Kohler Command CH18 Service Manual

Liquefied petroleum gas (lpg) or lpg/natural gas (ng) fueled

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Service manual (93 pages)

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CH18, CH20, CH23, CH25, CH640, CH730, CH740

Liqueﬁ ed Petroleum Gas (LPG) or LPG/Natural Gas (NG) Fueled

Service Manual

IMPORTANT:

Read all safety precautions and instructions carefully before operating equipment. Refer to operating

instruction of equipment that this engine powers.

Ensure engine is stopped and level before performing any maintenance or service.

Safety

Maintenance

Speciﬁ cations

Tools and Aids

Troubleshooting

Air Cleaner/Intake

Fuel System

Governor System

Lubrication System

Electrical System

Starter System

Disassembly/Inspection and Service

Reassembly

24 690 30 Rev. C

KohlerEngines.com

Table of Contents

Troubleshooting

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Do you have a question about the Command CH18 and is the answer not in the manual?

Questions and answers

Bruce

June 11, 2025

Working on a kohler eng CH18s complete rebuild. Engine starts good only it stays in the wide open position unless i hold the governor shaft in idle position then it runs fine. Could this be an internal problem?

Summary of Contents for Kohler Command CH18

Page 1 CH18, CH20, CH23, CH25, CH640, CH730, CH740 Liqueﬁ ed Petroleum Gas (LPG) or LPG/Natural Gas (NG) Fueled Service Manual IMPORTANT: Read all safety precautions and instructions carefully before operating equipment. Refer to operating instruction of equipment that this engine powers.
Page 2: Safety Precautions
Safety SAFETY PRECAUTIONS WARNING: A hazard that could result in death, serious injury, or substantial property damage. CAUTION: A hazard that could result in minor personal injury or property damage. NOTE: is used to notify people of important installation, operation, or maintenance information. WARNING WARNING WARNING...
Page 3: Maintenance Instructions
Must be performed by a Kohler authorized dealer or qualiﬁ ed LPG personnel only. REPAIRS/SERVICE PARTS Kohler genuine service parts can be purchased from Kohler authorized dealers. To ﬁ nd a local Kohler authorized dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada).
Page 4: Oil Recommendations
Maintenance OIL RECOMMENDATIONS STORAGE Synthetic oil is recommended for use in LPG/NG fueled If engine will be out of service for 2 months or more engines. Other high-quality detergent oils (including follow procedure below. synthetic) of API (American Petroleum Institute) service 1.
Page 5: Specifications
Speciﬁ cations Engine Dimensions Dimensions in millimeters. Inch equivalents shown in [ ]. 24 690 30 Rev. C KohlerEngines.com...
Page 6: Engine Identification Numbers
Lubricate threads with engine oil prior to assembly. Any and all horsepower (hp) references by Kohler are Certiﬁ ed Power Ratings and per SAE J1940 & J1995 hp standards. Details on Certiﬁ ed Power Ratings can be found at KohlerEngines.com.
Page 7 Speciﬁ cations TORQUE SPECIFICATIONS CH18/CH20/ CH23 CH25/ CH640 CH730/CH740 Crankcase Breather Cover Fastener 7.3 N·m (65 in. lb.) Oil Drain Plug 13.6 N·m (10 ft. lb.) Cylinder Head Fastener (torque in 2 increments) ﬁ rst to 16.9 N·m (150 in. lb.) ﬁ...
Page 8: Clearance Specifications
Speciﬁ cations TORQUE SPECIFICATIONS CH18/CH20/ CH23 CH25/ CH640 CH730/CH740 Starter Assembly Thru Bolt Inertia Drive 4.5-5.7 N·m (40-50 in. lb.) Nippondenso Solenoid Shift 4.5-7.5 N·m (40-84 in. lb.) Delco-Remy Solenoid Shift 5.6-9.0 N·m (49-79 in. lb.) Mounting Screw 15.3 N·m (135 in. lb.) Brush Holder Mounting Screw 2.5-3.3 N·m (22-29 in.
Page 9 Speciﬁ cations CLEARANCE SPECIFICATIONS CH18/CH20/ CH23 CH25/ CH640 CH730/CH740 Crankcase Governor Cross Shaft Bore I.D. 6 mm Shaft 6.025/6.050 mm (0.2372/0.2382 in.) Max. Wear Limit 6.063 mm (0.2387 in.) 8 mm Shaft 8.025/8.075 mm (0.3159/0.3179 in.) Max. Wear Limit 8.088 mm (0.3184 in.)
