Kohler LH630-775 Service Manual
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Kohler LH630-775 Service Manual

Kohler LH630-775 Service Manual

Liquid-cooled horizontal crankshaft
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S
M
ERVICE
ANUAL
AEGIS
LH630-775
™
L
-C
IQUID
OOLED
H
C
ORIZONTAL
RANKSHAFT

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Summary of Contents for Kohler LH630-775

  • Page 1 ERVICE ANUAL AEGIS LH630-775 ™ IQUID OOLED ORIZONTAL RANKSHAFT...

  • Page 2: Table Of Contents

    Section 1. Safety and General Information ... Section 2. Tools & Aids ... Section 3. Troubleshooting ... Section 4. Air Cleaner System ... Section 5. Fuel System and Governor ... Section 5B. Electronic Fuel Injection (EFI) Fuel System ... Section 6. Lubrication System ... Section 7.

  • Page 3: Section 1. Safety And General Information

    Safety and General Information Safety Precautions To ensure safe operations please read the following statements and understand their meaning. Also refer to your equipment manufacturer's manual for other important safety information. This manual contains safety precautions which are explained below. Please read carefully. WARNING Warning is used to indicate the presence of a hazard that can cause severe personal injury, death, or substantial property damage if the warning is ignored.
  • Page 4 Section 1 Safety and General Information WARNING Explosive Fuel can cause fires and severe burns. Do not fill the fuel tank while the engine is hot or running. Explosive Fuel! 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.
  • Page 5 Engine Identification Numbers When ordering parts, or in any communication involving an engine, always give the Model, Specification, and Serial Numbers, including letter suffixes if there are any. The engine identification numbers appear on a decal, or decals, affixed to the engine. The primary location is on the side of the flywheel cover.
  • Page 6 Section 1 Safety and General Information Oil Recommendations Using the proper type and weight of oil in the crankcase is extremely important. So is checking oil daily and changing oil regularly. Failure to use the correct oil, or using dirty oil, causes premature engine wear and failure.
  • Page 7 Perform these maintenance procedures more frequently under extremely dusty, dirty conditions. Safety and General Information Gasoline/Alcohol blends Gasohol (up to 10% ethyl alcohol, 90% unleaded gasoline by volume) is approved as a fuel for Kohler engines. Other gasoline/alcohol blends are not approved. Gasoline/Ether blends...
  • Page 8 Section 1 Safety and General Information Storage If the engine will be out of service for two months or more, use the following storage procedure: 1. Clean the exterior surfaces of the radiator and engine. On EFI engines, avoid spraying water at the wiring harness or any of the electrical components.
  • Page 9 440.00 (17.323) (0.906) Rain Cap Removal Fuel Pump 2X 184.20 (7.252) 127.90 C L Mounting Hole (5.035) C L Mounting Hole 458.49 (18.051) Overall Flywheel End 119.78 (4.716) Starter Side 120.96 (4.762) 39.00 Coolant (1.535) Overflow Oil Fill Air Intake Optional Orientation Fill 583.30 (22.965)
  • Page 10 Section 1 Safety and General Information General Specifications Power (@3600 RPM, exceeds Society of Automotive Engineers-Small Engine Test Code J1940.) LH630 ... Maximum ... 16.4 kW (22 HP) LH640 ... Maximum ... 17.9 kW (24 HP) LH685 ... Maximum ... 18.6 kW (25 HP) LH690 ...
  • Page 11 General Specifications cont. Compression Ratio LH630,LH640,LH685,LH690 ... 8.5:1 LH750,LH755,LH760,LH775 ... 8.7:1 Dry Weight LH630,LH640,LH685,LH690,LH755 ... 51.7 kg (114 lb.) LH760,LH775 ... 52.6 kg (116 lb.) Oil Capacity (w/filter) - approximate, determined by oil filter used: ... 1.6-1.8 L (1.7-1.9 U.S. qt.) Coolant Capacity (equal parts of water and ethylene glycol) ...
  • Page 12 Section 1 Safety and General Information Crankcase Governor Cross Shaft Bore I.D. New ... 8.025/8.075 mm (0.3159/0.3179 in.) Max. Wear Limit ... 8.088 mm (0.3184 in.) Breather Cover Fastener Torque ... 10.7 N·m (95 in. lb.) into new hole Oil Drain Plug Torque ... 13.6 N·m (10 ft. lb.) Closure Plate Closure Plate Fastener Torque ...
  • Page 13 Cylinder Bore cont. Max. Wear Limit LH630,LH640 ... 77.063 mm (3.0340 in.) LH685,LH690 ... 80.065 mm (3.1522 in.) LH750,LH755,LH760,LH775 ... 83.069 mm (3.2704 in.) Max. Out-of-Round ... 0.12 mm (0.0047 in.) Max. Taper ... 0.05 mm (0.0020 in.) Cylinder Head Cylinder Head Fastener Torque (torque in 2 increments) ...
  • Page 14 Section 1 Safety and General Information Ignition ® Spark Plug Type (Champion or equivalent) ... RC14YC Spark Plug Gap ... 0.76 mm (0.030 in.) Spark Plug Torque ... 24.4-29.8 N·m (18-22 ft. lb.) Ignition Module Air Gap ... 0.203/0.305 mm (0.008/0.012 in.) Ignition Module Fastener Torque ...
  • Page 15 Piston, Piston Rings, and Piston Pin cont. Top and Middle Compression Ring End Gap cont. LH685,LH690 New Bore Top Ring ... 0.180/0.430 mm (0.0071/0.0169 in.) Middle Ring ... 0.250/0.460 mm (0.0098/0.0181 in.) Used Bore (Max.) ... 0.80 mm (0.0315 in.) LH750,LH755,LH760 LH775 New Bore ...
  • Page 16 Section 1 Safety and General Information Valves and Valve Lifters cont. Exhaust Valve Stem Diameter New ... 6.970/6.988 mm (0.2744/0.2751 in.) Valve Guide Reamer Size Standard ... 7.048 mm (0.2775 in.) 0.25 mm O.S..7.298 mm (0.2873 in.) Intake Valve Lift ... 8.88 mm (0.3496 in.) Exhaust Valve Lift ...
  • Page 17 English Fastener Torque Recommendations for Standard Applications Tightening Torque: N·m (in. lb.) + or - 20% Bolts, Screws, Nuts and Fasteners Assembled Into Cast Iron or Steel Grade 2 Size 8-32 2.3 (20) 10-24 3.6 (32) 10-32 3.6 (32) 1/4-20 7.9 (70) 1/4-28 9.6 (85)

  • Page 18: Section 2. Tools & Aids

    By using tools designed for the job, you can properly service engines easier, faster, and safer! In addition, you’ll increase your service capabilities and customer satisfaction by decreasing engine downtime. Here is the list of tools and their source. Separate Tool Suppliers: Kohler Tools Contact your source of supply. &...
  • Page 19 Section 2 Tools & Aids ) . t . l a t f i l l a c i l f i l i t i & l i o i f i i f i i f i . s r a l i l a i l l a...
  • Page 20 - l e i l i ® e t i l i o s i s ® e t i e t i ® ® e t i ® e t i e t i ® ) t f . r e , s t s i l s i r...
  • Page 21 4. Use a flat washer with the correct I.D. to slip on the capscrew and approximately 1” O.D. (Kohler Part No. 12 468 05-S). Assemble the capscrew and washer to the joint surface of the rod, as shown in Figure 2-2.

