler authorized service center. Frequency Maintenance Required •...
  • Page 10 Section 1 Safety and General Information Dimensions in millimeters. Inch equivalents shown in (). VALVE COVER VIEW Figure 1-4. Typical Engine Dimensions.
  • Page 11 SV590, SV600, SV610, SV620 ................ 94 mm (3.70 in.) Stroke ........................86 mm (3.38 in.) Displacement SV470, SV480 (Early Models Only) ............. 477 cc (29.1 cu. in.) SV470, SV480, SV530, SV540 ................ 535 cc (32.6 cu. in.) SV590, SV600, SV610, SV620 ................ 597 cc (36.4 cu. in.) Compression Ratio SV470, SV480, SV530, SV540 ................
  • Page 12 Section 1 Safety and General Information Closure Plate Closure Plate Fastener Torque ................ 24.5 N·m (216 in. lb.) Balance Weight Guide Channel Width New ......................17.95/18.05 mm (0.707/0.711 in.) Max. Wear Limit ..................18.13 mm (0.714 in.) Connecting Rod Cap Fastener Torque (torque in 2 increments)..........5.5, 11.5 N·m (50, 100 in. lb.) Connecting Rod-to-Crankpin Running Clearance New .......................
  • Page 13 Section 1 Safety and General Information Crankshaft (Continued) Crankshaft Bore in Closure Plate Running Clearance New - Before Serial No. 3703200003 ............0.030/0.077 mm (0.0012/0.0030 in.) New - After Serial No. 3703200013 ............0.070/0.120 mm (0.0027/0.0047 in.) Crankshaft Bore in Crankcase Running Clearance New - Before Serial No.
  • Page 14 Section 1 Safety and General Information Cylinder Bore Cylinder Bore I.D. SV470, SV480-00XX .................. 84.000/84.025 mm (3.307/3.308 in.) SV470, SV480-01XX .................. 89.000/89.025 mm (3.504/3.505 in.) SV530, SV540 ..................... 89.000/89.025 mm (3.504/3.505 in.) SV590, SV600, SV610, SV620 ..............94.010/94.035 mm (3.701/3.702 in.) Max.
  • Page 15 Top Ring ....................0.15/0.40 mm (0.006/0.016 in.) Middle Ring ....................0.30/0.55 mm (0.012/0.022 in.) Used Bore (max.) ..................0.77 mm (0.030 in.) Piston Thrust Face O.D.² SV470, SV480-00XX New ......................83.948/83.962 mm (3.3050/3.3056 in.) Max. Wear Limit ..................83.828 mm (3.3003 in.) SV470, SV480-01XX New ......................
  • Page 16 Max. Wear Limit ..................93.828 mm (3.6940 in.) Piston Thrust Face-to-Cylinder Bore Running Clearance SV470, SV480, SV530, SV540 ..............0.045 mm (0.0018 in.) SV560, SV590, SV600, SV610, SV620 ............0.0880 mm (0.0035 in.) Rectifier-Regulator Mounting Screw Torque ................... 6.0 N·m (55 in. lb.) Into new as cast hole 4.0 N·m (35 in.
  • Page 17 Section 1 Safety and General Information Valves and Valve Lifters (Continued) Intake Valve Stem Diameter New ......................5.982/6.0 mm (0.2355/0.2362 in.) Exhaust Valve Guide I.D. New ......................6.038/6.058 mm (0.2377/0.2385 in.) Max. Wear Limit ..................6.160 mm (0.2425 in.) Exhaust Valve Stem Diameter New ......................
  • Page 18 Section 1 Safety and General Information 1.14...