Page 10 Speciﬁ cations CLEARANCE SPECIFICATIONS CH18/CH20/ CH23 CH25/ CH640 CH730/CH740 Cylinder Head Max. Out-of-Flatness 0.076 mm (0.003 in.) 0.1 mm (0.004 in.) Governor Governor Cross Shaft-to-Crankcase Running Clearance 6 mm Shaft 0.013/0.075 mm (0.0005/0.0030 in.) 8 mm Shaft 0.025/0.126 mm (0.0009/0.0049 in.) Cross Shaft O.D.
Page 11 Speciﬁ cations CLEARANCE SPECIFICATIONS CH18/CH20/ CH23 CH25/ CH640 CH730/CH740 Valves and Valve Lifters Hydraulic Valve Lifter to Crankcase Running Clearance 0.0241/0.0501 mm (0.0009/0.0020 in.) Intake Valve Stem-to-Valve Guide Running Clearance 0.038/0.076 mm (0.0015/0.0030 in.) Exhaust Valve Stem-to-Valve Guide Running Clearance 0.050/0.088 mm (0.0020/0.0035 in.)
Page 12: General Torque Values
Speciﬁ cations GENERAL TORQUE VALUES English Fastener Torque Recommendations for Standard Applications Bolts, Screws, Nuts and Fasteners Assembled Into Cast Iron or Steel Grade 2 or 5 Fasteners Into Aluminum Size Grade 2 Grade 5 Grade 8 Tightening Torque: N·m (in. lb.) ± 20% 8-32 2.3 (20) 2.8 (25)
Page 13 Here is a list of tools and their source. SEPARATE TOOL SUPPLIERS Kohler Tools SE Tools Design Technology Inc. Contact your local Kohler source of 415 Howard St. 768 Burr Oak Drive supply. Lapeer, MI 48446 Westmont, IL 60559...
Page 14 For reaming worn valve guides to accept replacement oversize valves. Can be used in low-speed drill press or with handle below for hand reaming. Reamer Handle Design Technology Inc. For hand reaming using Kohler 25 455 12-S reamer. DTI-K830 Valve Guide Service Kit (Courage, Aegis, Command, OHC) SE Tools KLR-82415 For servicing worn valve guides.
Page 15 Tools and Aids FLYWHEEL HOLDING TOOL ROCKER ARM/CRANKSHAFT TOOL A ﬂ ywheel holding tool can be made out of an old junk A spanner wrench to lift rocker arms or turn crankshaft ﬂ ywheel ring gear and used in place of a strap wrench. may be made out of an old junk connecting rod.
Page 16: Troubleshooting Guide
Troubleshooting TROUBLESHOOTING GUIDE When troubles occur, be sure to check simple causes which, at ﬁ rst, may seem too obvious to be considered. For example, a starting problem could be caused by an empty fuel tank. Some general common causes of engine troubles are listed below and vary by engine speciﬁ cation. Use these to locate causing factors.
Page 17 Troubleshooting EXTERNAL ENGINE INSPECTION Engine Loses Power NOTE: It is good practice to drain oil at a location away ● Dirty air cleaner element. from workbench. Be sure to allow ample time for ● Engine overheated. complete drainage. ● Excessive engine load. ●...
Page 18: Crankcase Vacuum Test
Troubleshooting CRANKCASE VACUUM TEST WARNING WARNING Carbon Monoxide can cause severe nausea, Rotating Parts can cause severe injury. fainting or death. Stay away while engine is in operation. Avoid inhaling exhaust fumes. Engine exhaust gases contain poisonous carbon Keep hands, feet, hair, and clothing away from all monoxide.
Page 19: Compression Test
Troubleshooting COMPRESSION TEST For Command Twins: A compression test is best performed on a warm engine. Clean any dirt or debris away from base of spark plug(s) before removing them. Be sure choke is off, and throttle is wide open during test. Compression should be at least 160 psi and should not vary more than 15% between cylinders.
Page 20: Breather Tube
Air Cleaner/Intake AIR CLEANER BREATHER TUBE These systems are CARB/EPA certiﬁ ed and components Ensure sure both ends of breather tube are properly should not be altered or modiﬁ ed in any way. connected. Air Cleaner Components AIR COOLING WARNING Hot Parts can cause severe burns.
Page 21: Fuel Recommendations
● Fuel Tank (Liquid Withdrawal) (LPG only) FUEL LINE ● Electric Lock-Off/Filter Assembly Low permeation fuel line must be installed on carbureted ● Vaporizer (LPG only) Kohler Co. engines to maintain EPA and CARB ● Regulator (Combination Primary/Secondary/Vacuum regulatory compliance. Lock-Off) ● Carburetor ●...
Page 22 Fuel System IMPCO Carburetor Components WARNING Explosive Fuel can cause ﬁ res and severe burns. If a gaseous odor is detected, ventilate area and contact an authorized service technician. LPG is extremely ﬂ ammable and is heavier than air and tends to settle in low areas where a spark or ﬂ ame could ignite gas.