  • Page 22: Section 3. Troubleshooting

    Troubleshooting Guide When troubles occur, be sure to check the simple causes which, at first, may seem too obvious to be considered. For example, a starting problem could be caused by an empty fuel tank. Some common causes of engine troubles are listed below.
  • Page 23 Section 3 Troubleshooting Engine Overheats 1. Radiator, and/or cooling system components clogged, restricted, or leaking. 2. Excessive engine load. 3. Low crankcase oil level. 4. Low cooling system fluid level. 5. High crankcase oil level. 6. Lean fuel mixture. 7. Fan belt failed/off. 8.
  • Page 24 • Check the condition of the oil. Drain the oil into a container - the oil should flow freely. Check the appearance (color) of the oil, and for metal chips or foreign particles. A milky, opaque color denotes the presence of engine coolant in the crankcase oil. Sludge is a natural by-product of combustion;...
  • Page 25 Section 3 Troubleshooting Compression Test A compression test is best performed on a warm engine. Clean any dirt or debris away from the base of the spark plugs before removing them. Be sure the choke is off, and the throttle is wide open during the test.

  • Page 26: Section 4. Air Cleaner System

    Air Cleaner System Air Cleaners General These engines are equipped with Kohler's heavy-duty, cyclonic air cleaner system. See Figure 4-1. The air cleaner includes a high-density, pleated paper main element (see Figure 4-2), and inner safety element (see Figure 4-3).

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

    Replace any damaged or questionable components. 5. If it is being replaced, install the new inner element, Kohler Part No. 25 083 04-S, followed by the canister outer element; Kohler Part No. 25 083 01-S. Slide each fully into place in the housing.

  • Page 28: Section 5. Fuel System And Governor

    Gasoline/Alcohol blends Gasohol (up to 10% ethyl alcohol, 90% unleaded gasoline by volume) is approved as a fuel for Kohler engines. Other gasoline/alcohol blends are not approved. Gasoline/Ether blends Methyl Tertiary Butyl Ether (MTBE) and unleaded gasoline blends (up to a maximum of 15% MTBE by volume) are approved as a fuel for Kohler engines.
  • Page 29 Fuel System and Governor Fuel Filter Most engines are equipped with an in-line fuel filter. Periodically inspect the filter and replace with a genuine Kohler filter every 200 operating hours. Troubleshooting – Fuel System Related Causes Test 1. Check the following: a.
  • Page 30 Mechanical Fuel Pump The mechanical fuel pump is built into the #2 valve cover. The actuating arm of the pump extends down inside the cover and contacts one of the rocker arms. Downward movement of the rocker arm allows the pump diaphragm to flex down, drawing in fuel.
  • Page 31 Section 5 Fuel System and Governor Figure 5-2. Valve Cover Torque Sequence. Carburetor General Engines in this series are equipped with emission compliant fixed main jet carburetors, manufactured by Keihin. All have self-relieving chokes for efficient operation. Depending on the specifications and application involved, most will also contain a fuel shut-off solenoid and an accelerator pump.
  • Page 32 Adjusting Low Idle Speed (RPM) Setting 1. Start the engine and run at half throttle for 5 to 10 minutes to warm up. The engine must be warm before making final low idle speed (RPM) adjustment. Check that the throttle and choke plates can fully open.
  • Page 33 Section 5 Fuel System and Governor Troubleshooting – Carburetor Related Causes Condition 1. Engine starts hard, runs roughly or stalls at idle speed. 2. Engine runs rich (indicated by black, sooty exhaust smoke, misfiring, loss of speed and power, governor hunting, or excessive throttle opening).
  • Page 34 Disassembly Disassemble the carburetor using the following steps. See Figure 5-6. 1. Remove the intake elbow and hose (if attached), breather hose, and carburetor. Refer to Section 9 - "Disassembly". 2. Remove the four screws and carefully separate the air horn assembly from the carburetor body. 3.
  • Page 35 Section 5 Fuel System and Governor NOTE: The fuel inlet needle tip is spring loaded. Make sure float assembly rests against the fuel inlet needle without depressing the tip. 6. The correct float height adjustment is 22 mm (0.86 in.) measured from the float bottom to the air horn casting.
  • Page 36 Figure 5-6. Carburetor - Exploded View. 1. Carburetor Upper Body (Choke) 2. Self-Relieving Choke 3. Body Gasket (Formed Rubber) 4. Slow Speed Jet 5. Inlet Needle Valve 6. Clip 7. Float Pin 8. Float Assembly (Kit) 9. Carburetor Lower Body (Throttle) 10.
  • Page 37 Section 5 Fuel System and Governor Carburetor Service/Repair Kits Always refer to the Parts Manual for the engine being serviced to ensure the correct repair kits and replacement parts are ordered. Carburetor Repair Kit Contains: Description Qty. Carburetor Body Gasket Carburetor Body Screw Idle Needle Spring Slow Jet O-Ring...
  • Page 38 Reassembly Procedure Reassemble the carburetor using the following steps. See Figure 5-6. 1. Assemble fuel inlet needle to the float tab. Install the float, float shaft and inlet needle to the carburetor upper body. Tighten the screw. Check float height using the procedure found previously in the "Adjustments"...
  • Page 39 Section 5 Fuel System and Governor Figure 5-8. Governor Controls and Linkage (External) (Air Cleaner Removed for Clarity). Adjustments General The governed speed setting is determined by the position of the throttle control. It can be variable or constant, depending on the engine application. Initial Adjustment NOTE: The LH760 and LH775 (EFI) engines require a special initial adjustment procedure, which is...
  • Page 40 Left Side Pull Choke Control Lever #1 Choke Control Cable Throttle Control Cable Kill Switch Adjusting Screw Dual Control High Speed Lever Stop Screw "Do Not Remove" Figure 5-9. Governor Control Connections. Fuel System and Governor Throttle Control Kill Switch Lever #2 High Speed Control Lever High Speed...
  • Page 41 Electronic Fuel Injection (EFI) Contents Description Initial Starting/Priming Procedure ... 5B.2 Fuel Recommendations ... 5B.2 EFI Fuel System Components ... 5B.3 Operation ... 5B.3 Important Service Notes ... 5B.4 Electrical Components Electronic Control Unit (ECU) ... 5B.4-5B.5 Engine Speed Sensor ... 5B.5-5B.6 Throttle Position Sensor (TPS) &...

  • Page 42: Description

    87 or higher. In countries using the Research method, it should be 90 octane minimum. Gasoline/Alcohol blends Gasohol (up to 10% ethyl alcohol, 90% unleaded gasoline by volume) is approved as a fuel for Kohler EFI engines. Other gasoline/alcohol blends are not approved. Gasoline/Ether blends...