  • Page 19: Section 2. Tools & Aids

    Fax 810-664-8181 Tools Description Source/Part No. Balance Gear Timing Tool (K & M Series) Kohler 25 455 06-S To hold balance gears in timed position when assembling engine. (Formerly Y-357) Camshaft Endplay Plate SE Tools KLR-82405 For checking camshaft endplay.
  • Page 20 Tools & Aids Tools (Continued) Description Source/Part No. Hydraulic Valve Lifter Tool Kohler 25 761 38-S To remove and install hydraulic lifters. Ignition System Tester Kohler 25 455 01-S For testing output on all systems, except CD. Kohler 24 455 02-S For testing output on capacitive discharge (CD) ignition system.
  • Page 21 Section 2 Tools & Aids Aids Description Source/Part No. Camshaft Lubricant (Valspar ZZ613) Kohler 25 357 14-S Dielectric Grease (GE/Novaguard G661) Kohler 25 357 11-S Dielectric Grease (Fel-Pro) Lubri-Sel Electric Starter Drive Lubricant (Inertia Drive) Kohler 52 357 01-S Electric Starter Drive Lubricant (Solenoid Shift)
  • Page 22 4. Use a flat washer with the correct I.D. to slip on 1. Using an abrasive cut-off wheel, cut out a six the capscrew and approximately 1” O.D. (Kohler tooth segment of the ring gear as shown. Part No. 12 468 05-S). Assemble the capscrew and washer to the joint surface of the rod, as 2.
  • Page 23 Section 3 Troubleshooting Section 3 Troubleshooting Troubleshooting Guide 11. Engine overheated-cooling/air circulation restricted. When troubles occur, be sure to check the simple 12. Flywheel key sheared. causes which, at first, may seem too obvious to be 13. Intake system leak. considered.
  • Page 24 Section 3 Troubleshooting • Check for buildup of dirt and debris on the Engine Overheats 1. Air intake/grass screen, cooling fins, or cooling crankcase, cooling fins, grass screen and other shrouds clogged. external surfaces. Dirt or debris on these areas 2.
  • Page 25 Section 3 Troubleshooting Make sure all traces of the cleaner are removed before 2. Start the engine and run at no-load high idle the engine is reassembled and placed into operation. speed (3200 to 3750 RPM). Even small amounts of these cleaners can quickly break down the lubricating properties of engine oil.
  • Page 26 Section 3 Troubleshooting Compression Test the slot of the holding tool, so it is perpendicular These engines are equipped with an automatic to both the holding tool and crankshaft, or insert compression release (ACR) mechanism. Because a shoulder bolt through the slot and thread it into of the ACR mechanism, it is difficult to obtain an the mounting hole.

  • Page 27: Section 4. Air Cleaner And Air Intake System

    Section 4 Air Cleaner and Air Intake System Section 4 Air Cleaner and Air Intake System Air Cleaner Intake air is drawn in through the upper opening from the blower housing, passes through the precleaner These engines are equipped with a replaceable, high (if so equipped), the paper element and then into density, paper air cleaner element.
  • Page 28 Do not wash the paper element or use pressurized air, as this will damage the element. Replace a dirty, bent, or damaged element with a genuine Kohler element. Handle new elements carefully; do not use if the rubber seal is damaged.
  • Page 29 Section 4 Air Cleaner and Air Intake System Reassembly The following procedure is for complete assembly of all air cleaner components. Steps 1-3 are necessary only if the air cleaner base and/or the cover mounting studs were removed in Section 8, Disassembly. 1.
  • Page 30 Section 4 Air Cleaner and Air Intake System Air Intake/Cooling System Clean Air Intake/Cooling Areas To ensure proper cooling, make sure the grass screen, cooling fins, and other external surfaces of the engine are kept clean at all times. Annually or every 100 hours of operation, (more often under extremely dusty, dirty conditions), remove the blower housing and any other cooling shrouds.

  • Page 31: Section 5. Fuel System And Governor

    Gasoline/Alcohol blends Gasohol (up to 10% ethyl alcohol, 90% unleaded gasoline by volume) is approved as a fuel for Kohler engines. Other gasoline/alcohol blends including E20 and E85 are not to be used and not approved. Any failures resulting from use of these fuels will not be warranted.

  • Page 32: Fuel Filter

    The inlet check valve has now closed, so not meet these requirements may not be used. Order the fuel is forced past the outlet check valve, to the replacement hose through a Kohler Service Center. carburetor. Fuel Pump...
  • Page 33 Section 5 Fuel System and Governor Installation WARNING: Explosive Fuel 1. Install the new fuel pump, and secure with the hex flange screws. Torque the hex flange screws Gasoline is extremely flammable and its vapors can explode to 5.9 N·m (52 in. lb.). Do not over tighten. if ignited.

  • Page 34: Carburetor Adjustment

    Section 5 Fuel System and Governor Troubleshooting – Fuel System Condition Possible Cause/Probable Remedy 1. Engine starts hard, runs roughly 1a. Low idle fuel mixture/speed improperly adjusted. Adjust the low or stalls at idle speed. idle speed screw, then adjust the low idle fuel needle. b.
  • Page 35 Section 5 Fuel System and Governor Low Idle Speed Setting Low Idle Mixture Adjustment* NOTE: Engines will have fixed idle (no adjustment 1. Start the engine and run at half throttle for 5 to 10 possible) or a limiter cap on the idle fuel minutes to warm up.
  • Page 36 Section 5 Fuel System and Governor Disassembly Throttle Lever and Shaft Dust Seal Throttle Plate Screw(s) Choke Lever and Shaft Choke Return Spring Throttle Plate Choke Plate Low Idle Speed Adjusting Screw and Spring Fuel Inlet Low Idle Fuel Adjusting Needle Needle and Spring with Float...
  • Page 37 Section 5 Fuel System and Governor 2. The choke plate is inserted into a slot in the choke shaft. Grasp the choke plate with pliers, and pull it out of the slot. See Figure 5-8. Tool No. KO1018 Pry Out Plug Do Not Allow Tip to Strike Carburetor Body...
  • Page 38 Section 5 Fuel System and Governor Welch Plug Installation • Throttle plate, choke plate, throttle shaft, and Use SPX Tool No. KO1017 and install new plugs as choke shaft. follows: NOTE: Do not submerge the carburetor in 1. Position the carburetor body with the welch plug cleaner or solvent when plastic, fiber, cavities to the top.

