Kohler CH18-745 Service Manual
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Kohler CH18-745 Service Manual

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Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983
S
M
ERVICE
ANUAL
COMMAND
CH18-745
H
C
ORIZONTAL
RANKSHAFT
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  • Page 1 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 ERVICE ANUAL COMMAND CH18-745 ORIZONTAL RANKSHAFT www.mymowerparts.com...
  • Page 2 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 1 Safety and General Information CH18-745 Section 1 Safety and General Information Safety Precautions To ensure safe operation 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.

  • Page 3: Section 1 Safety And General Information

    Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 1 Safety and General Information WARNING WARNING WARNING Explosive Gas can cause fires and Explosive Fuel can cause fires and Carbon Monoxide can cause severe acid burns. severe burns. severe nausea, fainting or death.
  • Page 4 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 1 Safety and General Information 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.
  • Page 5 SAE viscosity grade. See Figure 1-3. 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 Figure 1-3.
  • Page 6 Section 5B Perform these maintenance procedures more frequently under extremely dusty, dirty conditions. Have a Kohler Engine Service Dealer perform this service. Cleanout Kits 25 755 20-S (black) or 25 755 21-S (gold) allow cooling areas to be cleaned without removing shrouds.

  • Page 7: Inch Equivalents Shown In ()

    Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 1 Safety and General Information Dimensions in millimeters. Inch equivalents shown in (). Figure 1-4. Typical Engine Dimensions CH Series with Standard Flat Air Cleaner. www.mymowerparts.com...
  • Page 8 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 1 Safety and General Information Dimensions in millimeters. Inch equivalents shown in (). Figure 1-5. Typical Engine Dimensions CH EFI Series with Heavy-Duty Air Cleaner. www.mymowerparts.com...
  • Page 9 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 1 Safety and General Information General Specifications¹ Power (@ 3600 RPM, corrected to SAE J1995) CH18 ..........................13.4 kW (18 HP) CH20 ..........................14.9 kW (20 HP) CH22/23 ........................16.4 kW (22 HP) CH25, CH730 .......................
  • Page 10 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 1 Safety and General Information Camshaft End Play (With Shim) .................. 0.076/0.127 mm (0.0030/0.0050 in.) Running Clearance ..................0.025/0.063 mm (0.0010/0.0025 in.) Bore I.D. New ....................... 20.000/20.025 mm (0.7874/0.7884 in.) Max. Wear Limit ..................20.038 mm (0.7889 in.) Camshaft Bearing Surface O.D.
  • Page 11 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 1 Safety and General Information Closure Plate Closure Plate Fastener Torque .............. 24.4 N·m (216 in. lb.) Crankshaft End Play (Free) ..................0.070/0.590 mm (0.0028/0.0230 in.) End Play (With Thrust Bearing Components) ........0.070/0.270 mm (0.0028/0.0100 in.) Except CH25 Engines Below Serial No.
  • Page 12 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 1 Safety and General Information Cylinder Head Cylinder Head Fastener Torque Hex. Flange Nut - Torque in Two Stages .......... initially to 16.9 N·m (150 in. lb.) finally to 33.9 N·m (300 in. lb.) Head Bolt - Torque in Two Stages ..........
  • Page 13 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 1 Safety and General Information Muffler Muffler Retaining Nut Torque ..............24.4 N·m (216 in. lb.) Oil Filter Oil Filter Torque ..................10.4-12.7 N·m (90-110 in. lb.) Oil Cooler Oil Cooler/Adapter Nipple Torque ............27 N·m (20 ft. lb.) Piston, Piston Rings, and Piston Pin Piston-to-Piston Pin Running Clearance ..........
  • Page 14 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 1 Safety and General Information Piston, Piston Rings, and Piston Pin cont. Piston Thrust Face-to-Cylinder Bore² Running Clearance New - CH18, CH20, CH22 (624 cc) ..........0.014/0.057 mm (0.0005/0.0022 in.) New - CH22/23 (674 cc) ..............0.021/0.062 mm (0.0008/0.0024 in.) New - CH25, CH26, CH730-745 ............

  • Page 15: Tightening Torque: N·m (In. Lb.) + Or

    Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 1 Safety and General Information Valves and Valve Lifters cont. Exhaust Valve Guide I.D. New ....................7.038/7.058 mm (0.2771/0.2779 in.) Max. Wear Limit ................7.159 mm (0.2819 in.) Valve Guide Reamer Size Standard ..................
  • Page 16 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 1 Safety and General Information English Fastener Torque Recommendations for Standard Applications Tightening Torque: N·m (in. lb.) + or - 20% Bolts, Screws, Nuts and Fasteners Grade 2 or 5 Assembled Into Cast Iron or Steel...
  • Page 17 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 1 Safety and General Information 1.16 www.mymowerparts.com...

  • Page 18: Special Tools

    By using tools designed for the job, you can service engines easier, faster, and safer! In addition, you’ll increase your service capabilities and customer satisfaction by decreasing engine downtime. Kohler special tools are handled by SPX Corp., a division of Owatonna Tool Corp. (OTC). The tools are easy to purchase by contacting SPX/OTC by phone, fax, or mail.

  • Page 19: Section 2 Special Tools

    Obtain a flat washer with the correct I.D. to slip on the capscrew and an O.D. of approximately 1 in. Kohler Part No. 12 468 05-S can be used if you don’t have the right size on hand.
  • Page 20 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 2 Special Tools RTV Silicone Sealant RTV silicone sealant is used as a gasket between the crankcase and closure plate. Only oxime-based, oil resistant RTV sealants, such as those listed below, are approved for use. Loctite ®...
  • Page 21 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 2 Special Tools www.mymowerparts.com...