  • Page 43: Efi Fuel System Components

    EFI Fuel System Components General The Electronic Fuel Injection (EFI) system is a complete engine fuel and ignition management design. The system includes the following principal components: • Fuel Pump • Fuel Filter • Fuel Rail • Fuel Line(s) • Fuel Pressure Regulator •...

  • Page 44: Important Service Notes

    Section 5B EFI Fuel System Important Service Notes! • Cleanliness is essential and must be maintained at all times when servicing or working on the EFI system. Dirt, even in small quantities, can cause significant problems. • Clean any joint or fitting with parts cleaning solvent before opening to prevent dirt from entering the system.

  • Page 45: Engine Speed Sensor

    The ECU requires a minimum of 7.0 volts to operate. The adaptive memory in the ECU is operational the moment the battery cables are connected, however the adapted values are lost if the battery becomes disconnected for any reason. The ECU will “relearn” the adapted values if the engine is operated for 10-15 minutes at varying speeds and loads after the coolant temperature exceeds 55°C (130°F).
  • Page 46 Section 5B EFI Fuel System Dual Aligning Rails Corresponds #10 In Main Connector. Test Terminals Figure 5B-3. Speed Sensor Connector. 7. a. If the resistance is incorrect, remove the screw securing the sensor to the mounting bracket and replace the sensor. b.
  • Page 47 Mounted on the throttle body/intake manifold and operated directly off the end of the throttle shaft, the TPS works like a rheostat, varying the voltage signal to the ECU in direct correlation to the angle of the throttle plate. This signal, along with the other sensor signals, is processed by the ECU and compared to the internal pre-programmed maps to determine the required fuel and ignition settings for the amount of...

  • Page 48: Engine (Coolant) Temperature Sensor

    Section 5B EFI Fuel System 3. Locate the service connector plug in the wiring harness. To initiate the TPS auto-learn function, connect a jumper wire from the TPS initialization pin #24 (violet wire) to the battery voltage pin (red wire), or use a jumper connector plug with the blue jumper wire.

  • Page 49: Oxygen Sensor

    General The engine (coolant) temperature sensor (Figure 5B-7) is used by the system to help determine fuel requirements for starting (a cold engine needs more fuel than one at or near operating temperature). Mounted in the throttle body/intake manifold, it has a temperature-sensitive resistor that extends into the coolant flow.
  • Page 50 Section 5B EFI Fuel System The oxygen sensor can function only after being heated by exhaust temperatures to a minimum of 375°C (709°F). A cold oxygen sensor will require approximately 1-2 minutes at moderate engine load to warm sufficiently to generate a voltage signal. Proper grounding is also critical.

  • Page 51: Electrical Relay

    a. If the resistance is greater than 1.0 MΩ Ω Ω Ω Ω , go to step 5. b. If the resistance is less than 1.0 MΩ Ω Ω Ω Ω , the sensor is bad, replace it. 5. With the oxygen sensor disconnected and engine not running, disconnect the main harness connector from the ECU and set the meter to the Rx1 scale.

  • Page 52: Fuel Injectors

    Section 5B EFI Fuel System Terminal #85 - Ignition Switch Voltage Terminal #87A - Not used Terminal #30 - Permanent Battery Voltage Figure 5B-11. Relay Connector. a. Clean the connection and check wiring if circuit was not completed. 3. Set the meter for DC voltage. Touch the red tester lead to the #30 terminal in relay connector.
  • Page 53 Multi-Orifice Director Plate With Calibrated Opening 1. Filter strainer in 4. Valve housing fuel supply 5. Armature 2. Electrical connection 6. Valve body 3. Solenoid winding 7. Valve needle Figure 5B-14. Fuel Injector Details. The injector is opened and closed once for each crankshaft revolution, however only one-half the total amount of fuel needed for one firing is injected during each opening.
  • Page 54 Section 5B EFI Fuel System 2. Make sure all safety switch requirements are met. Crank the engine and check for flashing of noid light. Repeat test at other connector. a. If flashing occurs, use an ohmmeter (Rx1 scale) and check the resistance of each injector across the two terminals.

  • Page 55: Ignition System

    13. Depressurize the fuel system following the procedure in the fuel warning on page 5B.2. Remove the two fuel rail mounting screws. 14. Clean any dirt accumulation from the sealing/ mounting area of the faulty injector(s) and disconnect the electrical connector(s). 15.

  • Page 56: Spark Plugs

    Section 5B EFI Fuel System Disconnect the secondary lead from the spark plug. Connect an ohmmeter set on the Rx10K scale between the spark plug boot terminal and the red primary terminal. Secondary resistance should be 13,000-17,500 Ω Ω Ω Ω Ω . If the secondary resistance is not within the specified range, unscrew the spark plug lead nut from the coil secondary...

  • Page 57: Fuel Pressure Regulator

    Service The fuel pumps are non-serviceable and must be replaced if determined to be faulty. If a fuel delivery problem is suspected, make certain the pump is being activated through the relay, all electrical connections are properly secured, the fuses are good, and a minimum of 7.0 volts is being supplied.
  • Page 58 Section 5B EFI Fuel System Pressure Regulating Spring Valve Inlet Port Return Port (to tank) Figure 5B-22. Fuel Pressure Regulator Details. Service Depending on the application, the regulator may be located in the fuel tank along with the fuel pump, or outside the tank just down line from the pump.

  • Page 59: Fuel Filter

    60" of high-pressure hose and 10 Oetiker clamps), or use only the type specified. Special Oetiker clamps (Kohler Part No. 24 237 05-S) are used on all fuel line connections to prevent tampering and safety hazards with the high fuel pressure. The old clamp must be cut to open a connection, so replacement is necessary each time.

  • Page 60: Throttle Body/Intake Manifold Assembly

    Section 5B EFI Fuel System Throttle Body/Intake Manifold Assembly Figure 5B-28. Upper Intake Manifold. General The EFI engines have no carburetor, so the throttle function (regulate incoming combustion airflow) is incorporated in the intake manifold assembly. The manifold consists of a one-piece aluminum casting which also provides mounting for the fuel injectors, throttle position sensor, fuel rail, air baffle, idle speed screw, and air cleaner assembly.
  • Page 61 If the governor/throttle components are all intact, but you think there may be a problem with the adjustment, follow Procedure A to check the setting. If the governor lever was loosened or removed, go immediately to Procedure B to perform the initial adjustment.

  • Page 62: Troubleshooting

    Section 5B EFI Fuel System 3. Insert a nail into the hole in the top of the cross shaft. Using light pressure, rotate the governor shaft counterclockwise as far as it will turn, then torque the hex nut on the clamping screw to 6.8 N·m (60 in.