  • Page 39: High Altitude Operation

    1-800-544-2444 to find the names throttle when the key is turned off. Next, check the of the nearest Kohler Co. Service Centers or, access battery to ensure that it is not discharged or faulty. A our web site at: www.kohlerengines.com and click on minimum of 7.3 volts DC is required to activate the...
  • Page 40 Section 5 Fuel System and Governor Throttle Cable Adjustment 1. Loosen the control cable clamp. See Figure 5-12. Cable Clamp Warm Engine Cold Engine Figure 5-14. Typical Throttle/Choke Controls. Figure 5-12. Speed Control Bracket with Unitized 3. Early Models: Early models use a single Throttle/Choke Control.
  • Page 41 Do and Higher not jump start using another battery (refer to Battery, Section 7). See your Kohler Engine Service Dealer for Figure 5-16. Alignment Holes in Speed Control trouble analysis. Bracket and Throttle Lever. (Later Models) 4.
  • Page 42 Section 5 Fuel System and Governor Choke Adjustment Later Models: Later models utilize a new design control assembly, identified by two opposing This procedure must follow the High Speed alignment holes (close to the throttle lever pivot), Adjustment just described. If not already completed, instead of one.
  • Page 43 Section 5 Fuel System and Governor 5. Pull on the outer shield of the throttle control cable to remove any slack. Tighten the cable clamp securely. Choke Cable Clamp Alignment Hole Throttle for Less Than Cable Clamp Alignment Hole 3000 RPM for 3000 RPM and Higher Figure 5-19.
  • Page 44 Section 5 Fuel System and Governor Starting an Engine Equipped with Separate 4. To ensure that the RPM has been obtained, move Control Cables the throttle lever to low idle/slow then back to 1. Place the throttle control midway between the full throttle/fast position and check the RPM with slow and fast positions.
  • Page 45 Section 5 Fuel System and Governor The governor lever is clamped on the protruding end of the shaft and connected with linkage to the throttle lever on the carburetor, so any rotation of the shaft causes corresponding movement of the throttle plate. When the engine is at rest, and the throttle is in the fast position, the tension of the governor spring holds the throttle plate open.
  • Page 46 Section 5 Fuel System and Governor Figure 5-25. Governor Adjustment. Figure 5-26. Tightening Governor Lever Nut. Governor Sensitivity Adjustment Governor sensitivity is adjusted by repositioning the governor spring in the holes in the governor lever. If speed surging occurs with a change in load, the governor is set too sensitive. If a big drop in speed occurs when a normal load is applied, the governor should be set for greater sensitivity.
  • Page 47 Section 5 Fuel System and Governor Single Hole Alignment Hole for Less Than 3000 RPM Alignment Hole for 3000 RPM Throttle and Higher Lever Governor Governor Lever Lever (Single Hole) (Multiple Hole) High Speed Governed Governed Throttle Lever Alignment Idle RPM Lever Hole No.
  • Page 48 Section 5 Fuel System and Governor 5.18...

  • Page 49: Section 6. Lubrication System

    10W-30 overemphasized. Check oil BEFORE EACH USE as follows: 5W-20, 5W-30 1. Make sure the engine is stopped, level, and is Kohler 10W-30 cool so the oil has had time to drain into the °F -20 sump. °C -30 TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE 2.

  • Page 50: Lubrication System

    Add more the oil and filter as follows (see Figure 6-6). Always use oil, as necessary, so the oil level is up to but not a genuine Kohler oil filter. over the “F” mark.

  • Page 51: Oil Filter

    Section 6 Lubrication System Oil Filter NOTE: To prevent extensive engine wear or damage, always maintain the proper oil These engines are equipped with a full-flow oil filter. level in the crankcase. Never operate See Figure 6-8. the engine with the oil level below the ‘‘L’’...

  • Page 52: Testing Oil Pressure

    Section 6 Lubrication System Installation 1. Connect the continuity tester across the blade The pressure switch is installed into the center oil terminal and the metal case of the switch. With galley of the filter adapter casting on the closure plate. 0 psi pressure applied to the switch, the tester Based on the application an elbow adapter may also should indicate continuity (switch closed).

