Kohler M20`` Manuals

Manuals and User Guides for Kohler M20``. We have 2 Kohler M20`` manuals available for free PDF download: Service Manual

Kohler M20`` Service Manual (140 pages)

Twin Cylinder engine

Brand: Kohler | Category: Engine | Size: 4.27 MB

Contents
2
Safety and General Information
3
Engine Identification Numbers
5
Oil Recommendations
6
Oil Type
6
Check Oil Level
6
Change Oil
6
Fuel Recommendations
7
Oil Filter
7
Fuel Type
7
Overall Dimensions - Model M19 and M20
7
Specifications, Tolerances and Special Torque Values
8
Standard Torque Values
12
Oil Drain Plugs
12
Special Service Tool Kit No. 3211
13
Valve Service Tools
14
Seal and Bearing Installers
14
Other Applications
15
Tool Usage Chart Kit No. 3211
16
Engine Analysis Kit No. KO-1000
17
Ignition System Tester
18
For Twin Cylinder Engines
18
Using the Tester
18
RTV Silicone Sealant
19
Water Manometer
19
Cylinder Leakdown Tester
19
Periodic Maintenance
20
Required Maintenance
20
Oil Sentry
21
Oil Level Range
21
Oil Change Intervals
21
Oil Drain Plug Location
21
Change Oil Filter
22
Service Air Cleaner
22
Precleaner
22
Paper Element
22
Clean Air Intake/Cooling Areas
23
Inspect Air Cleaner Components
23
Check Spark Plugs
24
Ignition System Service
24
Check Fuel Filter
24
Service Starter Motor Drive
24
Clean Cylinder Heads and Combustion Chambers
25
Check Valve-To-Tapper Clearance
25
Remove Air Cleaner, Valve Covers, Breather, and Spark Plugs
26
Measure Valve-To-Tapper Clearance
26
Reinstall Spark Plugs, Breather, Valve Covers and Air Cleaner
26
Clearance Specifications
26
Storage
27
Troubleshooting Guide
28
External Engine Inspection
29
Cleaning the Engine
29
Basic Engine Tests
30
No Crankcase Vacuum/Pressure in Crankcase
30
Crankcase Vacuum Test
30
Compression Test
31
Low Compression
31
Cylinder Leakdown Test
32
Leakdown Test Instructions
32
Leakdown Test Results
32
Air Cleaner Components
33
Square Disassembly
33
Square Air Cleaner Assembly
33
Anti-Icing
34
Square Reassembly
34
Dome Disassembly
34
Dome Reassembly
34
Anti-Icing Disassembly
35
Anti-Icing Reassembly
35
Typical Decal - Anti-Icing Air Cleaner Cover Positions
35
Installing Anti-Icing Air Cleaner Cover
36
Fuel System Operation
37
Fuel System Troubleshooting
37
Fuel Filter
38
Fuel Pump Operation
38
Fuel Pump Removal
39
Fuel Pump Repair
39
Fuel Pump Installation
39
Carburetor Adjustment
39
Kohler-Built Adjustable Jet Carburetor
40
Carburetor Disassembly
41
Carburetor Cleaning
41
Kohler-Built Adjustable Jet Carburetor - Exploded View
41
Carburetor Repairs
42
Carburetor Inspection
42
Chart Throttle Shaft Replacement Selection
43
To Replace Throttle and Choke Shafts
43
Remote Throttle Plate and Throttle Shaft
44
Drill Choke Shaft Bores Using a Drill Press
45
Install Choke Shaft Bearings
45
Installing Choke Shaft Bushings
45
Install Throttle Shaft Bushing
46
Install Detent Spring and Ball, Choke Shaft and Choke Plate
46
Install Throttle Shaft and Throttle Plate
46
Reassembly Carburetor
47
Setting Float Level
47
Setting Float Drop
47
Checking Float Clearance
47
Governor Operation
48
Governor Adjustment
48
Centrifugal Flyweight Mechanical Governor
48
Initial Governor Adjustment
49
High Speed Adjustment
49
Engine Mounted Throttle and Choke Controls
50
Disassembly
50
Governor Sensitivity Adjustment