  • Page 63: Electrical System

    Electrical System The EFI system is a 12 VDC negative ground system, designed to operate down to a minimum of 7.0 volts. If system voltage drops below this level, the operation of voltage sensitive components such as the ECU, fuel pump, and injectors will be intermittent or disrupted, causing erratic operation or hard starting.
  • Page 64 Ignition Coil #2 Output Fan Control Output* *On LH775 Kohler liquid-cooled engines, the ECU and corresponding wiring harness provide two additional circuits. Pin circuit 32 provides ability to control an optional OEM electric cooling fan, switching it on and off at the appropriate coolant temperatures using a relay.

  • Page 66: Fuel System

    Section 5B EFI Fuel System Fuel System WARNING: Fuel System Under Pressure! The fuel system operates under high pressure. System pressure must be relieved through the test valve in the fuel rail prior to servicing or removing any fuel system components. Do not smoke or work near heaters or other fire hazards.
  • Page 67 Example of Diagnostic Display 1. Diagnostic display initiated through ignition key sequencing. Long Pause Figure 5B-35. Diagnostic Display. After the problem has been corrected, the fault codes may be cleared as follows. 1. Disconnect the negative (-) battery cable from battery terminal, or remove the main fuse for the ECU for approximately 1 minute.
  • Page 68 Section 5B EFI Fuel System Diagnostic Code Summary Blink OBD2 Code P-Code – – No RPM Signal Loss of Synchronization P0335 TPS - Open or Short Circuit to Ground P0122 P0123 TPS - Short Circuit to Battery P0601 Defective ECU Engine Speed Sensor P0174 System too Lean...
  • Page 69 Diagnostic Code Summary Code: Source: Engine Speed Sensor Explanation: ECU receiving inconsistent tooth count signals from speed sensor. Expected Engine Response: Possible misfire as ECU attempts to resynchronize, during which time fuel and spark calculations are not made. Possible Causes: 1.
  • Page 70 Section 5B EFI Fuel System Code: Source: Explanation: ECU is unable to recognize or process signals from its memory. Expected Engine Response: Engine will not run. Possible Causes: 1. ECU (internal memory problem). a. Diagnosable only through the elimination of all other system/component faults.
  • Page 71 2. Oxygen Sensor Related a. Sensor connector or wiring problem. b. Sensor contaminated or damaged. c. Exhaust leak. d. Poor ground path. e. Pin circuit #20 wiring or connectors. 3. TPS Sensor Related a. Throttle plate position incorrectly set or registered during “Initialization.’’...
  • Page 72 Section 5B EFI Fuel System Code: 43 and 44 Source: TPS “Auto-Learn” initialization function failed, throttle angle out of learning range. Explanation: While performing the TPS “Auto- Learn” function the measured throttle angle was not within acceptable limits. Expected Engine Response: MIL illuminated.

  • Page 73: Troubleshooting Flow Chart

    Code: Source: MIL (Diagnostic lamp) circuit open, shorted to ground, or shorted to battery. Explanation: MIL is not functioning because the circuit is open, shorted to ground, or shorted to battery. Expected Engine Response: Engine will run normally if no other errors are present.
  • Page 74 Section 5B EFI Fuel System *Operate for an appropriate period of time based upon original fault codes. Figure 5B-36. 5B.34...

  • Page 75: Flow Chart Diagnostic Aids

    Flow Chart Diagnostic Aids Diagnostic Aid #1 “SYSTEM POWER” (MIL does not illuminate when key is turned “on”) Possible causes: 1. Battery 2. Main system fuse 3. MIL light bulb burned out 4. MIL electrical circuit problem. Pin circuits 29 and 84.

  • Page 76: Common Complaints/Problems

    Section 5B EFI Fuel System Diagnostic Aid #5 “FUEL PUMP” (fuel pump not turning on) Possible causes: 1. Fuel pump fuse 2. Fuel pump circuit problem. Circuits 30, 87, and relay. 3. Fuel pump Diagnostic Aid #6 “RELAY” (relay not operating) Possible causes: 1.
  • Page 77 Engine idles too fast (after full warm-up). 1. Throttle linkage binding or not returning to idle position. 2. Idle speed adjustment incorrect. 3. Vacuum (intake air) leak. 4. Leaking fuel injector O-Rings (injector to manifold). 5. Engine (Coolant) Temperature sensor faulty. 6.

  • Page 78: Section 6. Lubrication System

    Lubrication System General This engine uses a full pressure lubrication system. This system delivers oil under pressure to the crankshaft, camshaft and connecting rod bearing surfaces. In addition to lubricating the bearing surfaces, the lubrication system supplies oil to the hydraulic valve lifters.
  • Page 79 (more often under severe conditions). Refill with service class SG, SH, SJ or higher oil, as specified in the ‘‘Viscosity Grades’’ table on previous page. Always use a genuine Kohler oil filter. Use chart below to determine part number to order.
  • Page 80 3. Before removing the oil filter, clean the surrounding area to keep dirt and debris out of the engine. Remove the old filter and wipe/clean the surface where the filter mounts. 4. Reinstall the drain plug. Make sure it is tightened to 13.6 N·m (10 ft.
  • Page 81 Section 6 Lubrication System To install the switch, follow these steps: 1. Apply pipe sealant with Teflon 59241 or equivalent) to the threads of the switch. 2. Install the switch into the tapped hole in the breather cover. See Figure 6-5. 3.

  • Page 82: Section 7. Cooling System

    WARNING: Explosive release of fluids from pressurized cooling system can cause serious burns! When it is necessary to open cooling system at radiator cap, shut off engine and remove filler cap only when cool enough to touch with bare hands. Slowly loosen cap to first stop to relieve pressure before removing completely. This section covers the operation and servicing of the liquid cooling system.
  • Page 83 Section 7 Cooling System DO NOT use antifreeze with stop-leak additive(s), or put any other additives in the cooling system. Cooling System Maintenance and Service Maintenance Maintaining the correct coolant level, cleaning any debris accumulation from the radiator surfaces, and insuring all parts are in proper operating condition, is critical to ensuring long life, proper system performance and preventing overheating.
  • Page 84 Figure 7-5. Coolant Levels on Reservoir. NOTE: Do not operate the engine without coolant in the system. Do not remove the radiator cap when hot. Engine coolant is hot and under pressure and can cause severe burns. To prevent engine overheating and damage, do not exceed more than 70% antifreeze in the cooling system.
  • Page 85 Section 7 Cooling System 5. Reinstall the reservoir into the mounting bracket, and install the cap. Do not kink/pinch the hose. 6. Flush the cooling system. Flushing Cooling System NOTE: To prevent engine damage, do not pour water into a hot engine. Do not operate engine without coolant.
  • Page 86 Use only Kohler Part No. 66 203 02-S belt if replacement is necessary. See an authorized Kohler Service Dealer for any necessary service.
  • Page 87 Section 7 Cooling System Intake Manifold Thermostat Figure 7-12. Intake/Thermostat. To Test Remove the thermostat from the system. Hang or suspend the thermostat by its frame in a container of water, so the thermostat does not touch the bottom of the container.
  • Page 88 4. After the engine has sufficiently cooled, check the coolant level in the system to make sure it is not low, or improperly mixed. 5. Check cooling system for leaks. 6. Check the thermostat, and pressure test the radiator cap. 7.
  • Page 89 Section 7 Cooling System 5. Observe the system pressure on the gauge. Gauge Needle Holds Steady If the gauge needle holds steady, there should be no serious leaks in the system. It is however, recommended that all connections be checked for overall condition anyway, using a flashlight.