  • Page 53: Section 7. Electrical System And Components

    Section 7 Electrical System and Components Section 7 Electrical System and Components This section covers the operation, service, and repair of the electrical system and electrical system components. Major electrical systems and components covered in this section include the ignition system, battery, battery charging systems, electric starter, and optional Oil Sentry ™...
  • Page 54 Section 7 Electrical System and Components Inspection Inspect the spark plug as soon as it is removed from the cylinder head. The deposits on the tip are an indication of the general condition of the piston rings, valves, and carburetor. Normal and fouled plugs are shown in the following photos.
  • Page 55 Section 7 Electrical System and Components Electronic CD Ignition System Spark Plug Boot Spark Plug Terminal (C) Spark Plug Air Gap 0.203/0.305 mm (0.008-0.012 in.) Ignition Module Lamination (A) Kill Terminal (B) Magnet Flywheel Kill Switch or Off Position of Key Switch Figure 7-2.
  • Page 56 Section 7 Electrical System and Components Spark Plug Figure 7-3. Capacitive Discharge Ignition Module. Operation NOTE: The CD ignition systems are sensitive to As the flywheel rotates, and the magnet passes the excessive load on the kill lead. Customer ignition module, the magnetic field induces current complaints of hard starting, low power, or in the input coil (L1).

  • Page 57: Section 8. Disassembly

    Section 7 Electrical System and Components CD Ignition System Troubleshooting Guide Problem Test Conclusion 1. Make sure the spark plug lead is connected to the spark plug. 2. Check the condition of spark plug. Make 2. If plug is in good condition, check/adjust sure gap is set to 0.76 mm (0.030 in.).

  • Page 58: Battery Charging

    Section 7 Electrical System and Components Battery Battery Test A 12 volt battery with a minimum current rating Test the battery voltage by connecting a DC voltmeter of 250 cold cranking amps is recommended. The across the battery terminals and cranking the engine. actual cold cranking amp requirement depends on If the battery drops below 9 volts while cranking, the engine size, application and starting temperatures.
  • Page 59 Section 7 Electrical System and Components 3 Amp Charging Stator Lighting Lead (Yellow) Diode Lighting Stator Charging Lead (Black) Figure 7-7. 3 Amp/70 Watt Stator. Optional Oil Sentry Switch (Indicator Light) White Ground-To- Ignition Kill Lead Module Stator Spark Regulator- Plug Flywheel Rectifier...
  • Page 60 Section 7 Electrical System and Components Troubleshooting Guide 3 Amp Battery Charging System With 70 Watt Lighting Stator NOTE: Zero ohmmeteres on each scale to ensure accurate readings. Voltage tests should be made with engine running at full throttle - no load. Battery must be fully charged. Conclusion Problem Test...
  • Page 61 Section 7 Electrical System and Components Troubleshooting Guide 3 Amp/70 Watt Braking Stator NOTE: Zero ohmmeteres on each scale to ensure accurate readings. Voltage tests should be made with engine running at full throttle - no load. Battery must be fully charged. Problem Test Conclusion...
  • Page 62 Section 7 Electrical System and Components Troubleshooting Guide 3 amp/70 Watt Braking Stator (Continued) Conclusion Problem Test 1. Make sure lights are not burned out. 1. Replace burned out lights. 2. If voltage is 35 volts or more, stator 2. Disconnect the braking lead (green) from is OK.
  • Page 63 Section 7 Electrical System and Components Battery Charging System 9 or 15 amp Ground-to-Kill Lead White Ignition Module Stator Key Switch Rectifier- Spark Flywheel Regulator Plug Violet Green Green Engine Optional Optional Connector Fuse Fuel Solenoid Optional Oil Sentry™ Optional Oil Sentry™ Indicator Light Switch (Shutdown) Battery...
  • Page 64 Section 7 Electrical System and Components Rectifier-Regulator 9 or 15 Amp Stator Figure 7-10. 9 or 15 amp Stator and Rectifier-Regulator. DC Volt Meter Rectifier-Regulator Flywheel Stator Ammeter Battery Figure 7-11. Proper Connection to Test 9 or 15 amp Charging System. 7.12...
  • Page 65 Section 7 Electrical System and Components Troubleshooting Guide 9 or 15 amp Regulated Battery Charging System NOTE: Zero ohmmeters on each scale to ensure accurate readings. Voltage tests should be made with engine running at full throttle - no load. The battery must be fully charged. Problem Test Conclusion...
  • Page 66 As the Kohler blade stop stator brake circuit often is operated in conjunction with other application circuits, the relay in the Kohler circuit is specially configured with a 680 ohm resistor in parallel with the relay coil. This is done to negate transient voltage signals that would be normally created by interrupting the relay current once the relay has been activated.
  • Page 67 Troubleshooting Stator Brake System Engine will crank but will not start The brake stator relay is interacting with the Problems that could occur with the Kohler portion application safeties or the reverse mow electronics, circuit generally could be caused by two component preventing normal engine start up.
  • Page 68 Section 7 Electrical System and Components Electric Starters NOTE: If the engine develops sufficient speed to disengage the inertia drive starter but does These engines use inertia drive starting motors. not keep running (a false start), the engine rotation must be allowed to come to a Operation complete stop before attempting to restart When power is applied to the starter, the armature...

