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Kohler Magnum M8 Service Manual

Single cylinder engine

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Owner's manual (9 pages)

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Table Of Contents

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Table of Contents

Contents
General Information
Engine Identification Numbers
Safety Information
Oil/Fuel Recommendations
Oil Type
Check Oil Level
Change Oil
Fuel Type
Overall Dimensions
Gasoline/Alcohol Blends
Standard Torque Values
Specifications, Tolerances and Special Torque Values
Special Tools
Valve Service Tools
Seal and Bearing Installers
Tool Usage Chart
Bearing and Seal Installers
Miscellaneous Tools
Engine Analysis Kit (no 25 800 01)
Ignition System Tester
Water Manometer
Cylinder Leakdown Tester
Inductance Tachometer
Periodic Maintenance
Required Maintenance
Oil Sentry
Service Air Cleaner
Clean Air Intake/Cooling Areas
Precleaner
Paper Element
Inspect Air Cleaner Components
Check Spark Plug
Service Optional Reduction Gear Unit
Servicing Spark Plug
Ignition System Service
Check Fuel Filter
Service Starter Motor Drive
Clean Cylinder Head and Combustion Chamber
Check Valve-To-Tappet Clearance
Cylinder Head Fastener Tightening Sequence
Measuring Valve-To-Tappet Clearance
Storage
Troubleshooting
External Engine Inspection
Cleaning the Engine
Basic Engine Tests
No Crankcase Vacuum/Pressure in Crankcase
Air Cleaner Disassembly
Air Cleaner Assembly - Exploded View
Air Cleaner Reassembly/Service
Fuel System and Governor
Fuel System Operation
Fuel System Troubleshooting
Typical Fuel System
Fuel Tank
Fuel Filter
Fuel Pump
Fuel Shutoff Valve
Isolation Mounts
Carburetor
Carburetor Adjustment
Carburetor Disassembly
Carburetor Cleaning
Carburetor Inspection
Carburetor Repair
Throttle and Choke Shaft Replacement
To Replace Throttle and Choke Shafts
Disassemble Carburetor
Remove Choke Plate and Choke Shaft; Transfer Choke Lever
Remove Throttle Plate and Throttle Shaft; Transfer Throttle Lever
Drill Choke Shaft Bores Using a Drill Press
Installing Choke Shaft Bushings
Install Throttle Shaft Bushing
Installing Choke Shaft
Install Throttle Shaft and Throttle Plate
Setting Float Level
Setting Float Drop
Governor Operation
Centrifugal Flyweight Mechanical Governor
Checking Float Clearance
Governor Adjustment
Initial Governor Adjustment
High Speed Adjusting Screw
Engine Mounted Throttle and Choke Controls
Sensitivity Adjustment
Engine Mounted Throttle and Choke Controls - Exploded View
Engine Mounted Throttle and Choke Controls - Disassembly/Reassembly
Retractable Starters
To Remove/To Install Starter
Retractable Starter on Model M8
To Replace Starter Pawls (Dogs)
Exploded View - Retractable Starter for Model M8
Starter Pawls
To Replace Rope
Removing Handle
Installing Rope
Releasing Spring Tension
Starter Disassembly
Position of Spring and Keeper on Pulley
Removing Pulley from Housing
Starter Inspection and Service
Starter Reassembly
Retractable Starter on Models M10, M12, M14, M16 Disassembly
Installing Pulley and Spring into Housing
Exploded View - Retractable Starter for Models M10, M12, M14, M16
Removing Spring from Housing
To Replace Recoil Spring
Spring Reassembly
Installing Spring Using Seal Installer and Handle
Positioning New Spring/C-Ring
Installing Pawls, Pawl Retainer and Related Components
Tensioning Spring
Winding Rope Onto Pulley
Electrical Systems and Components
Magnum Electronic Magneto Ignition System
Ignition System Troubleshooting Guide
Ignition Module Removal
Ignition Module Installation
Ignition Tester, Testing Module Secondary
Setting Magnet-To-Module Air Gap
Kill Lead with Optional Diode
Spark Plug Service
Kill Lead/Diode Replacement
Diode Test
Spark Plug Inspection
Electrical System Wiring Diagram and Battery Charging Systems
Manual Start Engines: Optional 70 Watt Lighting
Troubleshooting Guide: 70 Watt Lighting Stator
Electric Start Engine: 1.25 Amp or 3 Amp Unregulated Charging System, Optional 70 Watt Lighting
Wiring Diagram - Electric Start Engine/1,25 Amp or 3 Amp Unregulated Battery Charging System/70 Watt Lighting
1.25 Amp or 3 Amp Stator /70 Watt Lighting Stator
Troubleshooting Guide: 1,25 Amp Battery Charging System
Troubleshooting Guide: 3 Amp Battery Charging System with 70 Watt Lighting Stator
Electric Start Engines: 15 Amp Regulated Charging System
Amp Stator and Rectifier Regulator
Troubleshooting Guide: 15 Amp Battery Charging System
Electric Start Engines: 25 Amp Regulated Charging System
25 Amp Stator and Rectifier Regulator
Troubleshooting Guide: 25 Amp Battery Charging System
Keyswitch
Battery Test
Battery Charging, Maintenance
Checking Battery Voltage
Battery Testing
Solenoid Testing
Electric Starter
Electric Starter Operation
Bendix Drive Electric Starter
Electric Starter Troubleshooting Guide
Starter Removal and Installation
Starter Drive Service
Commutator End Cap with Brushes
Commutator Service Reassembly
Starter Assembly Match Marks