  • Page 90: Section 8. Electrical System And Components

    The engine is equipped with the following spark plugs: Type: The standard spark plug is a Champion RC14YC (Kohler Part No. 66 132 01-S). Equivalent alternate brand plugs can also be used. Gap: 0.76 mm (0.030 in.) Thread Size:...
  • Page 91 Section 8 Electrical System and Components Inspection Inspect each spark plug as it is removed from the cylinder head. The deposits on the tip can be an indication of the general condition of the engine and/ or adverse operating conditions. Normal and fouled plugs are shown in the following photos: Normal: A plug taken from an engine operating under...
  • Page 92 Overheated: Chalky, white deposits indicate very high combustion temperatures. This condition is usually accompanied by excessive gap erosion. Lean carburetor settings, an intake air leak, or incorrect spark timing are normal causes for high combustion temperatures. Battery General A 12-volt battery with 400 cold cranking amps is generally recommended for starting in all conditions.
  • Page 93 Section 8 Electrical System and Components DC Voltmeter Figure 8-2. Battery Voltage Test. Kill Switch or ‘‘Off’’ Position of Key Switch Figure 8-3. Capacitive Discharge Ignition System. Electronic CD Ignition Systems Operation of CD Ignition Systems Capacitive Discharge with Fixed Timing. This system consists of the following components.
  • Page 94 Eyelet Terminal for Ignition Key Switch (or Starter Post) Diodes Ignition Module Input B+ and Carburetor Solenoid Input Oil Pressure Safety Input Figure 8-4. Electronic CD Ignition System (For Customer Connected Tractor Applications). Figure 8-5. Capacitive Discharge Ignition Module. Operation: As the flywheel rotates, the magnet grouping passes the input coil (L1).
  • Page 95 As you have interrupted the kill circuit, it may not stop with the switch. 2. Test for spark on both cylinders with Kohler ignition tester (see Section 2). Disconnect one spark plug lead and connect it to the post terminal of the tester.
  • Page 96 CONNECTOR LAYOUT Starter (L/R) Ground Battery (R) Key Switch Starter Ground (B) Battery Run (R) Ignition Kill (W) Key Switch Accessory (Y) Ignition Kill Connector Battery Starter Solenoid Stud Fuse Starter Solenoid Tang Starter Assembly Figure 8-6. Wiring Diagram - 15/20/25 Amp Regulated Battery Charging System. Rectifier-Regulator Figure 8-7.

  • Page 97: Section 9. Disassembly

    Section 8 Electrical System and Components Stator The stator is mounted on the crankcase behind the flywheel. If the stator needs to be replaced, follow the procedures in Section 9 - “Disassembly.” Rectifier-Regulator The rectifier-regulator is mounted on the bracket below the overflow reservoir.
  • Page 98 Figure 8-11. a. If the “OK” (green) light comes on and stays steady, the part is good and may be used. b. If any other light is displayed,* the rectifier- regulator is faulty and should not be used. *NOTE: A flashing “LOW” light can also occur as a result of an inadequate ground lead connection.
  • Page 99 Section 8 Electrical System and Components DC Voltmeter Rectifier-Regulator Flywheel Stator (–) Ammeter Battery Figure 8-14. Connections for Testing Charging System. 8.10...
  • Page 100 Troubleshooting Guide 15/20/25 Amp Battery Charging Systems If it is difficult to keep the battery charged, or the battery overcharges, the problem is usually with the charging system or the battery. NOTE: Always zero ohmmeter on each scale before testing to ensure accurate readings. Voltage tests should be made with the engine running at 3600 RPM - no load.
  • Page 101 Section 8 Electrical System and Components Electric Starting Motors These engines utilize solenoid shift style starter motors for dependable operation. Operation, service and troubleshooting of the starter and starter system follow in this section. Starting Motor Precautions NOTE: Do not crank the engine continuously for more than 10 seconds at a time.
  • Page 102 Delco-Remy Starters Figure 8-15. Completed Delco-Remy Starter. Starter Disassembly 1. Remove the hex nut and disconnect the positive (+) brush lead/bracket from the solenoid terminal. 2. Remove the three screws securing the solenoid to the starter. See Figure 8-16. Phillips Head Screws Torx Head Screws Figure 8-16.
  • Page 103 Section 8 Electrical System and Components 4. Remove the two thru (larger) bolts. See Figure 8-19. Figure 8-19. Removing Thru Bolts. 5. Remove the commutator end plate assembly, containing the brush holder, brushes, springs, and locking caps. Remove the thrust washer from inside the commutator end.
  • Page 104 Figure 8-24. Retaining Ring Detail. 11. Remove the retainer from the armature shaft. Save the stop collar. NOTE: Do not reuse the old retainer. Collar Ring Stop Drive Armature Washer Tube Figure 8-26. Delco-Remy Starter. Electrical System and Components Figure 8-25. Removing Retaining Ring. 12.
  • Page 105 Section 8 Electrical System and Components Inspection Drive Pinion Check and inspect the following areas: a. The pinion teeth for abnormal wear or damage. b. The surface between the pinion and the clutch mechanism for nicks, or irregularities which could cause seal damage. c.
  • Page 106 Brush Replacement The brushes and springs are serviced as a set (4). Use Brush and Spring Kit, Kohler Part No. 25 221 01-S, if replacement is necessary. 1. Perform steps 1-5 in “Starter Disassembly.” 2. Remove the two screws securing the brush holder assembly to the end cap (plate).
  • Page 107 Section 8 Electrical System and Components Figure 8-33. Installing Thrust Washer. 4. Apply a small amount of oil to the bearing in the drive end cap, and install the armature with the drive pinion. 5. Lubricate the fork end and center pivot of the drive lever with drive lubricant (see Section 2).
  • Page 108 Figure 8-37. Installing Thrust Washer. 10. Starter reassembly when replacing the Brushes/ Brush Holder Assembly: a. Hold the starter assembly vertically on the end housing, and carefully position the assembled brush holder assembly, with the supplied protective tube, against the end of the commutator/armature.
  • Page 109 Section 8 Electrical System and Components Figure 8-41. Installing Brush Holder Assembly Using Tool with Extension. 11. Install the end cap onto the armature and frame, aligning the thin raised rib in the end cap with the corresponding slot in the grommet of the positive (+) brush lead.
  • Page 110 Solenoid Test Procedure Solenoid Shift Style Starters Disconnect all leads from the solenoid including the positive brush lead attached to the lower stud terminal. Remove the mounting hardware and separate the solenoid from the starter for testing. Test 1. Solenoid Pull-In Coil/Plunger Actuation Test.
  • Page 111 Section 8 Electrical System and Components Test 4. Solenoid Hold-In Coil/Contact Continuity Test. Use an ohmmeter set to the audible or Rx2K scale, and connect the two ohmmeter leads to the two large post terminals. Perform the preceding test (3) and check for continuity.
  • Page 112 WARNING: Accidental Starts! Disabling engine. Accidental starting can cause severe injury or death. Before working on the engine or equipment, disable the engine as follows: 1) Disconnect the spark plug lead(s). 2) Disconnect negative (-) battery cable from battery. General Clean all parts thoroughly as the engine is disassembled.