  • Page 69: Starter Removal And Installation

    (see Figure 7-15). Slide 6. The splines should have a light film of lubricant. the collar over the inner halves to hold them in Relubricate as necessary with Kohler bendix position. starter lubricant (See Section 2). Reinstall or replace the drive components, assembling them in the same sequence as they were removed.
  • Page 70 Section 7 Electrical System and Components Retaining Ring Installation 3. Remove the thru bolts and recessed hex nuts. 1. Position the retaining ring in the groove in one of the inner halves. Assemble the other half over the 4. Remove the commutator end cap and lift out top and slide on the outer collar.
  • Page 71 Section 7 Electrical System and Components Brush Replacement 2. Insert the armature into the starter frame. The magnets will hold it in place. See Figure 7-21. 1. Remove the hex flange nut and insulating washer from the positive (+) brush lead stud. 2.
  • Page 72 1.6-2.8 N·m (12-25 in. lb.), do not over torque. 9. Lubricate the drive shaft with Kohler bendix starter drive lubricant (See Section 2). Install the drive components following the instructions for servicing the drive. The completed starter is shown in Figure 7-25.
  • Page 73 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, disable the engine as follows: 1) Disconnect the spark plug lead. 2) Disconnect negative (-) battery cable from battery.
  • Page 74 Section 8 Disassembly Remove Muffler Remove Oil Sentry Pressure Switch ™ 1. Remove the hex flange nuts or 5/16-18 capscrews (On Models So Equipped) attaching the muffler or exhaust system to the 1. Disconnect the lead from the Oil Sentry™ engine.
  • Page 75 Section 8 Disassembly 3. Remove the two hex flange nuts, or single nut and long mounting screw securing the air cleaner base. See Figure 8-9. Figure 8-6. Removing Electric Starter. Remove Air Cleaner 1. Loosen the two knobs and remove the air cleaner Figure 8-9.
  • Page 76 Section 8 Disassembly 1. Shut off the fuel supply. Disconnect the fuel line from the carburetor inlet fitting. See Figure 8-11. If a fuel pump is used, disconnect the pulse line from the fitting on the closure plate. See Figure 8-12.
  • Page 77 Section 8 Disassembly 5. Mark the mounted position of the speed control bracket in the slotted holes and remove the two screws securing the speed control bracket to the closure plate. Note or mark the governor spring hole for correct installation later. Unhook the governor spring, then remove the control bracket (with fuel pump attached, if equipped) and linkages from the engine.
  • Page 78 Section 8 Disassembly 8. Remove the insert from the intake port (some models), if separate from the heat deflector. See Figure 8-20. Insert Figure 8-22. Removing Ignition Module. Remove Grass Screen, Fan, and Flywheel 1. Unsnap the grass screen from the cooling fan. See Figure 8-20.
  • Page 79 Section 8 Disassembly Figure 8-24. Removing Fan and Flywheel Mounting Figure 8-26. Removing Stator. Hardware. Remove the Valve Cover and Cylinder Head 3. Carefully lift the cooling fan to disengage the two 1. Remove the seven screws securing the valve cover drive pins and remove it from the flywheel.
  • Page 80 Section 8 Disassembly 3. Loosen the inner set screws (T15 TORX) and back off the rocker arm adjusting nuts. Remove the push rods and mark them, so they can be reinstalled in the same location. See Figure 8-29. Figure 8-31. Removing Cylinder Head and Gasket. 6.
  • Page 81 Section 8 Disassembly Disassemble Cylinder Head NOTE: Before disassembly, mark all valve train components that will be reused, to assure they are reassembled on the same side. 1. Remove the spark plug. See Figure 8-33. Figure 8-35. Removing Valves with Spring Compressor.
  • Page 82 Section 8 Disassembly 3. Remove the closure plate assembly and gasket. 2. Remove the six screws securing the oil passage See Figure 8-37. cover to the closure plate. Remove the cover and gasket. See Figure 8-39. 4. If the wiring harness needs to be separated from the closure plate, pry open the clamps and pull out through the slot.
  • Page 83 Section 8 Disassembly 2. Remove the screws securing the cam levers to the crankcase. See Figure 8-41. Mark the cam levers for proper reassembly. NOTE: Cam Gear assemblies may contain either two or four rivets. The four rivet design is shown in figures.
  • Page 84 Section 8 Disassembly 5. Remove the two screws securing the oil pump Remove Connecting Rod and Piston and intake side cam shaft to the crankcase. If 1. Rotate the crankshaft so the rod journal is in the a drain back tube is used, it may be unhooked 9 o’clock position.
  • Page 85 Section 8 Disassembly Remove Piston from Connecting Rod Remove Crankshaft and Balance Weight 1. Remove the wrist pin retainer and wrist pin. Assembly Separate the piston from the connecting rod. See 1. Carefully remove the crankshaft and balance Figure 8-50. weight assembly from the crankcase.
  • Page 86 Section 8 Disassembly Balance Weight Disassembly If necessary, the balance weight assembly can be separated from the crankshaft. Disassemble only if required. 1. Remove the crank gear from the crankshaft and carefully remove the key from the keyway. See Figure 8-54. Figure 8-55.
  • Page 87 Section 8 Disassembly 4. Mark the weights for proper reassembly and carefully slide the balance weights off the crankshaft eccentrics. See Figures 8-57 and 8-58. Figure 8-59. Removing Hitch Pin and Washer. 2. Slide the shaft inward and remove it through the inside of the crankcase.
  • Page 88 Section 8 Disassembly 8.16...

