Kohler XT675 Engine Service Manual 14_690_01_EN

March 25, 2018 | Author: bunkmonkey | Category: Gasoline, Motor Oil, Ignition System, Piston, Throttle
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XT-6, XTR-6, XT6.5, XT650, XT6.75, XT675, XT-7, XTR-7, XT775, XT8 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. 2 Safety 3 Maintenance 5 Specifications 10 Tools and Aids 13 Troubleshooting 17 Air Cleaner/Intake 18 Fuel System 24 Governor System 26 Lubrication System 27 Electrical System 31 Starter System 33 Disassembly/Inspection and Service 45 Reassembly 14 690 01 Rev. G KohlerEngines.com 1 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 CAUTION Explosive Fuel can cause Accidental Starts can Electrical Shock can fires and severe burns. cause severe injury or cause injury. Do not fill fuel tank while death. Do not touch wires while engine is hot or running. Disconnect and ground engine is running. Gasoline is extremely flammable spark plug lead(s) before and its vapors can explode if servicing. CAUTION ignited. Store gasoline only in approved containers, in well Before working on engine or Damaging Crankshaft ventilated, unoccupied buildings, equipment, disable engine as and Flywheel can cause away from sparks or flames. follows: 1) Disconnect spark plug personal injury. Spilled fuel could ignite if it comes lead(s). 2) Disconnect negative (–) in contact with hot parts or sparks battery cable from battery. from ignition. Never use gasoline as a cleaning agent. WARNING Using improper procedures can lead to broken fragments. Broken Hot Parts can cause fragments could be thrown from WARNING severe burns. engine. Always observe and use Rotating Parts can cause Do not touch engine precautions and procedures when severe injury. while operating or just installing flywheel. Stay away while engine after stopping. is in operation. Never operate engine with heat WARNING Keep hands, feet, hair, and shields or guards removed. Uncoiling Spring can clothing away from all moving cause severe injury. parts to prevent injury. Never WARNING operate engine with covers, Wear safety goggles or shrouds, or guards removed. Cleaning Solvents can face protection when cause severe injury or servicing retractable death. starter. WARNING Use only in well Retractable starters contain a Carbon Monoxide can ventilated areas away powerful, recoil spring that is cause severe nausea, from ignition sources. under tension. Always wear safety fainting or death. goggles when servicing retractable Carburetor cleaners and solvents Avoid inhaling exhaust are extremely flammable. Follow starters and carefully follow fumes. cleaner manufacturer’s warnings instructions in Retractable Starter and instructions on its proper and for relieving spring tension. Engine exhaust gases contain poisonous carbon monoxide. safe use. Never use gasoline as a Carbon monoxide is odorless, cleaning agent. colorless, and can cause death if inhaled. 2 KohlerEngines.com 14 690 01 Rev. G Maintenance MAINTENANCE INSTRUCTIONS WARNING Accidental Starts can cause severe injury or Before working on engine or equipment, disable engine as death. follows: 1) Disconnect spark plug lead(s). 2) Disconnect negative (–) battery cable from battery. Disconnect and ground spark plug lead(s) before servicing. 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 dealer. MAINTENANCE SCHEDULE After first 3-5 Hours ● Change oil. Lubrication System Every 25 Hours or Annually¹ ● Service/replace precleaner. Air Cleaner/Intake ● Check air cleaner for dirty, loose or damaged parts. Air Cleaner/Intake Every 50 Hours or Annually ● Change oil. Lubrication System ● Replace fuel filter (if equipped). Every 50 Hours or Annually¹ ● Replace air cleaner element. Air Cleaner/Intake Every 100 Hours or Annually¹ ● Clean spark arrestor (if equipped). Every 100 Hours or Annually² ● Have combustion chamber decarbonized. Every 125 Hours or Annually¹ ● Replace spark plug and set gap. Electrical System 1 Perform these procedures more frequently under severe, dusty, dirty conditions. 2 Have a Kohler authorized dealer perform this service. REPAIRS/SERVICE PARTS Kohler genuine service parts can be purchased from Kohler authorized dealers. To find a local Kohler authorized dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada). 14 690 01 Rev. G KohlerEngines.com 3 Maintenance OIL RECOMMENDATIONS STORAGE We recommend use of Kohler oils for best performance. If engine will be out of service for 2 months or more Other high-quality detergent oils (including synthetic) follow procedure below. of API (American Petroleum Institute) service class SJ 1. Add Kohler PRO Series fuel treatment or equivalent or higher are acceptable. Select viscosity based on to fuel tank. Run engine 2-3 minutes to get stabilized air temperature at time of operation as shown in table fuel into fuel system (failures due to untreated fuel below. are not warrantable). 2. Change oil while engine is still warm from operation. Remove spark plug(s) and pour about 1 oz. of engine oil into cylinder(s). Replace spark plug(s) and crank engine slowly to distribute oil. 3. Disconnect negative (-) battery cable. 4. Store engine in a clean, dry place. FUEL RECOMMENDATIONS WARNING Explosive Fuel can cause fires and severe burns. Do not fill fuel tank while engine is hot or running. Gasoline is extremely flammable and its vapors can explode if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied buildings, away from sparks or flames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Never use gasoline as a cleaning agent. NOTE: E15, E20 and E85 are NOT approved and should NOT be used; effects of old, stale or contaminated fuel are not warrantable. Fuel must meet these requirements: ● Clean, fresh, unleaded gasoline. ● Octane rating of 87 (R+M)/2 or higher. ● Research Octane Number (RON) 90 octane minimum. ● Gasoline up to 10% ethyl alcohol, 90% unleaded is acceptable. ● Methyl Tertiary Butyl Ether (MTBE) and unleaded gasoline blend (max 15% MTBE by volume) are approved. ● Do not add oil to gasoline. ● Do not overfill fuel tank. ● Do not use gasoline older than 30 days. 4 KohlerEngines.com 14 690 01 Rev. G Specifications ENGINE IDENTIFICATION NUMBERS Kohler engine identification numbers (model, specification and serial) should be referenced for efficient repair, ordering correct parts, and engine replacement. Model. . . . . . . . . . . . . . . . . . . . . XT-6 Courage Engine Vertical Shaft Numerical Designation Specification . . . . . . . . . . . . . . . XT149-0001 Serial. . . . . . . . . . . . . . . . . . . . . 4223500328 Year Manufactured Code Factory Code Code Year 42 2012 43 2013 44 2014 GENERAL SPECIFICATIONS3,6 XT-6, XTR-6 XT6.5, XT650, XT-7, XTR-7, XT6.75, XT675 XT775, XT8 Bore 65 mm (2.6 in.) 70 mm (2.8 in.) Stroke 45 mm (1.8 in.) Displacement 149 cc (9.1 cu. in.) 173 cc (10.6 cu. in.) Oil Capacity (refill) 0.6 L (20 oz.) Maximum Angle of Operation (@ full oil level)4 20° TORQUE SPECIFICATIONS3,5 XT-6, XTR-6 XT6.5, XT650, XT-7, XTR-7, XT6.75, XT675 XT775, XT8 Air Cleaner Base Stud Fastener 8 N·m (71 in. lb.) Crankcase Fastener 8 N·m (71 in. lb.) Blower Housing Stud 10 N·m (88 in. lb.) Nut 8 N·m (70 in. lb.) Brake Mounting Fastener 9.5 N·m (84 in. lb.) Breather Cover Fastener 10 N·m (88 in. lb.) Carburetor Stud Fastener 8 N·m (71 in. lb.) 3 Values are in Metric units. Values in parentheses are English equivalents. 4 Exceeding maximum angle of operation may cause engine damage from insufficient lubrication. 5 Lubricate threads with engine oil prior to assembly. 6 Any and all horsepower (hp) references by Kohler are Certified Power Ratings and per SAE J1940 & J1995 hp standards. Details on Certified Power Ratings can be found at KohlerEngines.com. 14 690 01 Rev. G KohlerEngines.com 5 ) Exhaust Stud Nut Fastener 9.) Pivot Jam Nut 9.5 N·m (38 ft.) Ignition Spark Plug 27 N·m (20 ft.5. lb. lb. XT675 XT775.5 N·m (84 in. Perma-Loc HL 126.0 N·m (98 in.) Cylinder Head Fastener (torque in 2 increments) first to 14 N·m (123 in.com 14 690 01 Rev.) 3 Values are in Metric units.) Bracket to Tank Fastener 4.) Module Fastener 10 N·m (88 in.5 N·m (84 in. Approved sealants include Perma-Loc LH 150. lb. No excess sealant allowed on inside or outside of joint.) Flywheel Retaining Nut 51.5 N·m (40 in. lb. Perma-Loc HH 120. 6 KohlerEngines.Specifications TORQUE SPECIFICATIONS3. lb.) Muffler Exhaust Stud 5.) Governor Lever Fastener 9. lb.) Crankcase Oil Drain Plug7 13. XTR-6 XT6. G .) Rocker Arm Stud 13.) Valve Cover Fastener 8 N·m (71 in. lb.6 N·m (120 in. XTR-7. 5 Lubricate threads with engine oil prior to assembly. Perma-Loc MM 115. lb.5 XT-6. lb.5 N·m (110 in. lb. XT-7.) Gear Fastener 9. lb. lb.8 N·m (246 in. lb.5 N·m (84 in.5 N·m (84 in.0 N·m (44 in.75.6 N·m (120 in.) finally to 27. lb.) Oil Pan Screw 11. XT650. lb. lb. XT8 Connecting Rod Cap Fastener (torque in increments) 12.) Speed Control Bracket Assembly Fastener 8 N·m (71 in. lb.7 N·m (130 in. Threads with preapplied sealant do not require use of additional sealant. 7 Apply thread sealant around three full threads before assembly. lb. lb.) Screw 10 N·m (88 in.) 14.) Fuel Tank Bracket to Crankcase Stud 8 N·m (71 in.) Retractable Starter Fastener 8 N·m (71 in. XT6. Values in parentheses are English equivalents. lb. lb. 062 in.006/13.0009 in.0127 mm (0.3/0. Out-of-Round 0.0004 in.019 mm 24.06496/1.0127 mm (0.D.) Max.1809 in.) Later Models 0.385 mm (0.0228 in.) Later Models 25.0005 in. Early Models 25.) Max. Values in parentheses are English equivalents.0168/0.D.) Crankcase Governor Cross Shaft Bore I.989 mm 24.755/2.D.008/0.045 mm (0.) Bore in Oil Pan Running Clearance Early Models 0.) (2.370/25. Taper 0.) Max. Taper 0.010 mm (0.5125 in.) Max.02 mm (2. New @ 21°C (70°F) 13.00217 in.00051/0.0009 in.121 mm (0.003 in.013/0. Out-of-Flatness 0.0230/1.) (1.2362/0.017 mm (0. XT8 Camshaft End Play 0.1805/1.0009 in.) (0.0008 in.975/24.005/25.D. Early Models 24.071 mm (1. 14 690 01 Rev.58 mm (0.025 mm (0.015/0.D.) Later Models 26.9850 in.0009 in.13/0.025/0. XT6.) 0.D.08 mm (0. XTR-7. New 6.427/1.D.050/27.0004 in.985/29.0003/0.0009 in.0009 in.017 mm 18.48 mm 0.0005/0.) Max.com 7 .061/1.0031/0.) Cylinder Bore Bore I.) (0.010 mm (0. XT-7.) Piston Pin End I.03/0.) Later Models 27. G KohlerEngines.008/0.989 mm (0.756 in.975/24.) Bearing (PTO) Journal O.) (0.025 mm (0.298 mm (0. 65.025 mm (0.7088/0.02 mm 70.025 mm (0.975/24.00118/0. Out-of-Round 0.) Max.) Bearing (flywheel) Journal O. Out-of-Round 0.0234 in.0051/0.0118/0.025 mm (0. Specifications CLEARANCE SPECIFICATIONS3 XT-6.00/65.010 mm (0.0009 in.9832/0.) Connecting Rod-to-Crankpin Side Clearance New 0.0555 mm (0.06578 in.024 mm (0.) Connecting Rod Journal O. XT675 XT775. XT650.559/2. Taper 0.025 mm (0.0009/0.) Connecting Rod Connecting Rod-to-Crankpin Running Clearance New 0.985/25.006/18.0189 in.0335 in.) Connecting Rod-to-Piston Pin Running Clearance 0.) Max.9838 in.) Cylinder Head Max.000/6.95/26. New 25.421 mm (0.5.051 mm (0.) (0.) 0.00/70.0005 in.400/25.) Max.) Running Clearance 0.97 mm (1.0004 in.9844/0.002 in.9838 in.75.7093 in.995 mm (1. Out-of-Round 0. Taper 0. XTR-6 XT6.989 mm (0.) 3 Values are in Metric units.) Bore in Oil Pan I.025 mm (0.9999/1.995 mm 29.010 mm (0.9832/0.00476 in.9838 in.85 mm (0.) 0.560 in.2372 in.5120/0.) 0.) Crankshaft End Play (free) 0.0004 in.05110 in.0017 in.9988/0.9994 in. Early Models 25.9832/0. ) (0.0007/0.19 mm (0.75.0035/0.D. After Serial No.7089 in.1/0.996 mm (0. XT-7.005 in.2165/0.) (0.082 mm (0.002/13.035 mm 0.09/0.5.5118/0.) Nominal Valve Face Angle 25°.) Cross Shaft O.2170 in.2346/0.020/0.25/0.127 mm (0.0074 in.2558 in.3/0.D.40 mm 0. XT8 Governor Governor Cross Shaft -to-Crankcase Running Clearance 0.0039/0.990/17.76 mm (0.0098/0.2151/0.512 mm (0.0007/0.1/0. Before Serial No.5 mm (0. Before Serial No.003/0.) Top and Center Compression Ring End Gap New Bore.020/0.06 mm (0.5114/0.) Pin O. After Serial No.001/0.500/5. G . Values in parentheses are English equivalents.2137/0.008 mm (0.2165/0.) Valves and Valve Lifters Intake and Exhaust Valve Lash 0.2143 in.0098 in. 5.2558/0.2170 in.7543/2.D. 8 KohlerEngines. XTR-6 XT6.500/5.02/0. 13.) Gear Shaft O.) Top and Center Compression Ring Side Clearance New Bore.) Ignition Spark Plug Gap 0. XT6.480 mm (0.D.0018 in.7551 in.960/69.0118/0.25 mm (0.) Piston Thrust Face-to-Cylinder Bore Running Clearance 0.7085 in.) Intake Valve Stem Diameter 5.01/6.00004/0.7082/0. XT675 XT775.25/0. XT650.0024 in.Specifications CLEARANCE SPECIFICATIONS3 XT-6.) (2.) (0.) Governor Gear Shaft-to-Governor Gear Running Clearance 0. XTR-7.) Exhaust Valve Stem Diameter 5.0299 in.) New Bore.2366/0.5121 in.055/0. 12.) Exhaust Valve Guide I. 40243XXXXX Top 0.0197 in.2157 in.990/12.254 mm (0.0010/0.465/5.020 mm (0.0157 in.0007/0.008 mm 18. and Piston Pin Pin Bore I.030 in.) Exhaust Valve Stem-to-Valve Guide Running Clearance 0.047 mm (0.25 mm 0.0098 in.) Center 0.61/0.com 14 690 01 Rev.0025 in.) Piston. 40244XXXXX 0. 40244XXXXX Top and Center 0.985 mm 69.D.0039/0.76 mm 0.) (0.7086/0.000/18. New 5.) (0. New 6. 40243XXXXX 0.98 mm (0.975/64. 60° 3 Values are in Metric units.0240/0.D.) Intake Valve Stem-to-Valve Guide Running Clearance 0.) New Bore. 64.430/5.512 mm (0.0014 in.D.996 mm 17.03 mm (0.0021/0.00080 in. 5.060 mm (0.2354 in.0762/0.) Thrust Face O.0098/0.010 in.40 mm (0.025/0.) (0.0157 in.) Module Air Gap 0.445 mm (0.96/5. 