Page 23: Troubleshooting Checklist
Fuel System TROUBLESHOOTING CHECKLIST 4. Make sure ignition, governor, exhaust, throttle, and choke control systems are all operating properly. If engine starts hard, runs roughly, or stalls, check following areas. 5. Check compression. 1. Make sure LPG fuel tank is ﬁ lled and shut-off valve If engine continues to start hard, run roughly, or stall is fully opened.
Page 24 Fuel System Condition Conclusion Engine stalls during operation. No fuel. Faulty lock-off or blocked ﬁ lter. Improper governor setting. Damaged diaphragms within regulator. Vacuum line leaking, loose, or pinched. Restricted fuel line. Loose/leaking fuel enrichment hose (IMPCO carburetor system). Low power. Air cleaner or exhaust system dirty/restricted.
Page 25 Replace with a new 3. Install a new adapter gasket and mount air cleaner Kohler high pressure hose (LP rated) if condition is adapter onto carburetor with screws. Torque screws questionable in any way. Secure new hose using to 4.0 N·m (36 in.
Page 26: High Altitude Operation
Cleaning of ﬁ lter element is not recommended. Order 1. Throttle linkage clamp bracket should be positioned a replacement ﬁ lter element by appropriate Kohler part on idle speed clamp bracket side of throttle shaft. number.
Page 27 Fuel System VAPORIZER ASSEMBLY IMPCO (Beam) Regulator Vaporizer Components Details and Components Vaporizer Fitting Elbow Outer surface of vaporizer should be kept free of dirt and debris accumulation, which will cause a loss of vaporization efﬁ ciency. Visual inspection and necessary cleaning should be performed on a regular basis, more frequently under dusty or dirty conditions.
Page 28 Fuel System LPG/NG vapor enters regulator, then passes into primary Primary chamber reduces high pressure fuel ﬂ ow from area, where pressure is reduced from up to 1724 kPa tank and vaporizer down to approximately 29 kPa (4 psi). (250 psi) at tank to 31 kPa (4.5 psi). Fuel pressure Fuel ﬂ...
Page 29 Fuel System Vacuum lock-off mechanism is located in secondary chamber. When engine is running, manifold vacuum above diaphragm draws it up, so secondary valve can function normally. When engine is stopped, manifold vacuum is terminated, and diaphragm relaxes and pushes down on secondary valve lever, preventing any fuel ﬂ...
Page 30: Governor System
Governor System GOVERNOR Engine is equipped with a centrifugal ﬂ yweight mechanical governor. It is designed to hold engine speed constant under changing load conditions. Governor gear/ﬂ yweight mechanism is mounted inside crankcase on closure plate, and is driven off gear on camshaft. Governor Components H Inside Engine Throttle Lever...
Page 31: Electronic Governor
Governor System 4. Insert a long thin rod or tool into hole on cross shaft GCU Safety Features and rotate shaft clockwise (viewed from end) as far In event of an engine overspeed condition, GCU will shut as it will turn, then torque nut to 6.8 N·m (60 in. lb.). down engine by grounding ignition modules.
Page 32: Check Oil Level
Lubrication System This engine uses a full pressure lubrication system which 4. Reinstall dipstick and tighten securely. delivers oil under pressure to crankshaft, camshaft, CHANGE OIL AND FILTER connecting rod bearing surfaces, and hydraulic valve Change oil while engine is warm. lifters.
Page 33: Installation
Lubrication System OIL SENTRY (if equipped) ™ This switch is designed to prevent engine from starting in a low oil or no oil condition. Oil Sentry may not shut ™ down a running engine before damage occurs. In some applications this switch may activate a warning signal. Read your equipment manuals for more information.
Page 34: Spark Plugs
Electrical System SPARK PLUGS Inspection Inspect each spark plug as it is removed from cylinder CAUTION head. Deposits on tip are an indication of general Electrical Shock can cause injury. condition of piston rings, valves, and carburetor. Do not touch wires while engine is running. Normal and fouled plugs are shown in following photos: Normal Spark Plug Component and Details...