  • Page 89: Section 9. Inspection And Reconditioning

    Section 9 Inspection and Reconditioning Section 9 Inspection and Reconditioning This section covers the operation, inspection, and repair/reconditioning of major internal engine components. The following components are not covered in this section. They are covered in sections of their own: Air Cleaner, Section 4 Carburetor and External Governor, Section 5 Ignition, Charging and Electric Starter, Section 7...
  • Page 90 Section 9 Inspection and Reconditioning Benefits Inspect the crankpin for wear, score marks or Reducing the compression at cranking speeds results aluminum transfer. Slight score marks can be cleaned in several important benefits. with crocus cloth soaked in oil. If wear limits are exceeded (see Section 1), it will be necessary to replace 1.
  • Page 91 Section 9 Inspection and Reconditioning 3. When the bore is within 0.064 mm (0.0025 in.) Measuring Piston-to-Bore Clearance of desired size, remove the coarse stones and Before installing the piston into the cylinder bore, it replace with burnishing stones. Continue with is necessary that the clearance be accurately checked.
  • Page 92 Section 9 Inspection and Reconditioning Balance Weight-to-Eccentric Clearance 3. The running clearance is the eccentric Before the balance weight assembly is reassembled to diameter subtracted from the balance weight the crankshaft, the running clearance to the crankshaft bearing diameter (step 1 minus step 2). If eccentrics must be accurately checked.
  • Page 93 Section 9 Inspection and Reconditioning 3. Use an outside micrometer again and measure Flywheel the O.D. of the balance weight guide pin. See Figure 9-8. Inspection Inspect the flywheel for cracks and check the keyway for wear or damage. Replace the flywheel if cracked. If the flywheel key is sheared or the keyway is damaged, replace the crankshaft, flywheel, and key.
  • Page 94 Section 9 Inspection and Reconditioning Cylinder Head and Valves Inspection and Service Carefully inspect the valve mechanism parts. Inspect the valve springs and related hardware for excessive wear or distortion. Check the valves and valve seats for evidence of deep pitting, cracks, or distortion. Check the running clearance between the valve stems and guides.
  • Page 95 Section 9 Inspection and Reconditioning Hard starting, or loss of power accompanied by high fuel consumption, may be symptoms of faulty valves. Although these symptoms could also be attributed to worn rings, remove and check the valves first. After removal, clean the valve heads, faces, and stems with a power wire brush. Then, carefully inspect each valve for defects such as warped head, excessive corrosion, or worn stem end.
  • Page 96 Section 9 Inspection and Reconditioning Excessive Combustion Temperatures: The white Stem Corrosion: Moisture in fuel or from deposits seen here indicate very high combustion condensation are the most common causes of valve temperatures, usually due to a lean fuel mixture. stem corrosion.
  • Page 97 Section 9 Inspection and Reconditioning Valve Guides If a valve guide is worn beyond specifications, it will not guide the valve in a straight line. This may result in burned valve faces or seats, loss of compression, Valve Seat Cutter and excessive oil consumption.
  • Page 98 Section 9 Inspection and Reconditioning When cylinder temperatures get too high, lacquer and Replacement pistons are available in STD and 0.08 varnish collect on pistons causing rings to stick which mm (0.003 in.) oversize, which include new rings and results in rapid wear. A worn ring usually takes on a piston pins.
  • Page 99 Section 9 Inspection and Reconditioning Some important points to remember when servicing piston rings: 1. If the cylinder bore is within the wear limits (refer to Section 1) and the old piston is within wear limits, free of score or scuff marks, the old piston may be reused.