45°.064 mm (0.5116 in. Piston Rings.0032 in.980 mm (0.0023 in.0007/0.020/0.2374 in.) Intake Valve Guide I. 3 (470) — Metric Fastener Torque Recommendations for Standard Applications Property Class Noncritical Fasteners Size 4.3 (38) 5.com 9 .8 (140) 22.5 (80) 155.8 8.3 (147) 332.7 (61) 116.6 (32) 4.9 (300) 40.9 (230) 447. lb.9 (26) 4.9 (115) — 1/2-20 94.7 (165) 311. = N·m x 8.9 12.2 (200) 440.7 (162) 94.6 (27) 47. lb.7 (16) 27.6 (85) 15.0 (150) 28.4 (60) 33.6 (100) 223. lb.0 (35) M6 4.6 (86) 139.8 (51) 8.5 (146) 6.5 (93) 13.3 (20) 2.5 (97) 184.5 (125) 237. x 1.8 (25) — 2. lb. lb.9 (70) Torque Conversions N·m = in.5 (35) 66.4 (49) 81.9 (230) — 5/8-11 149.6 (32) 4.5 (270) — — 3/8-16 29.0 (45) M14 58.3 (250) 39.2 (245) 474.0 (124) 16.) ± 10% M4 1.7 (103) 61.4 (105) 223.9 (70) 13.3 (175) — 9/16-18 135.7 (165) 7.5 (35) 82.737 14 690 01 Rev.4 (60) — 7/16-14 47.9 (300) — — — Tightening Torque: N·m (ft.0 (115) 18.5 (35) 67. x 0.) ± 10% M10 21.0 (150) 5/16-24 18. lb.5 (110) 244. lb.4 (260) — — — 3/8-24 33. 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.5 (40) — 3. = N·m x 0.7 (15) 2.1 (20) 47.1 (180) 352.4 (216) 33.5 (80) — 7/16-20 61.6 (350) 17.7 (75) 169.8 (60) M8 10.6 (55) 108.2 (11) 1. lb.6 (200) — 5/16-18 17.8 (50) 108.5 (330) — 3/4-10 199.4 (56) 131.9 Into Aluminum Tightening Torque: N·m (in.9 (88) 14. Specifications GENERAL TORQUE VALUES English Fastener Torque Recommendations for Standard Applications Bolts.7 (30) — 3/8-16 — 47.8 10.7 (165) 30. Screws.7 (360) 17.2 (40) 81.7 (75) 142.9 (70) 142.6 (120) 24.9 (70) 1/4-28 9.8 (140) 311.5 (22) 3.0 (18) M5 2.6 (350) — 3/4-16 271.1 (72) 9.8 5.7 (86) 4.4 (136) 219.356 ft.0 (45) 101.7 (165) — 9/16-12 101.3 (43) 76.85 N·m = ft.5 (40) — — 1/4-20 7.) ± 20% 8-32 2.6 (260) — 5/8-18 189.9 (25) M12 36. G KohlerEngines.7 (325) 637.7 (50) 9.8 (50) — 3/8-24 — 54.1 (36) 5.5 (105) — 1/2-13 67.0 (150) Tightening Torque: N·m (ft.) ± 20% 5/16-24 — — 40.2 (28) 5.0 (44) 2.6 (32) 10-32 3.3 (20) 10-24 3.5 (35) 74.113 in. Components of 24 761 01-S: Design Technology Inc. Cylinder Leakdown Tester Kohler 25 761 05-S For checking combustion retention and if cylinder. Alcohol Content Tester Kohler 25 455 11-S For testing alcohol content (%) in reformulated/oxygenated fuels. or valves are worn. piston. MI 48446 Westmont. Contact your local Kohler source of 415 Howard St. IL 60559 Phone 810-664-2981 Phone 630-920-1300 Toll Free 800-664-2981 Fax 630-920-0011 Fax 810-664-8181 TOOLS Description Source/Part No. EFI Service Kit Kohler 24 761 01-S For troubleshooting and setting up an EFI engine. Individual component available: Design Technology Inc. Red Wire DTI-027 Code Plug. Blue Wire DTI-029 Shrader Valve Adapter Hose DTI-037 Flywheel Puller SE Tools KLR-82408 For properly removing flywheel from engine. For checking crankcase vacuum. Adapter 12 mm x 14 mm (Required for leakdown test on XT-6 engines) DTI-731-03 Dealer Tool Kit (Domestic) Kohler 25 761 39-S Complete kit of Kohler required tools. Fuel Pressure Tester DTI-019 Noid Light DTI-021 90° Adapter DTI-023 In-line "T" Fitting DTI-035 Code Plug. Components of 25 761 39-S: Ignition System Tester Kohler 25 455 01-S Cylinder Leakdown Tester Kohler 25 761 05-S Oil Pressure Test Kit Kohler 25 761 06-S Rectifier-Regulator Tester (120 V AC/60Hz) Kohler 25 761 20-S Dealer Tool Kit (International) Kohler 25 761 42-S Complete kit of Kohler required tools. Lapeer. you’ll increase your service capabilities and customer satisfaction by decreasing engine downtime. Rubber Adapter Plug DTI-721-10 Electronic Fuel Injection (EFI) Diagnostic Software Kohler 25 761 23-S For Laptop or Desktop PC. 768 Burr Oak Drive supply. 10 KohlerEngines. faster. you can properly service engines easier.com 14 690 01 Rev. and reassembly procedures.Tools and Aids Certain quality tools are designed to help you perform specific disassembly. By using these tools. Here is a list of tools and their source. Camshaft Seal Protector (Aegis) SE Tools KLR-82417 For protecting seal during camshaft installation. Components of 25 761 42-S: Ignition System Tester Kohler 25 455 01-S Cylinder Leakdown Tester Kohler 25 761 05-S Oil Pressure Test Kit Kohler 25 761 06-S Rectifier-Regulator Tester (240 V AC/50Hz) Kohler 25 761 41-S Digital Vacuum/Pressure Tester Design Technology Inc. G . DTI-721-01 Individual component available: Design Technology Inc. SEPARATE TOOL SUPPLIERS Kohler Tools SE Tools Design Technology Inc. and safer! In addition. Camshaft Endplay Plate SE Tools KLR-82405 For checking camshaft endplay. repair. rings. Kohler 25 597 07-S Only oxime-based. Oil Pressure Test Kit Kohler 25 761 06-S For testing/verifying oil pressure on pressure lubricated engines. Hydraulic Valve Lifter Tool Kohler 25 761 38-S For removing and installing hydraulic lifters. (Command Series) Kohler 25 455 12-S For reaming worn valve guides to accept replacement oversize valves. DTI-K830 AIDS Description Source/Part No. DTI-110 Offset Wrench (K and M Series) Kohler 52 455 04-S For removing and reinstalling cylinder barrel retaining nuts. 5900® or 5910® are recommended for best sealing Loctite® Ultra Black 598™ characteristics. Loctite® Ultra Blue 587™ Loctite® Ultra Copper 5920™ Spline Drive Lubricant Kohler 25 357 12-S 14 690 01 Rev. DTI-K828 Valve Guide Reamer O. For hand reaming using Kohler 25 455 12-S reamer. aerosol dispenser. Valve Guide Reamer (K and M Series) Design Technology Inc. such as those listed. Can be used in low-speed drill press or with handle below for hand reaming. Starter Servicing Kit (All Starters) SE Tools KLR-82411 For removing and reinstalling drive retaining rings and brushes.com 11 . For properly sizing valve guides after installation. oil resistant RTV sealants. CS-PRO Regulator Test Harness DTI-031 Special Regulator Test Harness with Diode DTI-033 Spark Advance Module (SAM) Tester Kohler 25 761 40-S For testing SAM (ASAM and DSAM) on engines with SMART-SPARK™. Tools and Aids TOOLS Description Source/Part No. Rectifier-Regulator Tester (120 volt current) Kohler 25 761 20-S Rectifier-Regulator Tester (240 volt current) Kohler 25 761 41-S For testing rectifier-regulators. Camshaft Lubricant (Valspar ZZ613) Kohler 25 357 14-S Dielectric Grease (GE/Novaguard G661) Kohler 25 357 11-S Dielectric Grease Loctite® 51360 Kohler Electric Starter Drive Lubricant (Inertia Drive) Kohler 52 357 01-S Kohler Electric Starter Drive Lubricant (Solenoid Shift) Kohler 52 357 02-S RTV Silicone Sealant Loctite® 5900® Heavy Body in 4 oz. Inductive Tachometer (Digital) Design Technology Inc. are approved Loctite® 5910® for use. Reamer Handle Design Technology Inc. including CD. Individual component available: Starter Brush Holding Tool (Solenoid Shift) SE Tools KLR-82416 Triad/OHC Timing Tool Set Kohler 28 761 01-S For holding cam gears and crankshaft in timed position while installing timing belt. G KohlerEngines.S. Ignition System Tester Kohler 25 455 01-S For testing output on all systems. Loctite® Nos. For checking operating speed (RPM) of an engine. Components of 25 761 20-S and 25 761 41-S: Design Technology Inc. D. may be made out of an old junk connecting rod. tightening. cut out a six tooth 1. Bosses will lock tool and flywheel in 3. Find a 1 in.Tools and Aids FLYWHEEL HOLDING TOOL ROCKER ARM/CRANKSHAFT TOOL A flywheel holding tool can be made out of an old junk A spanner wrench to lift rocker arms or turn crankshaft flywheel ring gear and used in place of a strap wrench. Invert segment and place it between ignition bosses aligning steps of a Command rod. O. 1. to slip on capscrew and approximately 1 in.D. puller. Assemble capscrew and washer to joint surface of rod. 2.com 14 690 01 Rev. Remove studs of a Posi-Lock rod or grind off 3. Find a used connecting rod from a 10 HP or larger segment of ring gear as shown. Use a flat washer with correct I. 2. so joint surface is on crankcase so tool teeth engage flywheel ring flat. or removing with a match threads in connecting rod. G . long capscrew with correct thread size to position for loosening. Using an abrasive cut-off wheel. Grind off any burrs or sharp edges. 12 KohlerEngines. 4. engine. Remove and discard rod cap. gear teeth. stale. ignition kill circuit. water. ● Low crankcase oil level. mixture). ● Low compression. ● Faulty spark plug(s). ● Spark plug lead(s) disconnected. ● Restricted fuel tank cap vent. ● Interlock switch is engaged or faulty. ● Idle fuel adjusting needle(s) improperly set. ● Fuel pump malfunction-vacuum hose clogged or ● Radiator. ● Weak spark. stale. water. ● Battery is discharged. ● Quality of fuel (dirt. G KohlerEngines. water. restricted. ● Loose wires or connections that intermittently ground ● Diode in wiring harness failed in open circuit mode. and/or cooling system components clogged. at first.com 13 . ● Low oil level. ● Spark plug lead(s) disconnected. ● Blown fuse. ● DSAI or DSAM malfunction. mixture). ● Internal wear or damage. mixture). Engine Cranks But Will Not Start Engine Will Not Crank ● Battery connected backwards. stale. stale. be sure to check simple causes which. ● Faulty spark plug(s). ● Incorrect crankshaft position sensor air gap. ● Fuel pump malfunction-vacuum hose clogged or ● Idle speed adjusting screw improperly set. ● Spark plug lead boot loose on plug. ● Faulty key switch or ignition switch. stale. ignition kill circuit. 14 690 01 Rev. mixture). stale. ● Hydraulic lifter malfunction. Some general common causes of engine troubles are listed below and vary by engine specification. ● Lean fuel mixture. ● Faulty ignition coil(s). ● Interlock switch is engaged or faulty. ● High crankcase oil level. ● Water pump belt failed/broken. ● Restricted fuel tank cap vent. Engine Knocks ● Quality of fuel (dirt. leaking. ● Excessive engine load. mixture). ● Quality of fuel (dirt. ● Fan belt failed/off. ● Faulty or misadjusted choke or throttle controls. leaking. Engine Starts Hard ● Excessive engine load. ● Loose wires or connections that intermittently ground ● Water pump malfunction. ● Fuel shut-off valve closed. ● Inadequate fuel supply. ignition kill circuit. ● Clogged fuel line or fuel filter. mixture). ● Faulty electric starter or solenoid. ● Insufficient voltage to electronic control unit. Engine Overheats ● Cooling fan broken. ● Empty fuel tank. ● Pawls not engaging in drive cup. ● Quality of fuel (dirt. ● Low crankcase oil level. water. ● Low cooling system fluid level. water. ● Seized internal engine components. ● Incorrect oil viscosity/type. ● Faulty cylinder head gasket. water. ● SMART-SPARKTM malfunction. Engine Starts But Does Not Keep Running Engine Will Not Idle ● Faulty carburetor. ● Choke not closing. ● Interlock switch is engaged or faulty. Engine Runs But Misses ● Faulty spark plug(s). ● Flywheel key sheared. ● Carburetor adjusted incorrectly. ● Carburetor solenoid malfunction. a starting problem could be caused by an empty fuel tank. ● Faulty electronic control unit. ● Low compression. ● Clogged fuel line or fuel filter. ● Loose wires or connections that intermittently ground ● Key switch or kill switch in OFF position. Troubleshooting TROUBLESHOOTING GUIDE When troubles occur. ● Engine overheated. ● Quality of fuel (dirt. ignition kill circuit. leaking. may seem too obvious to be considered. ● Faulty ACR mechanism. ● Faulty spark plug(s). ● Engine overheated. Use these to locate causing factors. ● Fuel pump malfunction-vacuum hose clogged or ● Engine overheated. ● Interlock switch is engaged or faulty. ● Faulty carburetor. For example. or leaking. ● Ignition module(s) faulty or improperly gapped. ● Ignition module(s) faulty or improperly gapped. ● Spark plug lead loose. ● Loose wires or connections that intermittently ground ● Quality of fuel (dirt. ● Intake system leak. ● Faulty or misadjusted choke or throttle controls. indications of improper fit and seal. make a ● Faulty spark plug(s). condition. ● Low compression. Drain oil into a container. Even small amounts of these cleaners can quickly break down lubricating properties of engine oil. Dirt in throat is further indication that air cleaner was not functioning properly. Excessive sludge formation could indicate over rich fuel settings. ● Check if oil level is within operating range on dipstick. Before cleaning or disassembling engine. or leaky valves. and damaged components. or inoperative crankcase breather. grass screen. When such a cleaner is used. dirty or clogged element could indicate insufficient or ● Worn valve stems/valve guides. Look for holes. cracked or damaged sealing surfaces. stale. from workbench. G . Sludge is a natural by-product of combustion. There are many commercially available cleaners that will quickly remove grease. overextended oil change interval or wrong weight or type of oil was used. ● Check air cleaner element. Make sure all traces of cleaner are removed before engine is reassembled and placed into operation. Only clean parts can be accurately inspected and gauged for wear or damage. Gaskets ● Check carburetor throat for dirt. Carburetor cleaners and solvents are extremely flammable. clean engine thoroughly before disassembly. ● Breather reed broken. 