Page 35 Electrical System Carbon Fouled ELECTRONIC IGNITION SYSTEMS Ignition System Components Soft, sooty, black deposits indicate incomplete combustion caused by a restricted air cleaner, over rich Kill Switch/ carburetion, weak ignition, or poor compression. Off Position of Air Gap Key Switch Overheated Flywheel Magnet...
Page 36 Electrical System Wiring Diagram-15/20/25 Amp Regulated Battery Charging System with Fixed Timing KohlerEngines.com 24 690 30 Rev. C...
Page 37 Electrical System Fixed Ignition System This system uses a capacitive discharge (CD) coil. Ignition timing and spark remains constant regardless of engine speed. Timing of spark is controlled by location of ﬂ ywheel magnet group as referenced to engine TDC. A typical ﬁ xed ignition system consists of: ●...
Page 38 Electrical System Wiring Diagram-15/20/25 Amp Regulated Battery Charging System with Variable Ignition Timing SMART- SPARK ™ KohlerEngines.com 24 690 30 Rev. C...
Page 39 Electrical System Smart-Spark Advance Ignition System ™ SMART-SPARK equipped engines utilize an electronic capacitive discharge ignition system with electronic spark ™ advance. A typical application consists of following components: ● 1 magnet assembly which is permanently afﬁ xed to ﬂ ywheel. ●...
Page 40 Electrical System Wiring Diagram-15/20/25 Amp Regulated Battery Charging System with DSAI Ignition and Key Switch KohlerEngines.com 24 690 30 Rev. C...
Page 41 Electrical System Digital Spark Advance Ignition (DSAI) System This system uses a digital microprocessor which is located in ignition modules. Ignition timing varies depending upon engine speed with this system. There are 2 inductive-style ignition modules that control ignition timing based on engine RPM.
Page 42 Electrical System Wiring Diagram-3 Amp Unregulated Battery Charging System/70 Watt Lighting Optional Oil Optional Oil Ground-To-Kill Sentry Switch Sentry Switch 12 V. Battery Light Lead (White) ™ ™ (Shutdown) (Indicator Light) Optional Ground Optional Fuse Key Switch Ammeter Blue Solenoid Lights Starter Yellow...
Page 43 Electrical System Test for Spark NOTE: If 2 testers are available, testing can be performed simultaneously for both cylinders. However, if only 1 tester is available, 2 individual tests must be performed. Side not being tested must have spark plug lead connected or grounded.
Page 44 Electrical System Test Ignition Modules and Connections (Smart- Ignition Module Resistance Table Spark only) ™ 24 584 03 24 584 15-S NOTE: Resistance values apply only to modules that have been on a running engine. New service 24 584 11 24 584 36-S modules may have higher resistance until they (1 11/16 in.
Page 45 Electrical System Condition Possible Cause Conclusion Strong, steady spark is now present Problem should be corrected. Go to on both sides. Test SAM step 4. Still a spark problem. Test SAM. Test SAM 1. Trace red power source lead from SAM to harness connection. Separate connector and connect red lead of a DC voltmeter to harness terminal.
Page 46: Battery Charging System
Electrical System To test ASAM only using 25 761 21-S tester: ● Yellow tester lead to long yellow module lead. ● Brown tester lead to long brown module lead. NOTE: SAM must be at room temperature when tested. ● Red tester lead to red module lead. Disconnect all SAM leads, isolating it from main ●...
Page 47 Electrical System 15/20/25 Amp Regulated Charging System Stator Stator is mounted on crankcase behind ﬂ ywheel. Follow procedures in Disassembly and Reassembly if stator replacement is necessary. Rectiﬁ er-Regulator NOTE: When installing rectiﬁ er-regulator, take note of terminal markings and install plug(s) accordingly. NOTE: Disconnect all electrical connections attached to rectiﬁ...