Oil Sentry , Oil Level Monitor Operation
Float Switch Removal
Float Switch Installation/Removal
Float Switch Test
Automatic Compression Release - Operation
Automatic Compression Release - Starting Position
Automatic Compression Release - Running Position
Benefits
Compression Testing
Inspection and Service
Disassembly Procedure
Disconnect Spark Plug Lead Drain Oil from Crankcase
Remove Air Cleaner
Removing Spark Plug Lead, Oil Drain Plug and Air Cleaner Cover
Remove Muffler
Removing Choke Linkage, Throttle Linkage and Carburetor
Removing Air Cleaner Element
Removing Air Cleaner Base
Remove Fuel Pump
Removing Fuel Pump, External Governor Components, and Throttle and Choke Controls
Remove External Governor Components, and Throttle and Choke Controls
Remove Retractable Starter
Remove Electric Starter and Solenoid
Remove Fuel Tank
Removing Starter from Bearing Plate
Remove Cylinder Head Baffle, Blower Housing and Side Air Baffles
Remove Breather Assembly
Removing Cylinder Head Baffle, Blower Housing and Breather Cover
Removing Fuel Tank Bracket from Crankcase
Remove Spark Plug and Cylinder Head
Remove Ignition Module and Air Baffle
Remove Drive Cup or Rope Start, Pulley, Grass Screen, Flywheel and Fan
Rope Start Models
Electric Start Models
Retractable Start Models
Remove Valves
Remove Stator
Remove Oil Pan
Remove Connecting Rod and Piston
Remove Piston Rings
Remove Piston from Connecting Rod
Remove Crankshaft and Bearing Plate
Remove Camshaft and Tappets
Remove Governor Gear and Cross Shaft
Remove Oil Seals
Remove Bearings
Model M10, M12, M14, M16 Disassembly
Disconnect Spark Plug Lead
Drain Oil from Crankcase
Remove Rectifier-Regulator
Remove Choke Linkage, Throttle Linkage and Carburetor
Remove External Governor Components and Throttle and Choke Controls
Remove Breather
Remove Fuel Pump, Remove Retractable Starter
Remove Fuel Tank and Solenoid
Remove Oil Fill/Dipstick Tube
Remove Electric Starter
Removing Starter Tail Brace and Starter
Removing Carburetor Side Air Baffle
Remove Drive Cup or Rope Start Pulley, Grass Screen, Flywheel and Fan
Removing Flywheel Fastener
Removing Fan from Flywheel
Remove Stator, Valves, Oil Pan
Remove Balance Gears
Removing Bearing Plate Using a Puller
Removing Tappets
Remove Governor Gear, Cross Shaft
Remove Oil Seals, Bearings
Removing Balance Gears, Governor Gear and Cross Shaft
Inspection and Repair/Reconditioning
Flywheel Inspection
Cylinder Head Inspection
Checking Cylinder Head Flatness
Cylinder Block Inspection and Reconditioning
Honing
Cylinder Bore Crosshatch after Honing
Measuring Cylinder Bore
Valves Inspection and Service
Measuring Piston-To-Bore Clearance
Measuring Piston Diameter
Valve Spring Free Height
Valve Details
Valve Guides
Install Valve Guide
Valve Seat Inserts
Reaming Valve Guide
Remove Valve Seat Insert
Install Valve Seat Insert
Pulling Valve Seat Insert
Piston and Rings Identification
Piston and Rings Inspection
Piston and Rings Service
Common Types of Piston and Ring Damage
Intall Piston Rings
Measuring Piston Ring Side Clearance/End Gap
Posi-Lock Connecting Rods
Piston Ring Installation
Magnum M8 Posi-Lock Connecting Rods
Piston Ring Inspection and Service
Balance Gears and Stub Shafts
Governor Gear
Camshaft and Crankshaft Inspection and Service
Crankpin Fillets
Model M8 Reassembly
Install Rear Bearing
Install Governor Gear and Cross Shaft
Install Tappets and Camshaft
Installing Governor Gear
Measuring Camshaft End Play
Install Crankshaft
Install Bearing Plate
Install Fuel Line and Wiring Harness
Install Front Bearing
Install Oil Seals
Install Piston to Connecting Rod
Install Piston Rings
Install Piston/Connecting Rod
Install Oil Pan
Installing Pistons
Install Valves
Install Stator
Install Fan, Flywheel, Grass Screen and Drive Cup or Rope Start Pulley
Install Fan to Flywheel
Install Ignition Module and Air Baffle
Installing Ignition Module
Install Cylinder Head and Spark Plug
Install Side Air Baffles, Blower Housing and Cylinder Head Baffle
Installing Breather Components
Cylinder Head Fastener Torque Sequence
Install Fuel Tank and Brackets
Installing Blower Housing, Keyswitch Panel and Side Air Baffle
Installing Fuel Tank Bracket to Crankcase
Install Solenoid and Electric Starter
Install Retractable Starter
Installing Starter and Starter Tail Brace
Installing Fuel Tank
Install External Governor Components, and Throttle and Choke Controls
Install Fuel Pump
Install Carburetor, Throttle Linkage and Choke Linkage
Install Rectifier-Regulator
Installing Carburetor, Throttle Linkage and Choke Linkage
Adjusting Governor Arm/Cross Shaft
Install Muffler
Install Air Cleaner
Prepare the Engine for Operation

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Troubleshooting

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Magnum m10 Magnum m16 Magnum m12 Magnum m14

Kohler Magnum M8 Service Manual

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Troubleshooting

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