14 KohlerEngines. worn or damaged ● Blown head gasket/overheated. ● Check air cleaner cover and base for damage or ● Clogged. ● Restricted exhaust. ● Loose or improperly torqued fasteners. ● Quality of fuel (dirt. A ● Worn or broken piston rings. clogged or inoperative breather. might be found inside engines (and cause) when it is ● Low battery. cooling fins. or other ● Worn cylinder bore. broken. ● Incorrect oil viscosity/type. should flow freely. oil. CLEANING ENGINE WARNING Cleaning Solvents can cause severe injury or death. Check for metal chips and other ● Restricted exhaust. Dirt or debris on these areas can cause overheating. thorough inspection of its external appearance and ● High crankcase oil level. broken. ● Check condition of oil. weak ignition.Troubleshooting Engine Loses Power EXTERNAL ENGINE INSPECTION ● Dirty air cleaner element. improper maintenance. This inspection can give clues to what ● Incorrect governor setting. water. If it is above. ● Low crankcase oil level. follow manufacturer’s instructions and safety precautions carefully. Follow cleaner manufacturer’s warnings and instructions on its proper and safe use. Never use gasoline as a cleaning agent. damage that could allow unfiltered air into engine. or loose fasteners. complete drainage. Oil Leaks from Oil Seals. Engine Uses Excessive Amount of Oil ● Check for obvious fuel and oil leaks. Clean individual components as engine is disassembled. and other external surfaces. sniff for gasoline odor. foreign particles. Excessive oil leakage can indicate a ● Loose or improperly torqued fasteners. ● Clogged. or inoperative crankcase breather. it ● Piston blow by. and grime from engine parts. Be sure to allow ample time for ● Excessive engine load. disassembled. After inspecting external condition of engine. Use only in well ventilated areas away from ignition sources. ● Crankcase overfilled.com 14 690 01 Rev. seals or gaskets. a small accumulation is normal. ● Check for buildup of dirt and debris on crankcase. tears. mixture). NOTE: It is good practice to drain oil at a location away ● Engine overheated. ● Breather reed broken. atmosphere. Check that water level in manometer is Insert barbed gauge fitting into hole in stopper. Leave other tube open to tube.com 15 . and clothing away from all monoxide. check table below for possible open side (pressure). Insert rubber stopper into oil fill hole. cylinder bore. If reading is below specification. A partial vacuum should be present in crankcase when engine is operating. Stay away while engine is in operation. and movement to right indicates a pressure. Open clamp and note water level in tube. cm (4 in. valves guides. Piston blow by or leaky valves (confirm by inspecting Recondition piston. Make sure pinch clamp is closed. Remove dipstick or oil fill plug/cap. Check exhaust screen/spark arrestor (if equipped). Make fasteners. sure all fasteners are tightened securely. vacuum. Rotating Parts can cause severe injury. Seals and/or gaskets leaking. gaskets. at 0 line. Engine exhaust gases contain poisonous carbon Keep hands. clamp is installed on hose and use tapered adapters 2. Carbon monoxide is odorless. hair. feet. clean parts thoroughly. below. Install adapter into oil fill//dipstick tube opening. 4. to connect hose between stopper and one upside down over end of a small diameter dipstick manometer tube. or other available spots. Complete instructions are provided in kits.2 Digital tester–depress test button on top of tester. Avoid inhaling exhaust fumes. 3. or directly into engine if a tube is not used. or if vacuum).) of water. Crankcase vacuum should be a minimum of 10. Level in engine side should be a minimum of 10. shrouds. Pressure in crankcase (normally caused by a clogged or improperly assembled breather) can cause oil to be forced out at oil seals. Never operate engine and can cause death if inhaled. G KohlerEngines. 14 690 01 Rev. 2. Be sure pinch 1. or level in engine side is lower than level in pressure is present. or guards removed. Run engine and observe gauge reading. Repair or replace any other damaged/restricted muffler or exhaust system parts. Clean or replace as needed. moving parts to prevent injury. replace valve cover and recheck pressure. check sealing surfaces for flatness. Start engine and run no-load high speed. Analog tester–needle movement to left of 0 is a 3. colorless. Use appropriate torque valves and sequences when necessary. valves and components). To test crankcase vacuum with manometer: To test crankcase vacuum with vacuum/pressure gauge: 1. Troubleshooting CRANKCASE VACUUM TEST WARNING WARNING Carbon Monoxide can cause severe nausea. rings.2 cm If level in engine side is less than specified (low/no (4 in. Condition Conclusion Crankcase breather clogged or inoperative. fainting or death. Close pinch clamp before stopping engine. reassemble. NOTE: If breather is integral part of valve cover and cannot be serviced separately. Restricted exhaust. Disassemble breather. Loose or improperly torque Replace all worn or damaged seals and gaskets. and recheck pressure. check for conditions in table causes and conclusions.) above level in open side. Crankcase vacuum is best measured with either a water manometer or a vacuum gauge. with covers. but do not attach it to tester at this time. use cylinder leakdown test described below. 5. Just be certain that engine cannot rotate off of TDC in either direction. Ring or cylinder worn. Lock holding tool onto crankshaft. 8. G . 2. Condition Conclusion Air escaping from crankcase breather. Engine is still usable. Air escaping from intake. 1. Compression should be at least 160 psi and should not vary more than 15% between cylinders. 6. Rotate crankshaft until piston (of cylinder being tested) is at top dead center (TDC) of compression stroke. Install a 3/8 in. and crankcase breather. Gauge reading in high (red) zone. Be sure choke is off. An assistant may be needed to hold breaker bar during testing. use a breaker bar and socket on flywheel nut/screw to hold it in position. Turn regulator knob completely counterclockwise. By pressurizing combustion chamber from an external air source you can determine if valves or rings are leaking. it may be possible to hold it by clamping or wedging a driven component. Gauge reading in low (green) zone. Engine should be reconditioned or replaced. breaker bar into hole/slot of holding tool. Gauge reading in moderate (yellow) zone. Piston rings and cylinder in good condition. and how badly. Turn regulator knob clockwise (increase direction) until gauge needle is in yellow set area at low end of scale. Connect an air source of at least 50 psi to tester. Run engine for 3-5 minutes to warm it up.Troubleshooting COMPRESSION TEST For Command Twins: A compression test is best performed on a warm engine. Defective intake valve/improper seating. As an alternative. inexpensive leakdown tester for small engines. gradually open tester valve. 7. Connect tester quick-connect to adapter hose. Note gauge reading and listen for escaping air at combustion air intake. Customer should start planning for overhaul or replacement. Defective exhaust valve/improper seating. If engine is mounted in a piece of equipment. 4. 16 KohlerEngines. Rings and/or cylinder have considerable wear. Remove spark plug(s) and air filter from engine. but there is some wear present. Cylinder leakdown tester is a relatively simple. Clean any dirt or debris away from base of spark plug(s) before removing them. If flywheel end is more accessible. While firmly holding engine at TDC.com 14 690 01 Rev. CYLINDER LEAKDOWN TEST A cylinder leakdown test can be a valuable alternative to a compression test. Hold engine in this position while testing. It is difficult to obtain an accurate compression reading because of ACR mechanism. 3. This tester includes a quick-connect for attaching adapter hose and a holding tool. so it is perpendicular to both holding tool and crankshaft PTO. Air escaping from exhaust system. exhaust outlet. and throttle is wide open during test. All other models: These engines are equipped with an automatic compression release (ACR) mechanism. Install adapter into spark plug hole. Holding tool supplied with tester can be used if PTO end of crankshaft is accessible. should not be altered or modified in any way. 14 690 01 Rev. Replace or wash precleaner in warm water with Air Cleaner Components detergent. Install element with foam side out and seat rubber seal onto edges of base. Loosen knob or unhook latch and remove air cleaner cover. D C Reinstall air cleaner cover and secure with knob or latch. To prevent over heating. BREATHER TUBE B Make sure both ends of breather tube are properly connected. Install element with pleated side out and seat rubber seal onto edges of base. clean screens.com 17 . Remove foam element from base and replace. 2. F AIR COOLING WARNING Hot Parts can cause severe burns. Remove paper element from base and replace. G KohlerEngines. Air Cleaner/Intake AIR CLEANER Precleaner (if equipped) These systems are CARB/EPA certified and components 1. and other external surfaces B of engine. 2. Refer to Maintenance Schedule. Reinstall precleaner into cover. aligning hole in C precleaner with upper cover knob. Remove precleaner. 2. Rinse and allow to air dry. Paper Element E 1. cooling fins. Replace all bent or damaged components. A Never operate engine with heat shields or guards removed. Avoid spraying water at wiring harness or any electrical components. Do not touch engine while operating or just after stopping. NOTE: Paper element cannot be blown out with compressed air. D C Proper cooling is essential. D 3. F A A Air Cleaner Cover B Precleaner C Paper Element D Base E Air Cleaner Knob F Air Cleaner Latch NOTE: Operating engine with loose or damaged air cleaner components could cause premature wear and failure. Foam Element A 1. Use an approved fuel container to catch fuel. Check operation of fuel shut-off valve. Fuel is reaching combustion chamber. b. FUEL SYSTEM TESTS When engine starts hard. ● Fuel tank. Close choke on carburetor. fuel system might be causing problems. Condition Conclusion Fuel at tip of spark plug. a. Check for a restriction in fuel shut-off valve or inlet elbow. Check for fuel in combustion chamber. line to carburetor. 3. Check fuel flow from fuel tank (step 2). d. carburetor. Fuel flows from fuel line. Correct any observed problem and reconnect line. No fuel flow from fuel line. Disconnect and ground spark plug lead. regulatory compliance.Fuel System Typical carbureted fuel system and related components FUEL RECOMMENDATIONS include: Refer to Maintenance. G . refer to Carburetor. Clean bowl and screen as needed. Test fuel system by performing following tests. It controls fuel flow from tank to carburetor. or turns over but will not start. Check operation of fuel shut-off valve (step 3). a. 18 KohlerEngines. engines to maintain EPA and CARB ● Fuel shut-off valve (if equipped). FUEL SHUT-OFF (if equipped) Fuel tank outlet is located above carburetor inlet. Remove fuel line from inlet fitting of carburetor. ● Carburetor. 1.com 14 690 01 Rev. a. Check for dirt and water in sediment bowl and screen. Crank engine several times. Fuel enters carburetor through fuel shut-off valve and sediment bowl and then goes to carburetor float bowl. No fuel flows from valve. No fuel at tip of spark plug. Remove spark plug and check for fuel at tip. Some engines are equipped with a fuel shut-off located allowing gravity to feed fuel through in-line filter and fuel at carburetor. and fuel line. Remove fuel sediment bowl under inlet fitting of b. ● In-line fuel filter. in-line filter threaded into tank. Low permeation fuel line must be installed on carbureted ● Fuel tank filter (in-nipple). Check fuel tank vent. Check for faulty carburetor. Check for fuel flow from tank to carburetor. c. Turn fuel shut-off valve ON and OFF and observe operation. FUEL LINE ● Fuel line. Fuel is drawn into carburetor body and mixed with air. Fuel flows from valve. b. Kohler Co. and hold line below bottom of tank to observe fuel flow. 2. This fuel-air mixture is then burned in engine combustion chamber. com 19 . Typical One-Barrel Carburetor Components These engines are equipped with a fixed main jet carburetor. 1. fuel tank filter screen. 6. in well ventilated. fresh gasoline. Fuel System CARBURETOR WARNING Gasoline is extremely flammable and its vapors can explode if ignited. Spilled fuel could ignite if it comes Do not fill fuel tank while engine is hot or in contact with hot parts or sparks from ignition. unoccupied buildings. I exhaust system. or stalls at low idle speed. This includes checking fuel shut-off valve. gasoline as a cleaning agent. from sparks or flames. and throttle and choke controls are operating properly. Make sure air cleaner base and carburetor are E G securely fastened to engine using gaskets in good condition. fuel lines and fuel pump for D F restrictions or faulty components as necessary. Carburetor is designed to deliver correct fuel- A to-air mixture to engine under all operating conditions. 4. Idle mixture is set at factory and cannot be adjusted. 3. H 5. check these areas before adjusting or disassembling carburetor. B Troubleshooting Checklist When engine starts hard. Make sure fuel is reaching carburetor. Make sure air cleaner element (including precleaner if equipped) is clean and all air cleaner components are fastened securely. Never use running. 