  • Page 113: Shut Off Fuel Supply

    Section 9 Disassembly Shut Off Fuel Supply Remove Muffler 1. Remove the exhaust system, muffler, and attaching hardware from the engine. Remove Starter and Adapter Plate 1. Disconnect the leads attached to the starter solenoid terminals. 2. Remove the two hex flange screws securing the starter to the adapter plate.
  • Page 114 Drain Oil from Crankcase and Remove Oil Filter 1. Remove the oil fill cap and dipstick, and one or both of the drain plugs. See Figures 9-6 and 9-7. Allow sufficient time for the oil to drain out. Oil Fill Cap Dipstick Figure 9-6.
  • Page 115 Section 9 Disassembly Figure 9-10. Disconnecting Upper and Lower Radiator Hose. 4. Remove the four screws securing the two upper radiator supports to the air cleaner mounting bracket. See Figure 9-11. Figure 9-11. Remove Upper Radiator Support Screws. 5. Carefully tilt (pull) the radiator forward slightly to clear the fan and lift the complete assembly out of the lower mounting bracket.
  • Page 116 8. Further disassembly for component servicing may be performed as required. Remove Air Cleaner Assembly 1. Remove the two screws securing the elbow adapter and gasket to the carburetor. See Figure 9-15. Figure 9-15. Removing Elbow Adapter Mounting Screws. 2. Remove the two upper valve cover mounting screws on each side, which also secure the main mounting bracket for the air cleaner.

  • Page 117: Remove Carburetor And Adapter

    Section 9 Disassembly 3. Tilt the main bracket and disconnect the choke linkage from the choke lever. See Figure 9-19. Remove the main control bracket. Figure 9-19. Tilting Bracket and Unhooking Choke Link. 4. Unhook the choke linkage from the actuator lever on carburetor.
  • Page 118 4. Remove the carburetor, throttle linkage and governor lever as an assembly. See Figure 9-23. Figure 9-23. Removing Carburetor from Engine. 5. Remove the carburetor gasket. 6. The carburetor, adapter, throttle linkage, and governor lever may be separated for individual component servicing as required.

  • Page 119: Remove Lower Drive Pulley And Fan Belt

    Section 9 Disassembly 4. Remove the hex flange screw, breather reed retainer and breather reed from the breather chamber. See Figure 9-28. Figure 9-28. Removing the Breather Reed Assembly Parts. Remove Valve Covers 1. Remove the hex flange screws from the two lower valve cover mounting locations on each side.
  • Page 120 2. Remove the pulley halves with the spacer shims from the adapter, and take the fan belt off the upper pulley/fan assembly. Note the number of shims between pulley halves, and on the front side of pulley, especially if the same belt will be reinstalled.

  • Page 121: Remove Ignition Modules

    Section 9 Disassembly Remove Ignition Modules 1. Disconnect the kill leads from the ignition modules. See Figure 9-36. Figure 9-36. Removing Kill Leads from Ignition Modules. 2. Rotate the flywheel, so the magnet is away from the ignition modules. 3. Remove the mounting screws and take off each ignition module.
  • Page 122 Remove Stator Assembly 1. Remove the two mounting screws, and pull the stator, with the plug-in connector attached, from the engine. See Figure 9-40. Figure 9-40. Removing Stator Screws. Remove Intake Manifold, Thermostat Housing, By-pass Hose and Wiring Harness 1. Disconnect the by-pass hose from the fitting on the water pump.

  • Page 123: Remove Water Pump And Transfer Tube

    Section 9 Disassembly 4. Further disassembly of the intake manifold components may be performed as necessary. If the thermostat is to be removed, loosen and remove the two hex flange screws securing the thermostat housing to the intake manifold. Separate the housing and remove the thermostat, discard the old gasket.
  • Page 124 Figure 9-48. Removing Water Pump Screws. 3. Lift the water pump up, and carefully work the ferruled end of the transfer tube out of the fitting. Remove the water pump with the transfer tube and the hose section attached. Remove and discard the O-Ring from within the channel of the pump housing.
  • Page 125 Section 9 Disassembly 4. Remove the four hex flange nuts and washers from the cylinder head studs. Carefully remove the cylinder heads and head gaskets. See Figure 9-52. Figure 9-52. Removing Cylinder Heads and Gaskets. 5. Remove the hydraulic lifters using a hydraulic lifter removing tool (do not use a magnet).

  • Page 126: Remove Closure Plate

    Figure 9-56. Disassembled Head and Valve Components. NOTE: These engines use a valve stem seal on the intake and exhaust valves. Serial No. 3422000010 and lower used a seal on intake side only. See Figure 9-57. Always use new seals when the valves are removed from the cylinder head.

  • Page 127: Remove Camshaft

    Section 9 Disassembly Governor Assembly The governor assembly is located inside the closure plate. If service is required, refer to the service procedures under "Governor Assembly" in Section 10. Oil Pump Assembly The oil pump is mounted to the inside of the closure plate as well.
  • Page 128 Remove Governor Cross Shaft 1. Remove the retaining ring and nylon washer from the governor cross shaft. See Figure 9-64. Figure 9-64. Removing Governor Shaft Retaining Ring and Washer. NOTE: Always use a new retaining ring when reassembling. Do not reuse the old retaining ring.