50
Engine Mounted Throttle and Choke Controls Reassembly
51
Automatic Choke Function
52
Automatic Choke Adjustment
52
Automatic Choke Service Guide
52
Automatic Choke Inspection
53
Automatic Choke Service
53
Shutdown Control Function
53
Shutdown Control Inspection
53
Engines Equipped for Dual Fuel
54
Venturi Identification
54
LPG Carburetor
55
Carburetor Service (Walbro-Built)
56
Major Components and Service Locations - Typical Walbro Carburetor
57
Walbro Carburetor Troubleshooting
58
Adjusting Walbro Carburetors
59
Optimum Main Fuel Setting
59
Optimum Low Idle Fuel Setting
60
Walbro-Built Carburetor - Exploded View
60
Walbro Carburetor Disassembly
61
Throttle Shaft Removal
61
Choke Shaft Removal
62
Choke Shaft Cleaning
62
Marking Choke Plate and Carburetor Body
62
Removing Choke Lever/Shaft
62
Choke Shaft Inspection
63
Choke Shaft Repair
63
Throttle Shaft Installation
63
Choke Shaft Installation
64
Installing Choke Lever/Shaft
64
Installing Welch Plugs
64
High Altitude Operation (Fixed Main Carburetors)
65
Fuel Needle Clip
65
High Altitude Jet Installation
66
M29 Linkage and Dampening Spring Installation
66
Installing Bushings and Governor Linkage - M20 Engines
66
Lubrication System Operation
68
Lubrication System Service
68
Oil Pump Assembly
69
Oil Pickup
69
Oil Pressure Relief Valve
69
Crankshaft Splined Insert Lube Interval Recommendation
70
Installation Torques - Engine Mounted Oil Filter
70
Installation Torque - Filter Bypass Cover
70
Installation Torques - Remote Mounted Oil Filters
70
Oil Sentry Oil Pressure Monitor
71
Electrical System and Components
72
Magnum Electronic Magneto Ignition System Operation
72
Ignition System Troubleshooting Guide
73
Ignition Module Removal
74
Ignition Module Installation
74
Testing Module Primary
74
Kill Lead with Optional Diode
75
Spark Plugs Service
75
Diode Test
75
Spark Plugs Inspection
76
Electrical Systems Wiring Diagrams and Battery Charging Systems
77
Electric Start Engines 15 Amp Regulated Charging System
78
Electric Start Engines 25 Amp Regulated Charging System
79
Troubleshooting Guide - 15/25 Amp Battery Charging Systems
80
Connections for Testing 15 and 25 Systems
81
Battery Test
82
Battery Charging
82
Battery Maintenance
82
Checking Battery Voltage
82
Key Switch Testing
83
Solenoid Testing
83
Bendix Drive Electric Starter Operation
84
Bendix Drive Electric Starter Troubleshooting Guide
85
Starter Drive Service
85
Starter Drive Disassembly
85
Brush Replacement
86
Commutator Service
86
Brush Holder Tool
86
Solenoid Shift Electric Starter Operation
87
Starter Removal and Reinstallation
87
Exploded View of Nippensenso Solenoid Shift Starter
87
Starter Disassembly
88
Removing the Insulator
88
Removing the Armature and Drive Lever
88
Removing the Stop Collar
88
Removing the Front Stop Collar
89
Cutting Brush Lead Wires from the Frame Posts
89
Starter Service
90
Connecting Replacement Brushes
90
Soldering Brush Clips to Posts
90
Installing Snap Ring
90
Lubrication Points
91
Tightening the Snap Ring
91
Installing the Slop Collar
91
Installing the Brush Springs
92
Typical Disassembly Sequence
93
Disconnect Spark Plug Leads , Drain Oil and Remove Oil Filter
93
Remove Mufflers and Exhaust Elbows
94
Remove Air Cleaner
94
Remove Intake Manifold and Carburetor
94