2. Make sure fuel tank cap vent is not blocked and is operating properly. Store gasoline only in approved Explosive Fuel can cause fires and severe containers. away burns. J K L M N O Low Idle Speed A B Idle Jet Adjusting Screw C Fuel Shut-Off Gasket D Wave Washer E Fuel Shut-Off Valve F Main Nozzle Tube G Main Jet H Bowl Gasket I Fuel Inlet Needle J Spring K Hinge Pin L Float Bowl Retaining Screw M Fuel Bowl N Gasket O Bowl Retaining Screw 14 690 01 Rev. C in-line fuel filter. Make sure ignition system. G KohlerEngines. runs rough. governor system. Make sure fuel tank is filled with clean. Low Idle Speed (RPM) Adjustment Slow and Mid-Range NOTE: Actual low idle speed depends on application. dirt in fuel delivery Clean main fuel jet and all passages. sooty exhaust smoke. clean needle and seat and blow with compressed air. Air and fuel are mixed in body of slow jet and exit to idle progression (transfer port) chamber. Dirt under fuel inlet needle. cracked. Place throttle control into idle or slow position. choke is operating properly. Replace float. hunting. or excessive throttle opening). 20 KohlerEngines. When fuel is being consumed. or excessive throttle opening). Clean vent. and air bleeds. Carburetor Circuits Carburetor Adjustments Float NOTE: Carburetor adjustments should be made only Fuel level in bowl is maintained by float and fuel inlet after engine has warmed up. Idle seat. or Low idle fuel mixture (some models)/ Adjust idle speed screw or clean stalls at idle speed. loss of speed and power. Blow out all passages with compressed air. As throttle plate opening increases. Turn low From idle progression chamber. G . As throttle plate opens further. Float damaged. NOTE: Main and slow jets are fixed and size specific and can be removed if required. Clogged air cleaner. pressure. Replace gasket. Blow out with compressed air. Accidental Starts can cause severe injury or Main (high-speed) death. or damaged float. Main drop and fuel pressure will push inlet needle away from fuel jet is calibrated at factory and is not adjustable. Engine runs lean (indicated by Idle holes plugged. Disconnect negative (–) battery cable from battery. This mixture is then mixed with main body of Carburetor Servicing air and delivered to engine. Dirt under fuel inlet needle. Disconnect and ground spark plug lead(s) As a metered amount of air is drawn through air jet. needle. mixture is controlled by setting of idle fuel adjusting screws. no adjustment is possible. fuel is drawn through main jet. governor operation. At low idle air/fuel speed of 1800 RPM (± 75 RPM). misfiring. Carburetor has a fixed engine as follows: 1) Disconnect spark plug lead(s). runs rough. Remove needle. Remove needle. channels. As Refer to equipment manufacturer’s a metered amount of air is drawn through slow air bleed recommendations. Submerge float to check for leaks. allowing more fuel to enter bowl. buoyant force of float will again overcome fuel adjustable. disable delivered to combustion chamber. through slow jet. Carburetor bowl gasket leaks. float will mixture to engine under all operating conditions. blow out with compressed air.com 14 690 01 Rev. Leaky. 2) main circuit. Bowl vents plugged. When demand fuel adjusting needles are also set at factory and are not ceases. Engine runs rich (indicated by black. rising to predetermined setting and stop flow. Air and fuel are mixed in main nozzles then enters main body of airflow where further mixing of fuel and air occurs. Submerge float to check for leaks. clean needle and seat and blow with compressed air. governor hunting. vacuum signal becomes great enough at venturi so main circuit begins to work. Buoyant force of float stops fuel flow when Carburetor is designed to deliver correct fuel-to-air engine is at rest. fuel is drawn through main jet and further metered engines is 1800 RPM. loss Choke partially closed during Check choke lever/linkage to ensure of speed and power.Fuel System Troubleshooting-Carburetor Related Causes Condition Possible Cause Conclusion Engine starts hard. carburetor. At low speeds engine operates only on slow circuit. before servicing. Fuel leaks from carburetor. misfiring. Clean or replace air cleaner. Bowl vent or air bleeds plugged. Low idle speed for basic jets. speed improperly adjusted. This mixture is then Before working on engine or equipment. air fuel mixture is idle speed adjusting screw in or out to obtain allow idle metered through idle port passage. ports. greater amounts of air/fuel mixture are drawn WARNING in through fixed and metered idle progression holes. At high speeds/loads engine operates on main circuit. Fixed jets for high altitudes are available. Vacuum/Diaphragm wear or damage. Fuel can also be drained C prior to bowl removal by loosening/removing bowl drain screw. Seat for inlet D E needle is not serviceable and should not be removed. Gently actuate linkage and observe that choke plate has full range of movement (open and close).). holes. ● Inspect fuel inlet needle and seat for wear or damage. Carefully remove main jet from carburetor. do not use starting. Do not damage fuel bowl O-rings. 2. Design ● Inspect float for cracks. Save parts for cleaning and reuse unless a jet kit is system. Clean slow jets using a smooth choke system that facilitates easy reliable compressed air or carburetor cleaner. diaphragm design auto choke system and its Carburetor is now disassembled for appropriate cleaning components. wire. This engine should be operated in its original configuration below 1219 meters (4000 ft. Remove air cleaner cover. Housing 5. Check float hinge and shaft for wear or damage. 4. A diaphragm that operates from intake manifold vacuum assists spring 6.com 21 . Save all parts. air cleaner. Use following procedures to troubleshoot vacuum/ NOTE: There are 2 O-rings on body of idle jet. Clean exterior surfaces of dirt or foreign material before disassembling carburetor.) as damage may occur if high altitude carburetor kit is installed and operated below 1219 meters (4000 ft. and missing or damaged float tabs. End with 2 raised shoulders A bimetallic spring reacts to muffler heat and moves should be out/down adjacent to main jets. See instructions a cold engine. Cover. Remove float pin and inlet needle. C Breather Cover D Air Cleaner Base 1. main nozzles can be removed E Vacuum Hose through bottom of main towers.). and Breather Cover High Altitude Operation Engines may require a high altitude carburetor kit to C ensure correct engine operation at altitudes above 1219 meters (4000 ft. and breather cover from air cleaner base. Note orientation/ direction of nozzles. These procedures are to be performed on and installation of parts in overhaul kit. Clean carburetor bowl and inlet seat areas as Bimetallic Spring A B Linkage required. Element. Perform removal procedures for appropriate air cleaner and carburetor outlined in Disassembly. identify design and follow appropriate troubleshooting procedure. linkage that opens or closes choke. 3. com or call 1-800-544-2444 (U. and Canada). These two elements work together to operate also being installed. and other Auto Choke Components . Transfer any remaining fuel into an approved container. and carefully separate fuel bowl from carburetor. 2. Remove bowl A retaining screws. G KohlerEngines. Refer to Disassembly/ Inspection and Service and Reassembly A Air Cleaner Cover B Element procedure. After C Diaphragm Assembly D Choke Plate main jet is removed. provided with repair kits for more detailed information. Fuel System ● Inspect carburetor body for cracks. A NOTE: Procedures may be easier to perform with engine cover removed. Check choke linkage for binding or debris build up. 14 690 01 Rev. holes. D Auto Choke Troubleshooting (if equipped) B If engine is equipped with auto choke.S. B 1. To obtain high altitude kit information or to find a Kohler authorized dealer visit KohlerEngines. Attach vacuum hose to carburetor vacuum fitting. If diaphragm assembly is unable to open choke plate. B Diaphragm Assembly and Hose A D Bimetallic Spring C A Choke Plate B Assembly A B A Choke Plate B Vacuum Hose C Vacuum Fitting D Diaphragm Assembly 5. check again for binding of restricted linkage. Remove vacuum hose from carburetor vacuum Choke Plate and Bimetallic Spring Housing fitting.com 14 690 01 Rev. 22 KohlerEngines. Choke plate should open 1/2 to 3/4 under vacuum and with a minimum of 15" of water. This action is performed by bimetallic spring assembly being heated. Choke plate should gradually change to full open position after 2 to 2-1/2 minutes of running. leaks. NOTE: Inspect to ensure choke linkage is not binding. recheck linkage for binding.Fuel System 3. If reading is correct. or restrictions. If vacuum indicated is less than 15" of water. Note position of choke plate. If hose is in working condition and choke plate fails to open with specified vacuum. replace diaphragm assembly. G . Gauge should indicate a vacuum with a minimum of 15" of water. 7. problem is not an auto choke issue. Attach a vacuum pump to vacuum hose. If choke plate fails to open. 6. Start engine. Run engine while holding choke plate open. If necessary replace bimetallic spring assembly. Upon start up choke plate should be 1/2 to 3/4 open. Attach a vacuum gauge or manometer to carburetor vacuum fitting. or diaphragm fails to hold choke plate open for a minimum of 3 seconds. 4. check hose for cracks. If necessary replace vacuum hose. spring around base of choke shaft holds choke closed for starting. Fuel System Auto Choke Components . governor closes throttle from wide open to set governor speed. Remove air cleaner cover and element. There should not be any binding when choke shaft assembly is rotated. bimetallic spring overcomes choke shaft spring force and holds choke completely open. When engine is started. When engine starts. G KohlerEngines.Link Design When engine is cold. Reinstall air cleaner element and secure cover. Use these steps to check function of link design auto choke. 6. 5. A 1. choke plate should be 1/3 open. D C 4. which could cause choke to remain partially open. Choke plate should start to open and be completely open within 2 to 3 minutes at room B temperature.com 23 . Choke plate should be fully close when engine is cold. link between throttle and choke operates choke to a slightly open position. There should be light spring tension holding choke closed. As throttle closes. A E D C Bimetallic Spring A B Wire Choke Linkage Housing C Choke Plate D Choke Lever E Choke Link 14 690 01 Rev. 2. After engine B warms up. E 3. Governor gear/flyweight mechanism of lever of carburetor through external throttle linkage.Governor System GOVERNOR Governor Components B C A G K F D E H J I Intermediate Control A Control Spring B C Control Bracket D Governor Lever Lever E Compression Spring F Linkage G Regulating Pin H Flyweight(s) Governor Shaft I Governor Gear J Governor Gear Shaft K Retainer Governed speed setting is determined by position of ● As flyweights move outward.com 14 690 01 Rev. G . tension of governor spring holds throttle plate open. It can be variable or constant. Force applied by regulating pin against cross ● Centrifugal force acting on rotating governor gear shaft tends to close throttle plate. on engine application. they cause regulating pin throttle control. equipped with a centrifugal flyweight mechanical Rotating action of cross shaft is transmitted to throttle governor. mechanical governor is mounted inside crankcase and is ● When engine is at rest. Governor spring assembly causes flyweights to move outward as tension and force applied by regulating pin balance speed increases. 24 KohlerEngines. speed. Most engines are ● One end of cross shaft protrudes through crankcase. governor gear assembly is This governor design works as follows: rotating. and throttle is in fast position. to maintain engine them inward as speed decreases. When engine is operating. Governor spring tension moves each other during operation. driven off gear on camshaft. under changing load conditions. depending to move outward. ● Regulating pin contacts tab on cross shaft causing Governor is designed to hold engine speed constant shaft to rotate. increasing engine speed. Governor System ● When load is applied and engine speed and governor gear speed decreases. 1.com 25 . governor spring tension and force applied by regulating pin will again offset each other to hold a steady engine speed. 4. 2. governor spring tension moves governor arm to open throttle plate wider. 5. make sure throttle linkage is connected to both governor arm and throttle lever on carburetor. To ensure proper adjustment. Then torque nut to 9. This allows more fuel into engine.). 14 690 01 Rev. As speed reaches governed setting. Initial Governor Adjustment Make this initial adjustment whenever governor arm is loosened or removed from cross shaft. 3. Hold both in this position and torque governor lever bolt to 10 N·m (88. lb.). Rotate governor shaft clockwise until it stops.5 in. Loosen governor lever adjustment screw. lb. Grasp cross shaft with a pliers and turn shaft clockwise as far as it will go. G KohlerEngines. Do not apply excess force that may flex or distort throttle link.5 N·m (84 in. Move governor lever away from carburetor (wide open throttle). b. Remove dipstick. 5. upright. Threaded cap: reinsert dipstick into tube. Reinstall oil fill cap/dipstick and tighten securely.6 N·m (120 in. Fill crankcase with new oil. Remove dipstick. check oil level. After crankcase is drained completely. If oil is low on indicator. lb. Lubrication Components C A B D D A 1/4 Turn Cap B Threaded Cap C Air Cleaner D Crankcase Plugs OIL RECOMMENDATIONS CHANGE OIL Refer to Maintenance. drain oil into appropriate container. or 5. Dispose of used oil in accordance with local on tube.). Remove oil fill cap/dipstick. Dispose of used oil in accordance with local ordinances. Reinstall and secure dipstick. 