  • Page 129: Section 10. Inspection And Reconditioning

    Inspection and Reconditioning This section covers the operation, inspection, and repair/reconditioning of major internal engine components. Also included are water pump, cooling system and fan drive belt inspection criteria. The following components are not covered in this section. They are covered in sections of their own: Air Cleaner, Section 4 Carburetor &...
  • Page 130 Procedure to Install New Plug: 1. Use a single cylinder camshaft pin, Kohler Part No. 47 380 09-S, as a driver and tap the plug into the plug bore until it seats at the bottom of the bore.
  • Page 131 Honing While most commercially available cylinder hones can be used with either portable drills or drill presses, the use of a low speed drill press is preferred as it facilitates more accurate alignment of the bore in relation to the crankshaft crossbore. Honing is best accomplished at a drill speed of about 250 RPM and 60 strokes per minute.
  • Page 132 Replace the flywheel, the crankshaft, and the key if flywheel key is sheared or the keyway is damaged. Inspect the ring gear for cracks or damage. Kohler does not provide ring gears as a serviceable part. Replace the flywheel if the ring gear is damaged.
  • Page 133 Exhaust Valve Dimension 89° Seat Angle 36.987/37.013 mm (1.4562/1.4572 in.) Insert O.D. 4 mm (0.1575 in.) Guide Depth 7.038/7.058 mm (0.2771/0.2779 in.) Guide I.D. 33.37/33.63 mm (1.3138/1.3240 in.) Valve Head Diameter 45° Valve Face Angle 1.5 mm (0.0591 in.) Valve Margin (Min.) 6.982/7.000 mm (0.2749/0.2756 in.) Valve Stem Diameter Figure 10-6.
  • Page 134 Section 10 Inspection and Reconditioning Hard starting, or loss of power accompanied by high fuel consumption may be symptoms of faulty valves. Although these symptoms could also be attributed to worn rings, remove and check the valves first. After removal, clean the valve heads, faces, and stems with a power wire brush.
  • Page 135 Stem Corrosion: Moisture in fuel or from condensation are the most common causes of valve stem corrosion. Condensation occurs from improper preservation during storage and when engine is repeatedly stopped before it has a chance to reach normal operating temperatures. Replace corroded valves.
  • Page 136 Section 10 Inspection and Reconditioning Valve Guides If a valve guide is worn beyond specifications, it will not guide the valve in a straight line. This may result in burnt valve faces or seats, loss of compression, and excessive oil consumption. To check valve guide-to-valve stem clearance, thoroughly clean the valve guide and, using a split- ball gauge, measure the inside diameter.
  • Page 137 Pistons and Rings Inspection Scuffing and scoring of pistons and cylinder walls occurs when internal temperatures approach the welding point of the piston. Temperatures high enough to do this are created by friction, which is usually attributed to improper lubrication, and/or overheating of the engine.
  • Page 138 Section 10 Inspection and Reconditioning Replacement pistons are available in STD bore size, 0.08 mm (0.003 in.), 0.25 mm (0.010 in.), and 0.50 mm (0.20 in.) oversizes. Replacement pistons include new piston ring sets and new piston pins. The ring sets are also available separately.
  • Page 139 Piston Ring End Gap "Identification "Mark Piston Top Compression Ring Center Compression Ring Oil Control Ring (Three-piece) Expander Figure 10-12. Piston Ring Installation. 1. Oil Control Ring (Bottom Groove): Install the expander and then the rails. Make sure the ends of expander are not overlapped.