Page 48 Electrical System 15/20/25 Amp Battery Charging Systems NOTE: Always zero ohmmeter on each scale before testing to ensure accurate readings. Voltage tests should be made with engine running at 3600 RPM with no load. Battery must be good and fully charged. When problems occur in keeping battery charged or battery charges at high rate, charging system or battery might be causing problems.
Page 49 Electrical System 3 Amp/70 Watt Lighting Stator NOTE: Always zero ohmmeter on each scale before testing to ensure accurate readings. Voltage tests should be made with engine running at 3600 RPM with no load. Battery must be good and fully charged. To test charging system for no charge to battery: To test charging system for no lights: 1.
Page 50: Starter System
Starter System NOTE: Do not crank engine continuously for more than 10 seconds. Allow a 60 second cool down period between starting attempts. Failure to follow these guidelines can burn out starter motor. NOTE: If engine develops sufﬁ cient speed to disengage starter but does not keep running (a false start), engine rotation must be allowed to come to a complete stop before attempting to restart engine.
Page 51 4. Clean splines on drive shaft thoroughly with solvent. Dry splines thoroughly. 5. Apply a small amount of Kohler electric starter drive lubricant, to splines. Use of other lubricants may cause drive pinion to stick or bind.
Page 52 A brush holder tool can easily be made 5. Install thru bolts and tighten securely. from thin sheet metal. 6. Lubricate drive shaft with Kohler starter drive 1. Remove brush springs from pockets in brush holder. lubricant. Install drive components following 2.
Page 53 Starter System SOLENOID SHIFT ELECTRIC STARTERS Nippondenso Starters Solenoid Shift Starter Components Starter Disassembly NOTE: When removing lever and armature be careful not to lose thrust washer. 1. Disconnect lead wire from solenoid. 2. Remove nuts securing solenoid, and remove solenoid from starter assembly.
Page 54 Brush Replacement 4 brushes and springs are serviced as a set. Use a new Kohler brush and spring kit if replacement is necessary. 1. Perform steps 1-5 in Starter Disassembly. 2. Remove screws securing brush holder assembly to end cap (plate).
Page 55 Starter System 10. Starter reassembly when replacing brushes/brush Starter Reassembly holder assembly: NOTE: Always use a new retainer. Do not reuse old a. Hold starter assembly vertically on end housing, retainers that have been removed. and carefully position assembled brush holder NOTE: Correctly installed, center pivot section of drive assembly, with supplied protective tube, against lever will be ﬂ...
Page 56 Starter System Solenoid Tests NOTE: DO NOT leave 12 volt test leads connected to solenoid for any time over what is necessary for performing each of individual tests. Internal damage to solenoid may occur. Disconnect all leads from solenoid including positive brush lead attached to lower stud terminal. Remove mounting hardware and separate solenoid from starter for testing.
Page 57 Disassembly/Inspection and Service Before working on engine or equipment, disable engine as WARNING follows: 1) Disconnect spark plug lead(s). 2) Disconnect negative (–) battery cable from battery. Accidental Starts can cause severe injury or death. Before disconnecting negative (–) ground cable, make sure all switches are OFF.
Page 58 Disassembly/Inspection and Service Clean all parts thoroughly as engine is disassembled. Remove LPG/NG Components Only clean parts can be accurately inspected and gauged for wear or damage. There are many commercially available cleaners that will quickly remove WARNING grease, oil, and grime from engine parts. When such a Explosive Fuel can cause ﬁ...
Page 59 Disassembly/Inspection and Service Remove Throttle and Choke Controls Remove Carburetor Control Bracket Components WARNING Explosive Fuel can cause ﬁ res and severe burns. If a gaseous odor is detected, ventilate area and contact an authorized service technician. LPG is extremely ﬂ ammable and is heavier than air and tends to settle in low areas where a spark or ﬂ...