1/4 turn cap: reinsert dipstick into tube. 2. do not thread cap onto tube. 3. 6. Apply thread sealant around three full threads of drain plug. 1. Fill crankcase with new oil.Lubrication System These engines use a splash lubrication system. any debris. connecting rod. add oil up to top of indicator 2. 26 KohlerEngines. Level should be at top of completely down and turn 1/4 turn. Tilt engine on its side operating range indicator on dipstick. Reinstall oil fill cap/dipstick and tighten securely. tilt engine 1. Level should be at top of indicator on dipstick. cap/dipstick. supplying necessary lubrication to crankshaft. Level should be at Crankcase plug top of indicator on dipstick. Torque drain plug to 13. ordinances. 3. never run engine with oil level below or above 2. Remove crankcase plug on bottom of engine. CHECK OIL LEVEL Dipstick tube NOTE: To prevent extensive engine wear or damage. and valve train components. Clean area around oil fill cap/dipstick. 4. camshaft. 3. press 4. Remove oil fill mark. wipe oil off. reinstall drain plug. G . Drain oil into appropriate Ensure engine is cool. a. 1. with air cleaner facing up. 7. 4. Disable engine by disconnecting spark plug.com 14 690 01 Rev. Clean area around oil fill cap/dipstick. Clean oil fill cap/dipstick areas of container. indicator on dipstick. rest cap 6. Change oil while engine is warm. XT675. 0. Deposits on tip are an indication of general Electrical Shock can cause injury.76 mm (0. G KohlerEngines.75. Worn C D A Wire Gauge B Spark Plug C Ground Electrode D Gap NOTE: Do not clean spark plug in a machine using abrasive grit. Replace a worn condition. XT8* XT8* Gap 0.5. center electrode will be rounded and by a spark plug that has improper gap or is in poor gap will be greater than specified gap.76 mm (0. Torque plug to 27 N·m (20 ft.) 15.1 mm (3/4 in. Electrical System SPARK PLUGS Inspection CAUTION Inspect each spark plug as it is removed from cylinder head.9 mm (5/8 in.03 in. and carburetor. spark plug immediately. 1.) 19. Engine misfire or starting problems are often caused On a worn plug. XT-7. *Order replacement spark plug based on size in XT8 engine being serviced. XT6. valves. Check gap using wire feeler gauge. plug can be set to proper gap and reused. XTR-6. Install plug into cylinder head. a breather problem.com 27 .). a carburetor problem. Do not touch wires while engine is running. or operating engine with too much choke.) Refer to Maintenance for Repairs/Service Parts. or valve guides. caused by a restricted air cleaner. Adjust gap to worn piston rings. Oil in combustion chamber is usually Clean out spark plug recess. Excess fuel could be caused by a restricted air Service cleaner. XTR-7.76 mm (0.) Hex Size 18 mm (3/4 in. 3.03 in. lb. Engine is equipped with following spark plugs: Wet Fouled XT-6. Normal and fouled plugs are shown in following photos: Normal Spark Plug Component and Details A B Plug taken from an engine operating under normal conditions will have light tan or gray colored deposits. XT6. 14 690 01 Rev.1 mm (3/4 in.03 in.) 0. Some grit could remain in spark plug and enter engine causing extensive wear and damage. If center electrode is not worn. 2.) Thread Size 12 mm 14 mm Reach 19.). Remove plug and replace. XT775. XT650. condition of piston rings. A wet plug is caused by excess fuel or oil in combustion chamber. or incorrect spark timing are normal causes for high combustion temperatures. This condition is usually accompanied by excessive gap erosion. G . Overheated Chalky. an intake air leak. 28 KohlerEngines.com 14 690 01 Rev. Lean carburetor settings. weak ignition. white deposits indicate very high combustion temperatures. or poor compression. black deposits indicate incomplete combustion caused by a restricted air cleaner. over rich carburetion.Electrical System Carbon Fouled Soft. sooty. mounted on engine crankcase. it causes voltage in secondary coil to transformer. magnetic field induces current in primary Current pulse is rectified by a diode and this signal coil. Make sure ignition switch is in run position. no maintenance or timing adjustments are necessary or possible. G KohlerEngines. ● Electronic.254 mm (0. permanently affixed to flywheel. a change in polarity of signal produced by semiconductor switch.) As flywheel rotates and magnet passes CDI ignition As flywheel rotates and magnet passes IDI ignition module. This system consists of following components: ● Spark plug with metal boot. engine. ● Electronic. Electrical System ELECTRONIC IGNITION SYSTEM These engines are equipped with dependable solid-state magneto ignition systems. As magnetic directly connects charged capacitor to primary coil of field collapses. ● Magnets. A high voltage pulse combustion chamber. Both ignition systems are designed to be trouble free for life of engine. As magnet completes current in a small triggering coil. which then turns on a its pass. magnetic field induces current in charging coil. check all external wiring.010 in. This system consists of following is then delivered to spark plug. 14 690 01 Rev. Refer to Troubleshooting to determine root of a reported problem. This causes previously induced flywheel magnet turns on semiconductor switch.) 0.010 in. it induces charges a high-voltage capacitor. Be certain all terminal connections fit snugly. CDI Module Operation (aluminum flywheel) IDI Module Operation (cast iron flywheel) Ignition System Components Ignition System Components H H I J G G J F E I E D D C C A B A B F Kill Switch/ Kill Switch/ A Off Position of B Flywheel A Off Position of B Flywheel Key Switch Key Switch C Magnet D Ignition Module C Magnet D Ignition Module E Lamination F Kill Terminal E Lamination F Kill Terminal G Spark Plug H Spark Plug Boot G Spark Plug H Spark Plug Boot Air Gap Air Gap I Spark Plug Terminal J I Spark Plug Terminal J 0. This sharp rise in voltage is sufficient to at primary winding is transformed to high voltage in arc across spark plug’s gap. ● Kill switch (or key switch). Reported ignition problems are most often due to poor connections.254 mm (0. permanently affixed to flywheel. where it arcs across components: electrode gap and ignites fuel in combustion chamber. Be certain all ignition-related wires are connected. low voltage rise quickly. capacitive discharge ignition (CDI). Before beginning test procedure. and ignite fuel mixture in secondary winding of module. module.com 29 . capacitive discharge ignition module ● Kill switch (or key switch). As capacitor discharges energy. Two types of ignition modules are used on these engines. and magnetic field in primary coil to collapse. inductive discharge ignition module ● Spark plug with rubber boot. As ignition magnet completes its pass. ● Magnets. and inductive discharge ignition (IDI). including spark plug leads. Mechanical systems do occasionally fail or break down. grounds module to stop engine. grounds module to stop mounted on engine crankcase. Other than periodically checking/replacing spark plugs. Test for spark with ignition tester. G . Make sure gap is set to 0. produced. Connect clip to ground. kill switch produced. Check condition of spark plug. Wiring and Connections or key switch is in RUN position. and observe tester. 3. Visible and audible sparks are not Ignition Module or Make sure ignition switch. pulse. and install. Wiring and Connections wiring. If components. 2. Visible and audible sparks are not Ignition Module Replace ignition module. Spark plug in bad condition. Check all safety and operator presence control switches (for example: flywheel brake kill switch) and other components. Visible and audible sparks should be produced. Spark Plug Replace plug. test ignition module. Release switch to RUN position.Electrical System Electronic Ignition Systems Tests Test Ignition System 1. 2.030 in. including wiring and connections for accidental grounding. wiring. Disconnect spark plug lead and connect to post terminal of tester. set gap. 30 KohlerEngines. Turn engine ignition switch to START/RUN position to initiate test. reinstall plug. 1.com 14 690 01 Rev. Condition Possible Cause Conclusion Visible and audible sparks are Ignition System or Problem is elsewhere in system/ produced. Test for Spark NOTE: To maintain engine speeds obtained during cranking.). produced. do not remove spark plug. 4. Pull retractable starter or crank engine to a minimum of 500 RPM and check for spark. including terminals are all verified OK. Visible and audible sparks should be produced. Disconnect kill lead from terminal on ignition module. Condition Possible Cause Conclusion Spark plug is not receiving ignition Spark Plug Check gap and adjust if necessary. Crank engine to minimum of 500 RPM.76 mm (0. Test Ignition Module 1. Make sure spark plug lead is connected to spark plug. 2. not to spark plug. Condition Possible Cause Conclusion Visible and audible sparks are Ignition Module Ignition module is OK. when servicing retractable starters and carefully follow instructions in Retractable Starter for relieving spring NOTE: If starter does not crank engine. wiring harness. XT electric starters use brake switch for an interlock (on ground). Starter System NOTE: Do not crank engine continuously for more than RETRACTABLE STARTERS 10 seconds. cause could be brake assembly. Retractable Starter Components NOTE: Do not drop starter or strike starter frame. fuse. If starter is engaged while flywheel is Retractable starters contain a powerful. G KohlerEngines. D E K L M N F G H I J A Housing B Recoil Bushing C Recoil Plate D Recoil Spring E Pulley F Drive Pawl Springs G Drive Pawl (Dogs) H Pulley Spring I Drive Plate J Center Screw K Grommet L Starter Handle Double Left-Hand M Starter Rope N Knot O Hex Flange Nut 14 690 01 Rev. complete stop before attempting to restart engine. key switch. Allow a 60 second cool down period between starting attempts. Do not make further attempts to start engine until condition is corrected. shut off starter tension. Doing so can damage starter. starter pinion and flywheel ring gear that is under tension. When bail is held down. Always wear safety goggles may clash and damage starter. NOTE: If engine develops sufficient speed to disengage starter but does not keep running (a false start). switch in brake B assembly completes circuit of ground for starter. Uncoiling Spring can cause severe injury. Failure to follow WARNING these guidelines can burn out starter motor. Inertia drive electric starters are not serviceable. C battery. or starter itself. If there is a no crank situation. Engines in this series use inertia drive electric starters or A O retractable starters.com 31 . immediately. Wear safety goggles or face protection when engine rotation must be allowed to come to a servicing retractable starter. recoil spring rotating. remove rope from pulley. 2. Pull starter handle out until pawls engage in drive rotate slowly as spring tension is released. 7. an impact wrench should be 1. Rotate pulley counterclockwise to pre-tension spring (approximately 4 full turns of pulley). Untie slip knot and pull on starter handle until starter rope is fully extended.Starter System Remove Starter Pawls (dogs) Replacement NOTE: Whenever possible.). G . Enlist aid pulley. Rope Replacement 4. 6. 1. cup. When all spring tension on starter pulley is released. and slide 1. Place starter onto studs protruding from blower handle off. Tie a double left-hand knot in one end of new rope. 32 KohlerEngines. Pull rope out approximately 12 in. and tie a check operation of pawls. 9. Remove parts from pulley. 1. Remove starter assembly from engine. untie knot. Start nuts onto studs. starter rope will retract fully and starter handle will stop against starter housing. 11. Remove nuts securing starter to blower housing. Allow pulley to 2. left-hand knot at end of starter rope. pawl. 3. If recoil spring is properly tensioned. but do not tighten. Hold pulley firmly and untie slipknot. 8. Continue rotating pulley counterclockwise until rope hole in pulley is aligned with rope guide bushing of starter housing. Position drive plate over pawls. Install Starter 3. All parts must by dry. 2. lb. lb. 4. aligning actuating Rope can be replaced without complete starter slots in place with raised sections on each drive disassembly. Insert knot into hole in handle.).com 14 690 01 Rev. Hold handle in this position and torque nuts to 8 N·m (71 in. Tie a slipknot approximately 12 in. Remove clamp and pull starter rope out part way to 2. Install a clamp to hold pulley in starter housing and used to loosen nuts securing retractable starter. Insert unknotted end of new rope through rope hole in starter pulley and rope guide bushing of housing. 5. 12. Torque center screw to 5-6 N·m (44-54 in. prevent it from rotating. Hold pulley firmly and allow it to rotate slowly until slipknot reaches guide bushing of housing. temporary (slip) knot in it to keep it from retracting into starter. housing. 6. 10. Unscrew center screw and lift off drive plate. Insert starter rope through starter handle and tie a double. of a helper if necessary. Remove starter assembly. 