Disconnect Wiring; Remove Rectifier-Regulator, Key Switch, and Solenoid
96
Remove Top Baffle, Cylinder Head Baffles and Blower Housing
96
Remove Breather and Valve Cover
96
Remove Fuel Pump
97
Remove Ignition Module and Bracket
97
Remove Grass Screen, Flywheel and Fan
97
Remove Electric Starter
98
Remove Stator
98
Identify Engine Sides
99
Remove Spark Plugs and Cylinder Heads
99
Remove Cylinder Barrels
99
Remove Valves
100
Remove Pistons from Connecting Rods
100
Remove Piston Rings
100
Remove Closure Plate, Oil Pressure Relief Valve and Rear Oil Seal
101
Remove Oil Filter Adapter
101
Split the Crankcase
101
Remove Camshaft and Tappets
102
Remove Crankshaft, Front Oil Seal and Bearings
102
Remove Connecting Rods
103
Remove Governor Gear and Cross Shaft
103
Remove Oil Pickup and Oil Pump
103
Inspection and Reconditioning
105
Flywheel Inspection
105
Cylinder Heads Inspection
105
Checking Cylinder Head Flatness
105
Cylinder Barrels Inspection and Reconditioning
106
Honing
106
Cylinder Bore Crosshatch after Honing
106
Clean Cylinder Bore after Honing
107
Measuring Piston-To-Bore Clearance
107
Valve Inspection and Service
107
30 Changeover
108
Remove Valve Guide
111
Install Valve Guide
111
Pulling Valve Guide
111
Valve Seat Inserts
112
Pistons and Rings Identification
113
Valve Stem Seals
113
Install Valve Seat Insert
113
Pistons and Rings Inspection
114
Pistons and Rings Service
115
Common Types of Piston and Ring Damage
115
Install Piston Rings
116
Measuring Piston Ring Side Clearance
116
Measuring Piston Ring End Cap
116
Posi-Lock Connecting Rods Inspection and Service
117
Camshaft and Crankshaft Inspection and Service
117
Camshaft/Valve to Tappet Clearance Change
118
Oil Pump Inspection and Service
118
Governor Gear Inspection
119
Typical Reassembly Sequence
120
Install Oil Pump and Oil Pickup
120
Install Cross Shaft and Governor Shaft
121
Install Connecting Rods
122
Install Bearing and Crankshaft
123
Install Tappets and Camshaft
124
Roller Thrust Bearings
124
Install Camshaft Bore Plug and Seal Crankcase
125
Recommended Sealants
126
Install Front Oil Seal
127
Install Oil Filter Adapter
127
Install Oil Pressure Relief Valve, Closure Plate, and Rear Oil Seal
128
Closure Plate Alignment
129
Install Pistons in Cylinder Barrels
129
Install Cylinder Barrels
129
Measure Valve-To-Tappet Clearance
130
Install Valves
131
Install Cylinder Heads and Spark Plugs
131
Install Stator
132
Install Electric Starter
132
Install Fan, Flywheel, and Grass Screen
132
Install Bracket and Ignition Module
133
Install Fuel Pump
133
Install Valve Cover and Breather
134
Install Blower Housing, Cylinder Head Baffles and Baffle
134
Install Solenoid, Key Switch, Rectifier-Regulator and Connect Wiring
134
Install Carburetor and Intake Manifold
135
Install Air Cleaner
136
Install Exhaust Elbows and Mufflers
137
Install Oil Filter
137
Prepare the Engine for Operation
138
Testing the Engine
138

Kohler M20`` Service Manual (139 pages)

twin cylinder engine

Brand: Kohler | Category: Engine | Size: 4.09 MB

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Kohler M20`` Manuals

Kohler M20`` Service Manual (140 pages)

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Kohler M20`` Service Manual (139 pages)

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