Page 60 Disassembly/Inspection and Service 5. Remove outer bafﬂ es on both sides. 3. Remove two remaining screws holding breather cover to crankcase. 6. On engines equipped with a metal debris screen, remove screen before removing blower housing. 4. Pry under protruding edge of breather cover with a Plastic debris screens can be removed after blower screwdriver to break RTV or gasket seal.
Page 61: Exhaust Valve
Disassembly/Inspection and Service 1. Remove screws or nuts and washers securing each Remove Spark Plugs cylinder head. Discard nuts and washers once Remove spark plug from each cylinder head. removed. Do not reuse. Studs (if present) should only be removed if damaged or if cylinder Remove Cylinder Heads and Hydraulic Lifters reconditioning is necessary.
Page 62 If lifters need to be replaced, apply a liberal Then, carefully inspect each valve for defects such as a coating of Kohler lubricant to base of each new lifter warped head, excessive corrosion, or a worn stem end. before it is installed.
Page 63 Use a hook-end tool next to post and pull Inspect ring gear for cracks or damage. Kohler does not outward to separate small metal retainers. Then provide ring gear as a serviceable part. Replace ﬂ ywheel unsnap fan from remaining mounting posts.
Page 64 Disassembly/Inspection and Service Crankcase Components Gerotor Gears Oil Seal Closure Plate (Style A) Dipstick Tube (Style A) Oil Pick-Up Tube Oil Pump Assembly Governor Gear Shaft Governor Gear (Style A) (Style A) Camshaft Piston Pin Piston Ring Set Piston Pin Retainer Connecting Rod End Piston Connecting Rod...
Page 65 Disassembly/Inspection and Service Inspection Governor Gear Assembly Inspect governor gear teeth. Replace gear if it is worn, chipped, or if any teeth are missing. Inspect governor Governor Shaft Component and Details weights. They should move freely in governor gear. Disassembly NOTE: Governor gear is held onto shaft by small molded tabs in gear.
Page 66 Disassembly/Inspection and Service Oil Pump Assembly (Style A) Oil Pump Assembly (Style B) Oil pump is mounted inside closure plate. If service is Oil pump is mounted inside closure plate. If service is required, continue with Disassembly, Inspection, and required, continue with Disassembly, Inspection, and Reassembly.
Page 67 Disassembly/Inspection and Service NOTE: Rings must be installed correctly. Ring Remove Connecting Rods with Pistons and Rings installation instructions are usually included with NOTE: If a carbon ridge is present at top of either new ring sets. Follow instructions carefully. Use cylinder bore, use a ridge reamer tool to remove a piston ring expander to install rings.
Page 68 Disassembly/Inspection and Service Some important points to remember when servicing Remove Crankshaft piston rings: Inspection and Service 1. Cylinder bore must be deglazed before service ring Crankshaft Components and Details sets are used. 2. If cylinder bore does not need reboring and if old piston is within wear limits and free of score or scuff marks, old piston may be reused.
Page 69 Disassembly/Inspection and Service Inspect crankpin for score marks or metallic pickup. Governor Cross Shaft Oil Seal Slight score marks can be cleaned with crocus cloth soaked in oil. If wear limits, as stated in Speciﬁ cations Cross Shaft Oil Seal Details and Tolerances are exceeded, it will be necessary to either replace crankshaft or regrind crankpin to 0.25 mm (0.010 in.) undersize.
Page 70 Use following procedure for crankcases with a cast iron sleeve. NOTE: Kohler pistons are custom-machined to exacting 6 mm (0.2362 in.) tolerances. When oversizing a cylinder, it should be machined exactly 0.25 mm (0.010 in.) or 0.50 NOTE: Do not use a feeler gauge to measure piston-to- mm (0.020 in.) over new diameter (refer to...
Page 71 Reassembly Crankcase Components Gerotor Gears Oil Seal Closure Plate (Style A) Dipstick Tube (Style A) Oil Pick-Up Tube Oil Pump Assembly Governor Gear Shaft Governor Gear (Style A) (Style A) Camshaft Piston Pin Piston Ring Set Piston Pin Retainer Connecting Rod End Piston Connecting Rod Crankshaft...