  • Page 140: Section 11. Reassembly

    Section 10 Inspection and Reconditioning Figure 10-13. Removing Governor Gear. 2. Remove the locking tab thrust washer located under the governor assembly. 3. Carefully inspect the governor gear shaft and replace it only if it is damaged. After pulling damaged shaft, press or lightly tap replacement shaft into closure plate to depth shown in Figure 10-14.
  • Page 141 Reassembly 1. Install the oil pickup to the oil pump body. Lubricate the O-Ring with oil and make sure it remains in the groove as the pickup is being installed. 2. Install the rotor. 3. Install the oil pump body to the closure plate and secure with the two hex flange screws.
  • Page 142 3. Check the v-belt for excessive wear, cracking or damage. If proper belt tension cannot be obtained, or the condition of the belt is suspect; replace it with Kohler Part No. 66 203 02-S. Do not use a substitute belt.
  • Page 143 General NOTE: Make sure the engine is assembled using all specified torque values, tightening sequences and clearances. Failure to observe specifications could cause severe engine wear or damage. Always use new gaskets. Apply a small amount of oil to the threads of critical fasteners before assembly, unless a Sealant or ®...
  • Page 144 Section 11 Reassembly Install Flywheel End Oil Seal and Camshaft Oil Seal 1. Check to make sure that there are no nicks or burrs in the crankshaft and camshaft seal bores of the crankcase. 2. Apply a light coat of engine oil to the outside diameter of the flywheel end oil seal.
  • Page 145 Install Crankshaft 1. Lightly lubricate the lips of crankshaft seal with grease. NOTE: Apply cellophane tape over the crankshaft keyway to prevent cutting the oil seal during installation. 2. Carefully slide the flywheel end of the crankshaft into the crankcase through the oil seal. See Figure 11-5.
  • Page 146 Section 11 Reassembly Figure 11-8. Attaching #1 Rod Cap. Figure 11-9. Torquing #1 Rod Cap. NOTE: Make sure to align the chamfer of the connecting rod with the chamfer of its mating end cap. When installed, the flat faces of the connecting rods should face each other.
  • Page 147 Checking/Setting Camshaft End Play 1. Install the shim removed during disassembly onto the camshaft. 2. Position the end play tool on the camshaft. 3. Apply pressure on the end play checking tool (pushing the camshaft toward the crankshaft). Use a feeler gauge to measure the end play between the shim and the end play tool.
  • Page 148 Section 11 Reassembly The race for the thrust bearing presses loosely into the closure plate. If it is not already installed, push it into the crankshaft bore inside the closure plate. Pack the thrust bearing with heavy grease and stick the bearing into the race.
  • Page 149 Figure 11-16. Closure Plate Sealant Pattern. 4. Make sure end of governor cross shaft is lying against the bottom of cylinder #1 inside of the crankcase. See Figure 11-17. 5. If alignment pins were removed previously, install them in their respective locations in the crankcase.
  • Page 150 Section 11 Reassembly Figure 11-20. Torquing Closure Plate Screws. Install Cylinder Studs NOTE: Do not reinstall or attempt to reuse any cylinder studs that have been removed. Discard any removed stud(s) and replace with new. If any of the cylinder studs were removed, install new stud(s) as follows: 1.
  • Page 151 4. Install the breather filter into the cavity in the crankcase. See Figure 11-24. Figure 11-24. Installing Breather Filter. 5. Carefully install the breather cover gasket and breather cover onto the crankcase. See Figure 11-25. Figure 11-25. Installing and Torquing Breather Cover/Screws.
  • Page 152 Section 11 Reassembly Figure 11-28. Crankcase Vacuum Fitting Position. Install Hydraulic Lifters 1. Lubricate the lifters and lifter bores in the crankcase with engine oil. NOTE: Hydraulic lifters should always be installed in the same position as before disassembly. 2. Install the lifters into their respective lifter bores according to location and cylinder number marked during assembly.
  • Page 153 Figure 11-32. Assembling Valves with a Valve Spring Compressor. Install Cylinder Heads 1. Check to make sure there are no nicks or burrs on the sealing surfaces of the cylinder head or crankcase. 2. Rotate the crankshaft to position the piston in cylinder #1 to top dead center (TDC) on the compression stroke.
  • Page 154 Section 11 Reassembly #1 Cylinder Head #2 Cylinder Head Figure 11-36. Cylinder Head Torque Sequence. 7. Repeat the installation procedure for the #2 side cylinder head. Install Push Rods and Rocker Arms 1. Note the mark or tag identifying the push rod as either intake or exhaust for cylinder #1.
  • Page 155 2. Install new valve cover gaskets onto the valve covers. See Figure 11-39. Figure 11-39. Installing Valve Cover Gaskets. 3. Install the valve covers with gaskets in their original locations. 4. Install the lower two mounting screws in each cover, and finger tighten only. Upper screws will be installed later.
  • Page 156 Section 11 Reassembly Figure 11-43. Test Fitting Pulley. 2. If the water pump by-pass hose fitting was removed previously, apply pipe sealant with ® ® Teflon (Loctite 59241 or equivalent) on the threads and tighten it into pump. Orient the fitting so the outlet points in the 11 o'clock position as shown in Figure 11-44.
  • Page 157 6. Slide the smaller diameter clamp onto the extruded end of the formed metal tube and insert this end of the tube into the hose section. Position the tube so its formed offset leads down and away from outlet, perpendicular to the pump. Install the clamp onto the hose and position the tangs of the clamp parallel to those of the first clamp.
  • Page 158 Section 11 Reassembly Figure 11-51. Water Pump Torque Sequence. NOTE: When installation is complete, the tangs of the two hose clamps should face outward, away from the flywheel and slightly down. See Figure 11-52. Figure 11-52. Transfer Tube Hose Clamp(s) Detail. 9.
  • Page 159 Figure 11-55. Torquing Mounting Screw of Cam Pulley. Install Intake Manifold Assembly 1. Check that the gasket surfaces of the intake manifold and cylinder heads are clean and free of any nicks or damage. 2. Install new intake manifold gaskets onto the port surfaces of the cylinder heads.
  • Page 160 Section 11 Reassembly 5. Connect the wire leads to the temperature warning switch, audible alarm, and/or Oil Sentry™ switch as equipped. If the thermostat and thermostat housing were removed from the intake manifold, reassemble them at this time. 6. Make sure the sealing surfaces of housing and manifold are clean and free of nicks or damage.
  • Page 161 3. Connect the wire leads to the temperature warning switch, audible alarm, and/or Oil Sentry™ switch, as equipped. Install Stator Assembly 1. Place a small amount of pipe sealant with Teflon ® (Loctite ® 59241 or equivalent) into the holes for the two stator mounting screws. Position the stator assembly onto the mounting studs so the leads are at the bottom, and directed out toward the #1 side, in the 3 o'clock position.
  • Page 162 Section 11 Reassembly NOTE: Before installing the flywheel make sure the crankshaft taper and flywheel hub are clean, dry, and completely free of lubricants. The presence of lubricants can cause the flywheel to be overstressed and damaged when the hex flange screw is torqued to specifications. NOTE: Always use a flywheel strap wrench or holding tool to hold the flywheel when tightening the flywheel fastener.
  • Page 163 5. Using a light, visually check that sufficient clearance exists between the cooling system components and bottom of flywheel. See Figure 11-71. • If clearance is OK, continue with installation of ignition modules. • If clearance is insufficient or contact is noted, remove the flywheel and adjust as required.
  • Page 164 Side. Install Spark Plugs ® 1. Use new Champion RC14YC (Kohler Part No. 66 132 01-S) or equivalent spark plugs. 2. Set the spark plug gap to 0.76 mm (0.030 in.). 3. Install the plugs and torque to 24.4-29.8 N·m (18-22 ft.
  • Page 165 Install Carburetor and Adapter 1. If separated, install the breather tube to breather cover as shown in Figure 11-78. Figure 11-78. Breather Hose Installed onto Breather Cover. 2. Install the carburetor gasket on the intake manifold. See Figure 11-79. Figure 11-79. Installing Carburetor Gasket on Intake Manifold.
  • Page 166 Section 11 Reassembly 5. Connect the upper end of the breather hose to the fitting on the rear of the adapter. See Figure 11-82. 6. Connect the long end of the choke linkage to carburetor as shown in Figure 11-83. Figure 11-83.
  • Page 167 Figure 11-87. Installing Main Throttle Bracket. 5. Connect the dampening spring to the throttle lever as shown. Hook the governor spring from the throttle control bracket in the appropriate governor lever hole, as indicated in the chart below. Note that the hole positions are counted from the pivot point of the governor lever.
  • Page 168 Section 11 Reassembly Figure 11-90. Lower Pulley and Shim Details. Figure 11-91. Installing Lower Pulley. 4. Install the upper fan mounting bracket to the intake manifold with the two screws. See Figure 11-92. Torque: M6 Screws to 7.3 N·m (65 in. lb.) M8 Screws to 24.
  • Page 169 Figure 11-95. Fan Assembly (Front View). Figure 11-96. Fan Assembly (Rear View). Make sure one flat washer is placed between the two bearings in the hub. The other washer is located under the front hex flange nut. Torque the four fan/pulley/hub mounting screws to 6.8 N·m (60 in.
  • Page 170 Section 11 Reassembly If the belt tension is low, remove the belt and relocate a shim from between the pulley halves to the outside (front). Reinstall the belt and recheck the tension. Repeat the procedure until the correct tension is reached. if the shims have all been moved to the outside, and the belt is still too loose, replace the belt.
  • Page 171 Figure 11-104. Fuel Line Hose Routing Outside Leg of Air Cleaner Bracket. 3. Torque the two elbow mounting screws to 7.3 N·m (65 in. lb.). See Figure 11-105. Then torque the eight valve cover mounting screws to 6.2 N·m (55 in. lb.) in the sequence shown in Figure 11-107. Figure 11-105.
  • Page 172 Section 11 Reassembly Figure 11-109. Preassembled Radiator for Installation. 2. Tighten the radiator drain plug. See Figure 11-110. Figure 11-110. Tightening Drain Plug. 3. Carefully set the radiator assembly into place, guiding the lower radiator hose inside RH support bracket. Make sure that cooling fins do not come in contact with the fan blades as radiator is installed.
  • Page 173 Figure 11-113. Installing Upper Hose Connection. Figure 11-114. Installing Lower Radiator Hose Clamp. 6. Check for adequate clearance between fan and shroud. Adjust the lower radiator supports as required, then torque the four mounting screws to 9.9 N·m (88 in. lb.). See Figures 11-115 and 11-116.
  • Page 174 Section 11 Reassembly Figure 11-118. Torquing Top Nuts on Upper Brackets. 9. If a "pulse" style fuel pump is used, install it to the tapped holes in the #2 side, upper radiator support bracket and torque the two screws to 6.8-7.3 N·m (60-65 in.
  • Page 175 Figure 11-121. Installing Oil Filter. 4. Remove the oil fill cap from the valve cover. Fill the crankcase with new oil to the "F" mark on the dipstick. Refer to "Oil Type" and "Check Oil Level" on pages 6.1 and 6.2. Check oil level again after initial running.
  • Page 176 Section 11 Reassembly Testing the Engine It is recommended that the engine be appropriately secured and operated on a test stand or bench, prior to installation in the application. 1. Make sure all hardware is tightened, and hose clamps are properly secured. 2.
  • Page 177 FOR SALES AND SERVICE INFORMATION IN U.S. AND CANADA, CALL 1-800-544-2444 ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044 FORM NO.: TP-2527-A ISSUED: 9/03 REVISED: 3/06 LITHO IN U.S.A.

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