5. Slowly retract starter rope into starter assembly. Note positions of pawls and pawl springs before removing. from free end of rope. Pull knot end out of handle. Install pawl springs and pawls into pawl slots of NOTE: Do not allow pulley/spring to unwind. G KohlerEngines. Disconnect and ground spark plug lead(s) before servicing. Disassembly/Inspection and Service WARNING Accidental Starts can cause severe injury or Before working on engine or equipment. follows: 1) Disconnect spark plug lead(s). External Engine Components A D B C E F G H H J I L J K K H J L K Engine Cover and Engine Cover and A B Engine Cover C D Retractable Starter Insert Retractable Start E Blower Housing F Muffler Guard G Muffler H Air Cleaner Base I Breather Hose J Paper Element K Air Cleaner Cover L Precleaner 14 690 01 Rev. disable engine as death. 2) Disconnect negative (–) battery cable from battery.com 33 . B Empty Fuel Tank 1. Remove nuts securing engine cover and retractable starter. oil. After crankcase is completely drained. and then remove it. 34 KohlerEngines. 2. an impact wrench should be used to loosen nuts securing retractable starter. Remove Engine Cover Insert (if equipped) and Cover NOTE: Whenever possible. 2. G .com 14 690 01 Rev. Drain Oil From Crankcase Plug (if accessible) Only clean parts can be accurately inspected and gauged for wear or damage. 2. Even small amounts of these cleaners can quickly break down A lubricating properties of engine oil. 4. To keep dirt. Remove crankcase plug on bottom of engine. 4. Remove Engine Cover and Retractable Starter (if equipped) B NOTE: Whenever possible. Remove nuts securing engine cover. There are many commercially available cleaners that will quickly remove grease. 1. and other debris out of engine. to prevent damage to spark plug lead. an impact wrench should be used to loosen nuts securing retractable starter. Remove engine cover. grass clippings. Disconnect Spark Plug NOTE: Pull on boot only. Dispose of used oil in accordance with local ordinances. clean area around oil fill cap/dipstick. and is completely out of fuel. Remove gas cap. 3. 5. clean area around oil fill cap/dipstick. and grime from engine parts. follow manufacturer's instructions and safety precautions carefully. When such a cleaner is used. Drain oil into an approved container. and other debris out of A engine. 2. Disconnect lead from spark plug. 3.Disassembly/Inspection and Service Clean all parts thoroughly as engine is disassembled. A Air Cleaner B Oil 1. Remove oil fill cap/dipstick. Drain oil into an approved container. Drain Oil From Crankcase Crankcase Plug Drain Oil from Dipstick Tube A Crankcase Plug B (Bottom of Engine) 1. Remove engine cover and retractable starter. Tilt engine on its side with air cleaner facing up. Remove Torx screws securing engine cover insert. Dispose of used oil in accordance with local ordinances. Ensure fuel tank is empty by running engine until it stops. To keep dirt. tilt engine back to level. grass clippings. Make sure all traces of cleaner are removed before engine is reassembled and placed into operation. and gasket. Choke (if equipped) Remove Blower Housing Lift off blower housing and retain stud spacers. G KohlerEngines. 2. noting orientation. 3. 5. Remove air cleaner base and detach primer hose C from carburetor (primer bulb equipped models only). 6. 14 690 01 Rev. Remove Air Cleaner Assembly D A 1.com 35 . 3. Remove heat deflector gasket from exhaust studs. 2. Squeeze hose clamp and slide it and fuel line off carburetor. spacer. Gasket and Spacer A Carburetor Stud(s) B Kit Gasket and Heat C D Linkage Shield Kit E Carburetor NOTE: Ensure fuel tank is empty by running engine until it stops. Loosen knob or unhook latch and remove air cleaner cover. Slide muffler off studs. noting orientation. Remove nuts and screw securing air cleaner base to cylinder head and crankcase. Slide carburetor to end of intake studs. Remove paper element and foam precleaner (if B equipped). If equipped. 3. and is completely out of fuel. Disassembly/Inspection and Service Remove Retractable Starter Carburetor Components Remove screws securing retractable starter assembly to Remove Carburetor with Primer or Carburetor with engine. E 2. Remove Muffler Assembly 1. 4. noting sequence. Remove air cleaner base gasket from carburetor. Slide off carburetor heat shield. Rotate carburetor until choke linkage can be disconnected from carburetor. 5. Turn throttle lever clockwise until it stops. Detach breather hose from crankcase. 1. Gently push rod and spring linkages up to disconnect them from throttle lever. 4. Remove nuts securing muffler guard to cylinder head. it will remain attached to fuel hose (not A Nut(s) B Arm Assembly including California engines). 2. Remove nuts securing arm assembly to muffler. Remove wire choke linkage while sliding carburetor away from engine a couple of inches. disconnect fuel line from fuel filter or carburetor and slide bracket off E Governor Linkage F Linkage Spring hose. Disconnect fuel line.com 14 690 01 Rev. Do not disconnect fuel hose from fuel tank. D 6. 7. H Remove Speed Control Bracket NOTE: Fuel hose connecting carburetor and fuel tank is held in place by a plastic ring. G . Remove screws securing arm assembly to carburetor. Remove carburetor. B 4. Should replacement C Linkage D Choke Linkage of speed bracket be required. G Wire Choke Linkage H Choke Link Remove screws securing speed control bracket. 3. mounted on back of speed control bracket. If bracket is removed from crankcase. F A Control Components B C E A B A F G H C D E A F C A Flywheel Brake B Speed Control Spring Bracket C Linkage Spring D Governor Lever B E Governor Spring F Throttle Linkage Remove Speed Control Bracket Disconnect governor spring from speed control bracket. Second nut is located behind arm assembly base securing it to top of muffler. 36 KohlerEngines. Disconnect governor linkage and linkage spring from carburetor. Remove arm assembly from muffler. C E 5.Disassembly/Inspection and Service Remove Carburetor with Auto Choke (if equipped) 1. 14 690 01 Rev. Remove Flywheel D 1. J K Inspection Inspect flywheel for cracks and check keyway for wear or damage. E Stud(s) F Drive Cup Remove Spark Plug G Fan H Flywheel Remove spark plug from cylinder head. Remove flywheel key from crankshaft. To break it C loose. Flywheel Brake Remove Flywheel Brake Assembly I Screw(s) J Assembly Remove screws securing flywheel brake assembly. remove nut inside drive cup. Any oil separated out through filter drains back into crankcase. I 3. Disconnect kill lead from ignition module. Remove screw and stud securing ignition module. 2. Replace flywheel if ring gear is damaged. Disconnect Flywheel Brake Spring H E Grasp 1 end of flywheel brake spring with a pliers and stretch it to disconnect it. use a rubber mallet to land a firm blow toward outer rim of flywheel. G 2. crankcase gases are A pushed past reed through mesh filter into intake system. Detach fuel tank from crankcase bracket by removing nut or screw. Remove studs securing top of fuel tank and lift off tank. F Remove Ignition Module 1. replace crankshaft. B Remove Electric Starter (if equipped) Remove screws securing electric starter to engine. 1. Remove drive cup and lift off fan. shaft. Replace flywheel if cracked. Inspect ring gear for cracks or damage. C Electric Starter D Ignition Module 2. Flywheel is mounted on a tapered shaft. and key. Remove breather spring.com 37 . Ensure fuel tank is empty. G KohlerEngines. disc and screen. If flywheel key is sheared or keyway is damaged. flywheel. Mark stud for identification during reassembly. K Breather Assembly retain spacers (if equipped). Upward travel of pistons closes reed and creates a low vacuum in lower crankcase. Flywheel/Ignition/Fuel Tank Components 3. Remove flywheel. noting orientation on flywheel for reassembly. 2. When pistons move downward. Using a flywheel strap wrench to hold flywheel. 4. Ring gears are not available separately. Remove Breather Assembly Breather system is designed to control amount of oil in head area and still maintain necessary vacuum in crankcase. Remove screws securing breather cover. Remove A Fuel Tank B Crankcase Bracket cover. Disassembly/Inspection and Service Remove Governor Lever Remove Fuel Tank Loosen governor lever nut and slide lever off governor 1. Valve Cover with RTV Sealant Remove Jam Nuts and Rocker Arm Pivots NOTE: Valve cover is sealed to cylinder head using RTV Use a socket and wrench to remove jam nuts and rocker silicone sealant. When removing valve cover. Remove screws securing valve cover. Remove cover and gasket. G . Using a brass wire brush and gasket remover or 1. use arm pivots from rocker studs. Strike wood firmly with a mallet. 2. care not to damage gasket surfaces of cover and cylinder head. To break RTV seal. Remove screws from valve cover. clean old RTV from surface of cylinder head and valve cover. Valve Cover with Gasket 2.com 14 690 01 Rev. repeat procedure on other side.Disassembly/Inspection and Service Cylinder Head Components P M L O K N I F J C H G E D B A A A Valve Cover B Gasket C Jam Nut D Rocker Arm Pivot E Rocker Arms F Rocker Arm Stud G Push Rod H Push Rod Guide Plate I Valve Keeper J Valve Spring K Intake Valve Seal L Spark Plug M Baffle N Cylinder Head O Valve P Dowel Pin Remove Valve Cover 1. similar solvent. 38 KohlerEngines. hold a block of wood against 1 flat face of valve cover. If seal doesn't break loose after 1 or 2 attempts. Valve Details D E E D A A F F G G B B C C Dimension Intake Exhaust A Seat Angle 90° 90° B Guide Depth 22.512 mm 5. or distortion.80 mm G Valve Stem Diameter 5. Remove screws securing cylinder head.5 mm C Guide I.80 mm 0.) 0.125 mm 23.512 mm D Valve Head Diameter 25.125 mm E Valve Face Angle 45° 45° F Valve Margin (Min.875/26. Following diagram Remove Guide Plate outlines valve running clearances between valve stems 1. Remove cylinder head. Remove head gasket and discard. 3.480 mm 14 690 01 Rev. Check valves and valve seats for evidence of deep pitting.com 39 .465/5. Remove guide plate from rocker studs. Disassembly/Inspection and Service Remove Rocker Arms Remove Cylinder Head Noting orientation. springs and related hardware for excessive wear or distortion. Note orientation of guide plate (tabs down) for use during reassembly. Remove push rods and mark them for reinstallation. and guides. G KohlerEngines.D. noting positioning of dowels. 1.500/5. Valve Inspection and Service Remove Rocker Studs Carefully inspect valve mechanism parts. Inspect valve Unscrew and remove rocker studs from cylinder head. lift rocker arms off rocker studs.6 mm 20. Remove Push Rods 2. cracks.480 mm 5. 2.875/24.500/5. 5.465/5. Valve Seat Inserts Hardened steel alloy intake and exhaust valve seat inserts are press fitted into cylinder head. Maximum (I. and valve seat cut properly (44. Push end of intake valve to release valve seal. carefully inspect each valve for defects such as warped head.047 mm (.0018 in.D. Final cut should be made with an 90° cutter as specified for valve seat angle. Inspection and Service Hard starting. Recondition valve seat inserts following instructions provided with valve seat cutter (A) being used. cylinder head should be replaced.512 mm (0.2170 in. Use a hand valve grinder with suction cup for final lapping. determine whether valve stem or guide is responsible for excessive clearance. Guides are not removable.). 1. There is no valve seal on exhaust side. Replace valves found to be in bad condition. using a split-ball gauge. If guides are within limits but valve stems are worn beyond limits. while 5. 4. but they can be reconditioned if not too badly pitted or distorted. faces. or worn stem end. using an outside micrometer.). Lapping Valves Reground or new valves must be lapped in.) wear on intake valve guide is 5. Inserts are not replaceable. After removal. Remove valve spring keepers and springs. 2. 40 KohlerEngines. replace valves. measure diameter of valve stem at several points on stem where it moves in valve guide. measure inside diameter. With proper 45° valve face angle.0° full cut) interference angle where maximum pressure occurs on valve face and seat. Continue grinding until smooth surface is obtained on seat and on valve face.2170 in. Thoroughly clean cylinder head in soap and hot water to remove all traces of grinding compound. Then. Lightly coat valve face with fine grade of grinding compound. Valve Guides To check valve guide-to-valve stem clearance.082 mm (.512 mm (0. may be symptoms of faulty valves. thoroughly clean valve guide and. or loss of power accompanied by high fuel consumption.) is maximum allowed on exhaust guide. then rotate valve on seat with grinder.0032 in. Push down on valve spring keepers to release valve springs from valve stems.5° as measured from center line when cut 90°) this would result in desired 0. Use largest stem diameter to calculate clearance. Remove both valves from opposite side of head. clean valve heads. If intake clearance exceeds 0. remove and check valves first. After drying cylinder head. If seats are cracked or badly warped. Then. to provide a good seal. apply a light coating of engine oil to prevent rusting. excessive corrosion. 3. and stems with a power wire brush.) or exhaust clearance exceeds 0.Disassembly/Inspection and Service Remove Valve Assembly NOTE: Only intake valve has a seal. Although these symptoms could also be attributed to worn rings.com 14 690 01 Rev.5° (1. G . Remove tube. G KohlerEngines. 