Page 72 Reassembly NOTE: Cylinders are numbered on crankcase. Make Install Governor Cross Shaft sure to install piston, connecting rod and end 1. Lubricate governor cross shaft bearing surfaces in cap into its appropriate cylinder bore as crankcase with engine oil. previously marked at disassembly. Do not mix end caps and connecting rods.
Page 73 Reassembly Determining Camshaft End Play Thrust Bearing, Washer and Shim 1. Install shim removed during disassembly onto Thrust Bearing, Washer, and Shim Sequence camshaft. 2. Position camshaft end play checking tool on camshaft. 3. Apply pressure on camshaft end play checking tool (pushing camshaft toward crankshaft).
Page 74 Reassembly Remove closure plate. If end play requires adjustment, Install Closure Plate Assembly remove original spacer and install appropriate size shim spacer in its place. Then follow procedure under Install Sealant Pattern and Torque Sequence Closure Plate Assembly. Install Closure Plate Oil Seal Oil Seal Depth RTV sealant is used as a gasket between closure plate and crankcase.
Page 75 Reassembly Flywheel/Ignition Components Debris Screen Flywheel Screw Washer Flywheel Magnet Stator Ignition Module Backing Plate Woodruff Key Spring Washer Spacer Metal Debris Screen Ring Support Metal Debris Screen Washer Assembly NOTE: Make sure ﬂ ywheel key is installed properly in Install Stator and Backing Plates keyway.
Page 76 Reassembly Install Plastic Debris Screen Install Supports for Metal Debris Screen 1. If a metal debris screen is used, with threaded CAUTION individual supports, install a spacer washer on external threads. Apply Loctite (removable) ® ® Failure to utilize or reassemble debris screen onto threads.
Page 77 Reassembly 3. Install new mounting stud(s) into crankcase. Assemble Cylinder Heads a. Thread and lock two mounting nuts together on Prior to installation, lubricate all components with engine smaller diameter threads. oil, paying particular attention to lip of valve stem seal, valve stems and valve guides.
Page 78 Reassembly Install Spark Plugs Install Intake Manifold 1. Check gap using wire feeler gauge. Adjust gap to Torque Sequence 0.76 mm (0.03 in.) for all except NG with CD ﬁ xed timing or 0.51 mm (0.02 in.) for NG with CD ﬁ xed timing.
Page 79 Reassembly External Engine Components Vaporizer Lock-off/Filter Regulator Carburetor Gasket Intake Manifold Plastic Intake Manifold Outer Bafﬂ e Inner Bafﬂ e Breather Reed Breather Gasket Breather Cover Breather Tube Oil Sentry Filter Air Cleaner ™ Oil Filter Nipple Oil Cooler Electric Starter Lifting Bracket Fixed Guard Blower Housing...
Page 80 Reassembly 3. Position outer bafﬂ es and loosely start mounting Install Breather Cover and Inner Bafﬂ es screws. M6 screws go into back of cylinders. Short Breather Cover Details and Torque Sequence M5 screws go into lower holes closest to blower housing.
Page 81 Reassembly Install Carburetor Control Bracket Components WARNING Explosive Fuel can cause ﬁ res and severe burns. If a gaseous odor is detected, ventilate area and contact an authorized service technician. LPG is extremely ﬂ ammable and is heavier than air and tends to settle in low areas where a spark or ﬂ...
Page 82 Reassembly Governor Lever Hole Position (6 mm) 6 mm Governor Lever and Hole Position/RPM Chart Governor Gov. Lever High Idle RPM Spring Color Hole No. Code 3801-4000 Clear 3601-3800 Clear 3451-3600 Clear 3301-3450 Clear 3101-3300 Purple 2951-3100 Purple 2800-2950 Purple 3750* Clear 3150*...
Page 83 Reassembly 4. Locate cover with oil ﬁ ll neck on same side as Install Control Panel (if equipped) removed and install lifting strap in original position. 1. Install panel to blower housing. With O-ring type covers, position cover on cylinder head.
Page 84 Reassembly Install Oil Filter and Fill Crankcase with Oil NOTE: Make sure both oil drain plugs are installed and torqued to speciﬁ cations to prevent oil leakage. 1. Install oil drain plug(s). Torque plug(s) to 13.6 N·m (10 ft. lb.). If oil drain valve is used, make sure valve body is closed and cap is on.
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