  • Page 100: Section 10. Reassembly

    Section 9 Inspection and Reconditioning 1. Oil Control Ring (Bottom Groove): Install the Oil Passages expander and then the rails. Make sure the ends of the expander are not overlapped. 2. Compression Ring (Center Groove): Install the center ring using a piston ring installation tool. Make sure the identification mark is up when the ring is installed.
  • Page 101 Section 9 Inspection and Reconditioning Procedure to Install Governor Shaft: Governor Gear and Shaft 1. Install new pin by pressing or lightly tapping it into the closure plate. It must be installed so that Inspection it protrudes 44.50 mm (1.750 in.), plus or minus Inspect the governor gear teeth.
  • Page 102 Section 9 Inspection and Reconditioning 9.14...
  • Page 103 Section 10 Reassembly Section 10 Reassembly The following sequence is suggested for complete 13. Assemble cylinder head. engine reassembly. This procedure assumes that all 14. Install cylinder head. components are new or have been reconditioned, and 15. Install rocker arms and push rods. all component subassembly work has been completed.

  • Page 104: Install Governor Cross Shaft

    Section 10 Reassembly Hitch Pin Oil Seal Thick Washer Figure 10-4. Securing Governor Shaft. Seal Depth Install Oil Pump Assembly and Intake 5.5 mm (0.216 in.) Cam Shaft 1. If the oil pump assembly was removed from the Figure 10-2. PTO Seal Depth Details. intake cam shaft, reassemble it onto the shaft.
  • Page 105 Section 10 Reassembly drilled for lower bearing lubrication. Both styles of outlet seals are shown in Figure 10-9. If a new seal is to be ordered, be sure it is the same style as the one that was taken out. Lightly lubricate the ends of the oil pump outlet seal with oil and install in into the outlet of the oil pump.
  • Page 106 Section 10 Reassembly 5. Install the intake cam shaft down into the 6. If the engine uses a drain back tube, insert the crankcase boss. Seat the rubber oil pump outlet round flanged end into the hole near base of seal into the machined pocket.
  • Page 107 Section 10 Reassembly 2. Carefully install crank gear key in keyway. See Figure 10-16. PTO Side Crank Gear Key Guide Pin Figure 10-14. Assembling Balance Weight to Crankshaft (Guide Shoe Design). Figure 10-16. Installing Crank Gear Key. Engines Serial No. 3618005223 and Above: c.

  • Page 108: Install Piston Rings

    Section 10 Reassembly Control Link Guide Figure 10-20. Installed Control Link on Crankcase Figure 10-18. Installed Guide Shoe Guide Pin (Above Serial No. 3618005223). (Above Serial No. 3618005223). Install Piston Rings 3. Make sure pivot pin on boss in lower section of crankcase is clean and free of any nicks, or NOTE: For detailed piston inspection procedures surface irregularities.
  • Page 109 Section 10 Reassembly Install Piston and Connecting Rod NOTE: Proper orientation of the piston/connecting Soft End rod inside the engine is extremely important. of Handle Improper orientation can cause extensive wear or damage. Ring Compressor 1. Stagger the piston rings in the grooves until the end gaps are 120°...

  • Page 110: Install Cam Levers

    Section 10 Reassembly Install Cam Levers 2. Apply a dab of grease to the formed groove in the thrust washer. Slide the washer onto the 1. Install the two cam levers as shown in Figure cam shaft so the short drive pin is seated in 10-25.
  • Page 111 Section 10 Reassembly Install Intake Cam on Cam Shaft 1. Lift the intake cam lever and install the intake cam gear onto the intake cam shaft, engaging the slot with the upper drive pin. Rotate the gear and shaft so the IN timing mark on the cam gear is in the 4 o’clock position.
  • Page 112 Section 10 Reassembly Install Flywheel Side Oil Seal 1. Lubricate the outside diameter and lip of the Guide Channel flywheel end oil seal. Support the closure plate and install the oil seal. Using a seal driver, drive the seal to a depth of 5 mm (0.196 in.) in the seal bore.

  • Page 113: Install Cylinder Head

    Section 10 Reassembly NOTE: If the crankshaft has not been turned since the installation of the crank gear, turn it one (1) complete revolution. This will set the piston at top dead center (TDC) of the compression stroke, for proper valve lash adjustment later. 2.

  • Page 114: Install Rocker Arms And Push Rods

    Section 10 Reassembly Washer (Position 6) Figure 10-42. Installing Guide Plates and Rocker Arm Pivot Studs. Figure 10-40. Installing Cylinder Head Fasteners. 2. Apply grease to the contact surfaces of the rocker 6. Using the torque sequence shown in Figure arms and adjusting nuts and install them onto 10-41, torque the cylinder head screws in two the pivot studs.

  • Page 115: Install Valve Cover

    Section 10 Reassembly Install Valve Cover 4. With the engine at TDC of the compression stroke, insert the correct size flat feeler gauge 1. Make sure the sealing surfaces of the valve cover (see below) between the appropriate valve stem and cylinder head are clean, and free of any nicks and rocker arm.