14 690 01 Rev. Using a flat blade screwdriver as a wedge. Remove Oil Pan Inspection NOTE: Some engines have an oil pan gasket. Remove old gasket (if equipped) and discard. Remove screws securing oil pan. some Inspect oil seal in oil pan and remove it if it is worn or engines use RTV to secure oil pan to crankcase.com 41 . Remove screw securing dipstick tube. carefully separate oil pan from crankcase. damaged. 3. 1. Disassembly/Inspection and Service Crankcase Components A A B C B C G D E H F F H I I M M L K R Q N P L P J J K G N R Q O O U S S T V T Governor Cross A Crankcase Oil Seal B Crankcase C D Oil Pan Gasket Shaft E Crankcase Bearing F Camshaft G Piston Pin Retainer H Piston Pin Connecting Rod I Piston J Piston Ring Set K Connecting Rod L End Cap M Crankshaft N Retainer O Governor Shaft P Governor Gear Q Governor Washer R Governor Cup S Oil Pan T Oil Pan Oil Seal U Dipstick Tube V Screw Remove Dipstick Tube (Extended Dipstick) 2. which meet than engines without ACR. Service replacement connecting rods are available in ACR lowers compression at cranking speeds to make STD size. because 2. Preignition Remove Governor Gear and Shaft damage is often more severe than detonation damage. Remove screw and retainer securing governor gear. They should move freely in governor gear. condition. or if some are missing. Check Connecting Rod Inspection and Service condition and operation of Automatic Compression Check bearing area (big end) for excessive wear. which prevent kickback which would occur during starting. 3. Without burned along with fuel. and explode to create extreme hammering pressures on a specific area of piston. which is usually attributed to improper so it protrudes above heel of exhaust lobe. an improperly seated valve. Rotate crankshaft to allow access to 2 screws on Inspection and Service connecting rod cap. causing arm to retract. score Release (ACR) mechanism. Always use new piston rings when Remove Tappets installing pistons. Engines with ACR start much faster in cold weather after ignition. Engines without ACR are more difficult to start with those same spark plugs. Oil control is also lost when ring gaps are not staggered during installation. and activated by a return when internal engine temperatures approach welding spring. Remove tappets. making manual shiny or bright appearance. If unusual wear or damage Carefully guide piston and attached connecting rod out is evident on either camshaft lobes or mating tappets of cylinder bore. consumption and blue exhaust smoke. starting safer.Disassembly/Inspection and Service Remove Camshaft Remove Connecting Rod Cap Remove camshaft from crankcase. which are worn or fouled. Remove hitch pin securing governor shaft. Detonation generally occurs 6. spark plug. flooding occurs. or pieces of hard metal. This creates two flame fronts. lacquer and would be required on engines without ACR to varnish collect on pistons. These engines are equipped with an ACR mechanism. Preignition is caused by a hot spot in combustion 1. Manual (retractable) starting is much easier. 42 KohlerEngines. running and side clearances. decompression weight holds arm created by friction. Piston and Rings Inspection ACR mechanism consists of a decompression weight Scuffing and scoring of pistons and cylinder walls occurs and arm mounted to camshaft. to move outward.com 14 690 01 Rev. High oil consumption can also ACR. Inspect governor gear teeth. exhaust valve off its seat during first part of compression stroke. Inspect governor new piston pins. Mark them INTAKE and EXHAUST for reinstallation. Replace gear if it is worn. Inspect gear teeth of camshaft. or if any teeth are missing. Remove cooling fins. ignites spontaneously from heat and pressure shortly 5. A worn ring usually takes on a ACR eliminates this kickback. chamber such as glowing carbon deposits. several important benefits are obtained: oil is allowed to enter combustion chamber where it is 1. excess fuel is blown out opened Detonation damage occurs when a portion of fuel charge exhaust valve and does not hamper starting. camshaft and both tappets must be replaced. When engine is rotating at low cranking speeds point of piston. Benefits Ring failure is usually indicated by excessive oil As a result of reduced compression at cranking speeds. marks. When rings fail. Choke control setting is less critical with ACR. Electric start models can use a smaller starter and ring cannot properly conform to cylinder wall under this battery which are more practical for application. occur when piston ring end gap is incorrect. Remove screws and cap. a new operates at FULL compression and power. If original piston and connecting rod can After engine speed increases above approximately 1000 be reused after new rings are installed. replacement of Remove Piston and Connecting Rod camshaft will be necessary. G . blocked 2. Temperatures high enough to do this are (1000 RPM or less). original pin can RPM. This holds lubrication and/or overheating of engine. dirt. Normally. arm has no effect on exhaust valve and engine boss in piston or pin itself is worn or damaged. Engines with ACR can be started with spark plugs from using low octane fuels. centrifugal force causes decompression weight also be reused but new piston pin retainers are required. weights. Scratches on rings and pistons are caused by abrasive 4. If material such as carbon. A spark retard/advance mechanism When cylinder temperatures get too high. Preignition or ignition of fuel charge before timed spark can cause damage similar to detonation. or a wrong shaft. Replacement ring sets are also available separately for STD pistons. piston assembly is required. causing rings to stick. results in rapid wear. ACR eliminates need for a spark retard/advance mechanism. Replacement pistons include new piston ring sets and chipped. When in this Piston pin is included as part of piston assembly – if pin position. very little wear takes place in piston boss or piston pin area. Never use old rings. Inspection Replacement pistons are available in STD bore size. manual starting would be virtually impossible. Replace connecting ACR rod and end cap if scored or excessively worn. starting easier. If teeth are badly worn or chipped. Install oil control ring assembly (bottom groove) first. Adjust ring gaps. 2. A B and bottom rail. and consists of a top rail. 4. old piston may be reused. 5. Make sure identification mark is up or colored dye stripe (if contained) is left of end gap. Oil control ring assembly (bottom groove): Install expander first then bottom rail and top rail last. check piston-to-ring side clearance. Compare clearance to Clearance Specifications. Adjust ring gaps. place top 2 (≥ 60°) rings. G KohlerEngines. Before installing new rings on piston. Cylinder bore must be de-glazed before service ring B sets are used. Never reuse old rings. Oil control ring assembly is a three-piece Top Compression Middle Compression design. 3. a new piston must be used. E Expander Ring F Bottom Rail 1. and top compression ring (top groove) last. in its running area in cylinder bore and check end gap. 2. Adjust ring gaps. Install New Piston Rings C Oil Ring Expander A B Bottom Oil Rail Gap Gap A Intermediate C Top Oil Rail Gap D Compression Ring Gap B Top Compression E D Ring Gap E C NOTE: Rings must be installed correctly. If cylinder bore does not need re-boring and if old piston is within wear limits and free of score or scuff E marks. Make sure identification mark is up or colored dye stripe (if contained) is left of end gap. Remove old rings and clean up grooves. Top compression ring (top groove): Install top compression ring using a piston ring expander tool. expander ring. 14 690 01 Rev. Compare ring gap to A Clearance Specifications.com 43 . After installing new compression (top and middle) rings on piston. 3. Middle compression ring (center groove): Install middle compression ring using a piston ring expander tool. Make sure ends of expander are not overlapped. F middle compression ring (center groove) second. Ring Ring C Oil Control Ring D Top Rail Use a piston ring expander to install rings. each in turn. If D side clearance is greater than specified. Disassembly/Inspection and Service Some important points to remember when servicing Piston Ring Orientation piston rings: 1. it will be necessary to replace crankshaft. replacement of crankshaft will be necessary. If wear limits in Specifications are exceeded. unburned fuel can dissolve lubricating oil off piston and cylinder wall. 44 KohlerEngines.Disassembly/Inspection and Service Remove Crankshaft Remove crankshaft. no further reconditioning is necessary. Scoring of cylinder wall can also be caused by localized hot spots from blocked cooling fins or from inadequate or contaminated lubrication. crankcase and/or closure plate will need to be replaced. Inspect crankshaft keyway. Slight score marks can be cleaned with crocus cloth soaked in oil. etc. Measure running clearance between crankshaft journals and their respective bearing bores. Without lubrication. Use an outside micrometer to measure outside diameter of crankshaft main bearing journals. If worn or chipped.. In severe cases. and there is no evidence of scoring. Check cylinder wall for scoring. Inspect crankpin for score marks or metallic pickup. piston rings would make metal to metal contact with wall. Inspect crankshaft bearing surfaces for scoring. grooving. If running clearances are within specification. Check results against values in Specifications and Tolerances. Subtract journal diameters from their respective bore diameters to get running clearances. replacement of crankshaft will be necessary. or if some are missing. Use an inside micrometer or telescoping gauge to measure inside diameter of both bearing bores in vertical and horizontal planes. G .com 14 690 01 Rev. etc. Crankcase Inspection and Service Check all gasket surfaces to make sure they are free of gasket fragments and deep scratches or nicks. If any teeth are badly worn or chipped. causing scuffing and scoring. If bearing surfaces are worn or damaged. Inspection and Service Inspect gear teeth of crankshaft and ACR gear. grooving. G KohlerEngines. and fully seat into place. Rotate crankshaft until journal for connecting rod is away from cylinder. tightening sequences. NOTE: Make sure all components have been properly cleaned BEFORE reassembly. Failure to observe specifications could cause severe engine wear or damage. NOTE: Remove all traces of cleaners before engine is reassembled and placed into operation. 14 690 01 Rev. Reassembly Crankcase Components A A B C B C G D E H F F H I I M M L K R Q N P L P J J K G N R Q O O U S S T V T Governor Cross A Crankcase Oil Seal B Crankcase C D Oil Pan Gasket Shaft E Crankcase Bearing F Camshaft G Piston Pin Retainer H Piston Pin Connecting Rod I Piston J Piston Ring Set K Connecting Rod L End Cap M Crankshaft N Retainer O Governor Shaft P Governor Gear Q Governor Washer R Governor Cup S Oil Pan T Oil Pan Oil Seal U Dipstick Tube V Screw NOTE: Make sure engine is assembled using all specified torque values.com 45 . Even small amounts of these cleaners can quickly break down lubricating properties of engine oil. and clearances. NOTE: Always use new gaskets. Install Crankshaft Carefully install crankshaft into crankcase through front seal. connecting rod journal. 3 Install Camshaft 1.Reassembly Install Piston and Connecting Rod Install Oil Pan NOTE: Proper orientation of piston and connecting rod Torque Sequence inside engine is extremely important. 3. and torque screw to 9. as previously marked. Install governor cross shaft and secure it with hitch pin. rubber-grip hammer to tap piston into bore.5 N·m (84 in. 5 4. XT6. G .). Improper orientation can cause extensive wear or XT-7. crankshaft journal.). 3 6 2. piston. with piston attached.75. XT775.5 N·m (110 in. Install camshaft and align timing marks. 2. XTR-7. Align XT-6. XT8 damage. 4 into bore. Stagger piston rings in grooves until end gaps are 1 60° or more apart. Torque screws to 12. Position triangle on top of piston toward push rod chamber. Lubricate cylinder bore. Lubricate camshaft and cam gear surfaces with light 5 4 grease or oil. Compress piston rings using a piston ring compressor. 2 5. lb. XT650. Use handle of a soft. Install Tappets 1 6 Install intake and exhaust tappets into their respective positions. flat of governor shaft (located on outside of crankcase) should be turned so flat is parallel to crankcase gasket surface. 7 2 Install Governor Gear Assembly NOTE: When installing governor. Rotate crankshaft to mate with connecting rod. 1. 6.com 14 690 01 Rev. lb. 46 KohlerEngines. Carefully guide connecting rod. 2. XTR-6. XT675 rod cap and connecting rod to match marks. 1. and rings with engine oil. Install governor gear and retainer. Paddle of governor shaft (located inside crankcase) should be pointing away from crankcase gasket surface. XT6.5. 14 690 01 Rev. 1. Using sealant pattern. Always use fresh sealant.5.7 N·m (130 in. lb. XT6. 2. Using outdated sealant can result in leakage. ensure plunger on governor gear is pressed fully into governor. XT675 XT-7. OIL PAN GASKET: Using crankcase dowels as a guide.0 N·m (98 in. ensuring camshaft and governor gear align with their mating surfaces. dry and free of any nicks or burrs. XT6. securing oil pan to crankcase.75 11.) XT650. NOTE: When installing oil pan.5 mm (1/16 in.5 mm (1/16 in. XT8 Rotate crankshaft slightly to help engage governor gear.75 A A 1. Incorrectly installing governor plunger may result in damage.) XT775. RTV: Refer to Tools and Aids for a listing of approved sealants.) bead of sealant. XT8 XT6. Guide oil pan onto crankcase. NOTE: Some engines use an oil pan gasket. G KohlerEngines. XTR-7 14. install a new oil pan gasket onto crankcase. Sealing surfaces of crankcase and oil pan should be clean. XT775. Install and finger tighten screws.5. some engines use RTV to secure oil pan to crankcase. Use torque sequence shown and torque oil pan screws to: Model Torque XT6. apply a 1.com 47 . 6. Install 2 crankcase dowels into crankcase. Reassembly Sealant Pattern 4. A 5. XTR-6 XT6.) bead of sealant to sealing surface of oil pan. lb. 3. lubricate all components with engine oil. 2.com 14 690 01 Rev. Install intake valve seal onto intake valve.Reassembly Cylinder Head Components P M L O K N I F J C H G E D B A A A Valve Cover B Gasket C Jam Nuts D Rocker Arm Pivot Push Rod Guide E Rocker Arms F Rocker Arm Stud G Push Rods H Plate I Valve Keeper J Valve Spring K Intake Valve Seal L Spark Plug M Baffle N Cylinder Head O Valve P Dowel Pin Install Cylinder Head Assembly Prior to assembly. Next. 48 KohlerEngines. including tips of valve stems and valve guides. Install intake and exhaust valves into their respective positions in cylinder head. slide valve springs onto both valves and lock them in place with valve spring keepers. Install Valve Train 1. G . ). install rocker studs. following sequence shown. Tighten rocker studs to 13.0762-0. 3. Install Push Rod Assembly NOTE: Installation and seating of push rods into tappet A recesses during this sequence is critical. Valve Cover with Gasket 1.005 in. Prepare sealing surface of cylinder head and valve 7. 1. With piston at top dead center of compression cover.) 8 N·m (71 in. A RTV Sealant 3. G KohlerEngines.5 N·m (84 in. Install rocker arms onto rocker studs. Reassembly Install Cylinder Head Install Valve Cover Torque Sequence Torque Sequence 3 2 3 2 1 4 1 4 NOTE: Do not reuse cylinder head gasket. finally to 27. cover as shown. Valve Clearance Specifications: 3. 14 690 01 Rev. NOTE: To ensure proper adhesion of sealant to both 5. Tighten rocker pivot with a wrench until a slight drag is felt on feeler gauge. lb. 2. Torque screws in two stages. 8 N·m (71 in. stroke. position engine with cylinder head up. Always replace with new gasket.). Match sides of head together and finger tighten Valve Cover with RTV screws. Apply a 1. Install valve cover and finger tighten screws. lb.). (25.) bead of sealant to valve between 1 valve stem and rocker arm.005 in. 8.0762-0. Install push rods into intake and exhaust positions.004 in.). 2. tighten cover screws to Exhaust Valve 0.) 4. crankcase for nicks or burrs. Intake Valve 0.). tighten cover screws to head gasket. lb. insert a 0. Hold nut in position and tighten jam nut to 9. Apply grease to contact surfaces of rocker arms and dispenser. 2. 1.) flat feeler gauge 2. Using sequence shown.6 N·m (120 in. lb. Install valve cover and finger tighten screws. Match rocker sealing surfaces. NOTE: Always use fresh sealant. minutes maximum) after application of RTV. Using cylinder head dowels as a guide. Using outdated as previously marked.127 mm (0. Refer to Tools and Aids for important information on sealant 4. 4.1 mm (0. first to 14 N·m (123 in. and for adjusting valve lash. Perform same adjustment procedure on opposite valve. install a new 3.003-0.5 mm (1/16 in. 6. Recheck lash.127 mm (0. With tabs on guide plate facing down. When properly installed.8 N·m (246 in. To aid with proper installation of push rods and rocker arms. Using sequence shown.com 49 .4 mm) above guide plate. Position a new valve cover gasket on cylinder head. pivots. Loosely install pivots and jam nuts onto rocker studs. Examine sealing surfaces of cylinder head and 1. perform step 3 immediately (5 arm dimples with round push rod ends. lb.).003-0. push rods extend approximately 1 in. lb. sealant can result in leakage. H Fuel Cap Side of Engine 1. G Install Flywheel Brake Assembly Dipstick Side of Engine 1. Install spacers onto brake assembly screws. Set gap of a new spark plug to 0. Install breather disc and spring. 3.).). loosen both screws and readjust. C A B A A Screws B Fuel Tank C Crankcase Bracket D Electric Starter E Ignition Module F Stud(s) G Drive Cup H Fan I Flywheel J Screw(s) Flywheel Brake K L Breather Assembly Assembly 50 KohlerEngines.5 N·m (84 in. 2. lb. Visually inspect all wires are connected and micro switch is J D moving up and down when brake arm is pulled.com 14 690 01 Rev.). K L Install Breather Assembly 1. Place brake assembly onto engine and loosely install 2 brake assembly screws. Rotate brake lever clockwise around rear screw.03 in. 3. 4. pivoting on rear screw if necessary. Torque screws to 9.).968 in. 2. lb. lb. Install breather cover and secure with screws. G . Install breather screen. Actuate brake arm and verify an audible click is heard from micro switch (if equipped). 2. Reinstall kill E lead to ignition module or to bottom terminal on micro switch (if equipped). Torque screws to 10 N·m (88 in.Reassembly Install New Spark Plug Flywheel/Ignition/Fuel Tank Components 1.) gap. Install spark plug and torque to 27 N·m (20 ft. If an audible click from micro switch is not heard.76 mm (0. Install a caliper between brake lever and bracket to I F establish a 50 mm (1. Loosen NOTE: Before installing flywheel make sure crankshaft stud and let magnet draw module against feeler taper and flywheel hub are clean. Broken fragments could be thrown from aligned with module. 1. Loosely thread stud and screw into appropriate leg. Install and torque screws to 9. Secure fuel tank bracket to crankcase by torquing NOTE: Always use a flywheel strap wrench to hold nut or screw to 8 N·m (71 in. attach flywheel brake spring onto bracket hook. lb. Secure top of fuel tank to crankcase by installing flywheel from rotating. lb. Presence of 4. 3.). and check lubricants can cause flywheel to be over module does not come in contact with magnet.254 mm (0. 2. Rotate flywheel to release feeler gauge. Position ignition module on legs with kill tab down. Flywheel can become cracked or Install Fuel Tank damaged if key is not properly installed. flywheel when tightening flywheel fastener. Install spacers on studs. 5.) plastic feeler gauge between magnet and module. dry. completely free of lubricants.).5 N·m (38 ft.010 in. as these parts could threaded studs. Reassembly Install Flywheel Install Ignition Module NOTE: If stud for mounting ignition module was not kept CAUTION segregated from 2 studs for mounting fuel tank. Install flywheel onto crankshaft aligning keyway with key. into crankshaft keyway. Install Electric Starter (if equipped) Align and mount electric starter onto crankcase. torqued to specification. A A Brake Assembly Screws Using a pliers. and install and hand tighten nut. Pull module away from flywheel and tighten stud to Using improper procedures can lead to broken hold it in place. Using a flywheel strap wrench. Torque studs to 10 N·m (88 in. lb. hold flywheel still while simultaneously tightening nut to 51. Set air gap by placing a 0. Connect kill lead to ignition module kill tab. become cracked or damaged. Align teardrop slot on fan with raised teardrop on flywheel. Damaging Crankshaft and Flywheel can compare their lengths and choose short one. 1. Align drive cup on flywheel.). Do not use any type of bar or wedge to prevent 2. Make sure key is fully seated.). 4. Install Flywheel Brake Spring 2. lb. G KohlerEngines. and gauge.com 51 . stressed and damaged when mounting nut is Recheck air gap. Rotate flywheel so ignition magnet is fragments. Rotate flywheel so ignition magnets are away from ignition module legs. Install key. Always observe and use precautions and procedures when installing flywheel. lb.). NOTE: Make sure flywheel key is installed properly in keyway. 14 690 01 Rev. Torque fasteners to 10 N·m (88 in. 3. 3.5 N·m (84 in. engine. cause personal injury. 1. Install governor lever onto governor shaft with lever up. Images shown identify how different brackets connect to carburetors with and without choke. Attach throttle linkage and linkage spring to top of H governor lever. F Control Components G I A D E H F J K G A I B B M L D E C F J H D E K G F I Flywheel Brake Speed Control A B Spring Bracket C C Linkage Spring D Governor Lever Fixed Speed with Fixed Speed with E Governor Spring F Throttle Linkage A B Primer (No Choke) Choke Variable Speed with C D Throttle Linkage Choke E Linkage Spring F Throttle Lever Speed Control G Governor Spring H Bracket I Governor Lever J Choke Lever Dual Throttle Choke K Choke Linkage L Control Speed Control M Screw Install Speed Control Bracket NOTE: There are 3 different speed bracket variations for this engine. 52 KohlerEngines. D E 2.Reassembly Install Governor Assembly Speed Bracket Details 1.com 14 690 01 Rev. G . at end of linkage. E Throttle Linkage F Linkage Spring G Wire Choke Linkage H Choke Link 14 690 01 Rev. into choke lever. 2. Reassembly Loosely attach speed control bracket to crankcase Auto Choke Components using shorter screws. With carburetor not yet mounted on studs. A Install Carburetor and Linkage C NOTE: There are several different ways to attach carburetor linkage depending on carburetor and speed bracket used. Carburetor Components C E D F A D A B E B C E C A Gasket and Spacer A Carburetor Stud(s) B Kit Gasket and Heat F C D Linkage Shield Kit G H E Carburetor Install Carburetor Gaskets Place spacer gasket. rotate it slightly to allow connection of throttle linkage and linkage spring to throttle lever. Long screw will be used later for attaching air cleaner body. B Install Carburetor with Primer (if equipped) 1. cylinder head spacer and heat deflector gasket on carburetor studs in order shown. Connect throttle linkage and linkage spring to throttle A Nut(s) B Arm Assembly lever on carburetor. rotate it slightly and slot elbow. C Linkage D Choke Linkage 3. Slide carburetor onto mounting studs. 2. With carburetor not yet mounted on studs. G KohlerEngines. Install Governor Spring Install governor spring between governor lever and B speed control bracket. Install Carburetor with Choke H 1.com 53 . Slide carburetor onto mounting studs. 5 N·m (75 in. Reconnect Fuel Line Slide fuel line tight up against carburetor.3 N·m (20 in. Insert screws connecting arm assembly to carburetor. 3. lb. Slide carburetor at least halfway onto mounting studs. Connect wire choke linkage while sliding carburetor to its seated position against engine.com 14 690 01 Rev.). Adjust Governor Move governor lever away from carburetor to limit of its travel (wide-open throttle). 2.). 4. Torque to 8. Mount arm assembly onto muffler securing with nuts.). G . hold and tighten nut. Connect throttle linkage and linkage spring to carburetor. lb. and secure connection with a hose clamp. Torque nut to 9. flex or distort linkage. lb.5 N·m (84 in. Torque to 2. Grasp cross shaft with a pliers and turn shaft clockwise as far as it will go.Reassembly Install Carburetor with Auto Choke (if equipped) 1. and hold in this position. External Engine Components A D B C E F G H H I J J L K K H J L K Engine Cover and Engine Cover and A B Engine Cover C D Retractable Starter Insert Retractable Start E Blower Housing F Muffler Guard G Muffler H Air Cleaner Base I Breather Hose J Paper Element K Air Cleaner Cover L Precleaner 54 KohlerEngines. Do not stress. 3. and screw into crankcase. Install heat deflector gasket onto exhaust mounting studs. Tighten nuts to 8 N·m (71 in. Install Engine Cover Engine Cover (if equipped) 1.5 N·m (84 in. Attach air cleaner cover and hand tighten knob or secure latch. 2. 2.). Slide air cleaner base onto carburetor studs. Tighten screw to 8 N·m (71 in. 2. Install paper element and foam precleaner (if equipped) into air cleaner base. 3. lb. Attach primer hose to carburetor (if equipped). Install Blower Housing Install blower housing onto studs.5 N·m (20 in. Tighten to 2. 2. 5. Reassembly Install Air Cleaner Assembly 1.). 6. 3. lb. 2. Install Muffler Assembly 1.).). 2.). G KohlerEngines. Install engine cover and secure it with nuts. with gasket folds facing cylinder head. Engine Cover and Insert (if equipped) 1.). Install engine cover and secure it with nuts. Install engine cover insert (if equipped) onto engine cover. Tighten nuts to 8 N·m (71 in. Attach breather hose to crankcase. and secure with Torx screws. 4. Install Fuel Cap Screw fuel cap tightly onto fuel tank. Slide muffler onto exhaust studs.). lb. Tighten nuts to 8 N·m (71 in. lb. Engine Cover Insert and Retractable Starter (if equipped) 1. lb. lb. Install Dipstick Tube (Extended Dipstick) 1. Torque to 9. lb.com 55 . 14 690 01 Rev. Install engine cover insert and retractable starter and secure with nuts. Secure air cleaner base by torquing nuts and screw to 8 N·m (71 in. Install dipstick tube to crankcase. Install Retractable Starter Place retractable starter onto studs protruding from blower housing. Slide air cleaner gasket onto carburetor studs. Install muffler guard onto exhaust studs and secure with nuts. Attach base by loosely screwing nuts onto studs. G .© 2014 by Kohler Co. All rights reserved.com 14 690 01 Rev. 56 KohlerEngines.
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