  • Page 116: Install Stator And Wiring Harness

    Section 10 Reassembly Install Stator and Wiring Harness Install Stator 1. Position the stator onto the mounting bosses so that the leads lay in the channel and recess of the closure plate. See Figure 10-47. They will become captured when the blower housing is installed. If a clamp was used to retain the leads, remove the screw in the No.
  • Page 117 Section 10 Reassembly Install Fan and Flywheel WARNING: Damaging Crankshaft and Flywheel can Cause Personal Injury! Using improper procedures to install the flywheel can crack or damage the crankshaft and/or flywheel. This not only causes extensive engine damage, but can also cause personal injury, since broken fragments could be thrown from the engine.

  • Page 118: Install Electric Starter

    Section 10 Reassembly Install Electric Starter 2. Rotate the flywheel to align the magnet with the ignition module. 1. Install the electric starter to the closure plate and secure with the two #10-24 hex nuts. Make 3. Insert a 0.25 mm (0.010 in.) flat feeler gauge sure the wires are clear of any moving parts and between the magnet and ignition module.
  • Page 119 Section 10 Reassembly Stud Insert (Some Models) Figure 10-55. Tightening Clip around Sheathing. Figure 10-57. Mounting Stud and Installing Insert (Some Models). Install New Spark Plug 1. Use a new Champion ® RC12YC or QC12YC (or 2. Make sure all the gasket surfaces are clean and equivalent) spark plug.
  • Page 120 Section 10 Reassembly 4. Models with one screw and one mounting stud 7. If the carburetor has a fuel solenoid, fasten the only: Insert a 3/16” diameter rod, approximately ground lead to the crankcase boss, with the 4” long, into the open mounting hole in the heat toothed washer between the eyelet terminal and deflector to serve as a temporary alignment pin.
  • Page 121 Section 10 Reassembly 9. Install the air cleaner base. a. Install a new air cleaner base gasket. Check that the two metal spacers are in the air cleaner base mounting holes and install the base onto the stud(s), and or alignment pin.
  • Page 122 Section 10 Reassembly Install and Adjust Governor Lever Mounting Speed Control Bracket 1. Install the governor lever* onto the governor 1. Attach the governor spring to the governor lever shaft with the lever section up. Connect the and the throttle lever of the speed control bracket, throttle linkage using the black linkage bushing.
  • Page 123 Section 10 Reassembly Install Fuel Pump (If Equipped) 2. Attach the connector to the rectifier-regulator terminals. 1. Attach the fuel pump mounting bracket to the speed control bracket with the two M5 screws. Torque the screws to 6.5 N·m (55 in. lb.) into new as-cast holes, or 4.0 N·m (35 in.
  • Page 124 Section 10 Reassembly Center Passage Notch Figure 10-78. Installing Pipe Plug or Adapter. Figure 10-76. Installing Blower Housing Screws. 3. Snap the grass screen onto the cooling fan. See Figure 10-77. Oil Sentry™ Switch Figure 10-79. Installed Oil Sentry Switch. Figure 10-77.
  • Page 125 Section 10 Reassembly Install Air Cleaner Element, Precleaner, and Air Cleaner Cover 1. Install the air cleaner element with the pleated side “out.” Seat the rubber seal onto all the edges of the air cleaner base. See Figure 10-80. Figure 10-82. Installing Air Cleaner Cover. Install Muffler 1.
  • Page 126 Section 10 Reassembly Install Drain Plug, Oil Filter, and Oil Prepare the Engine for Operation 1. Install the oil drain plug and torque to 14 N·m The engine is now completely reassembled. Before (125 in. lb.). starting or operating the engine, be sure the following have been done.

  • Page 127: Section 11. Emission Compliance Systems

    Evaporative Emission Compliance System For the engine to be Tier III compliant, it may be fitted with a Kohler-supplied canister vapor recovery system, or a system developed and installed by the Original Equipment Manufacturer (OEM). Details on the Kohler system are included below.
  • Page 128 Section 11 Emission Compliance Systems Secondary Emission Compliance System For the engine to be Tier III compliant, it may be fitted with a secondary air induction system (SAI). Operation: The intake pulse of the engine activates the secondary air valve. Air is drawn through the inlet screen of the secondary air valve.
  • Page 129 Section 11 Emission Compliance Systems 1. Remove the inlet screen from the secondary air valve assembly by grasping the inlet screen at the base and gently pulling away from the valve assembly. See Figure 11-3. Secondary Air Valve Assembly Barb Inlet Screen Figure 11-3.
  • Page 130 Section 11 Emission Compliance Systems 11.4...
  • Page 132 FORM NO.: 20 690 01 Rev. B ISSUED: 8/10 REVISED: 1/11 FOR SALES AND SERVICE INFORMATION IN U.S. AND CANADA, CALL 1-800-544-2444 KohlerEngines.com ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044 © 2011 by Kohler Co. All rights reserved.

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