  • Page 22: Troubleshooting

    Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 3 Troubleshooting CH18-745 Section 3 Troubleshooting Troubleshooting Guide Engine Starts Hard 1. PTO drive is engaged. When troubles occur, be sure to check the simple 2. Dirt or water in the fuel system.

  • Page 23: Grade

    Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 3 Troubleshooting Engine Will Not Idle Engine Uses Excessive Amount of Oil 1. Dirt or water in the fuel system. 1. Incorrect oil viscosity/type. 2. Stale fuel and/or gum in carburetor.
  • Page 24 (SPX Part No. KO1048, formerly of “0” on the gauge, positive pressure is present. Kohler Part No. 25 761 02-S) or a vacuum gauge (SPX Part No. KO3223, formerly Kohler Part No. Crankcase vacuum should be 4-10 (inches of 25 761 22-S).

  • Page 25: Section 3 Troubleshooting

    Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 3 Troubleshooting No Crankcase Vacuum/Pressure in Crankcase Solution Possible Cause 1. Crankcase breather clogged or inoperative. 1. Disassemble breather, clean parts thoroughly, check sealing surfaces for flatness, reassemble, and recheck pressure.
  • Page 26 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 3 Troubleshooting Leakdown Test Results Air escaping from crankcase breather ........... Defective rings or worn cylinder. Air escaping from exhaust system ............Defective exhaust valve. Air escaping from carburetor ..............Defective intake valve.
  • Page 27 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 3 Troubleshooting www.mymowerparts.com...
  • Page 28 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 4 Air Cleaner and Air Intake System CH18-745 Section 4 Air Cleaner and Air Intake System Air Cleaners General Most engines are equipped with a replaceable, high- density paper air cleaner element, surrounded by an oiled foam precleaner, and housed under a flat outer cover.

  • Page 29: Section 4 Air Cleaner And Air Intake System

    Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 4 Air Cleaner and Air Intake System 3. Wash the precleaner in warm water with detergent. Rinse the precleaner thoroughly until all traces of detergent are eliminated. Squeeze out excess water (do not wring). Allow the precleaner to air dry.
  • Page 30 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 4 Air Cleaner and Air Intake System 5. Check the seal for any damage or deterioration. 7. Reinstall the air cleaner cover and secure with the Replace as necessary. See Figure 4-7.
  • Page 31 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 4 Air Cleaner and Air Intake System Air Cleaner Element Cover and Seal - Make sure element cover is not bent or damaged. Make sure the wing nut and seal are in place to ensure the element is sealed against leakage.
  • Page 32 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 4 Air Cleaner and Air Intake System 4. Do not wash the paper element and inner element or use compressed air, this will damage the elements. Replace dirty, bent or damaged elements with new genuine Kohler elements as required.
  • Page 33 Make sure the cooling shrouds are reinstalled. *Cleanout kits, Kohler Part No. 25 755 20-S (black) or 25 755 21-S (gold), are recommended to aid inspection and cleanout of the cooling fins. See Figure 4-15.
  • Page 34 Gasohol (up to 10% ethyl alcohol, 90% unleaded equipped with a fuel pump, the fuel tank outlet is gasoline by volume) is approved as a fuel for Kohler located above the carburetor inlet allowing gravity to engines. Other gasoline/alcohol blends are not feed fuel to the carburetor.

  • Page 35: Section 5 Fuel System And Governor

    Most engines are equipped with an in-line filter. gasoline blends (up to a maximum of 15% MTBE by Visually inspect the filter periodically and replace when volume) are approved as a fuel for Kohler engines. dirty with a genuine Kohler filter. Other gasoline/ether blends are not approved.
  • Page 36 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5 Fuel System and Governor Fuel Pump NOTE: On most models, the pulse line is connected to a fitting on the crankcase, while on early models, it is connected to General the valve cover.
  • Page 37 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5 Fuel System and Governor Carburetor WARNING: Explosive Fuel Gasoline is extremely flammable and its vapors can General explode if ignited. Store gasoline only in approved These engines are equipped with fixed main jet...
  • Page 38 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5 Fuel System and Governor Troubleshooting Checklist When current is removed the pin extends blocking the When the engine starts hard, runs roughly or stalls at main fuel jet and preventing fuel from entering the low idle speed, check the following areas before carburetor.
  • Page 39 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5 Fuel System and Governor Carburetor Adjustments 1. With the engine stopped, turn the low idle fuel adjusting needle in clockwise until it bottoms lightly. General In compliance with government emission standards,...
  • Page 40 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5 Fuel System and Governor 2. Disconnect the fuel line from the carburetor. See Figure 5-6. 3. Clean dirt and debris from exterior of carburetor. 4. Remove the four screws holding the two carburetor halves together.
  • Page 41 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5 Fuel System and Governor 7. In order to clean the ‘‘off-idle’’ vent ports and bowl • Inspect the fuel inlet needle and seat for wear or vent thoroughly, use a good carburetor solvent damage.
  • Page 42 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5 Fuel System and Governor 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.
  • Page 43 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5 Fuel System and Governor Reassembly Governor Spring Reassemble the carburetor using the following steps. See Figure 5-9. Cross Shaft 1. Assemble the fuel inlet needle to the float tab. Install the float, float shaft and inlet needle to the air horn.
  • Page 44 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5 Fuel System and Governor 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...
  • Page 45 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5 Fuel System and Governor Throttle Control Lever #2 Left Side Pull Choke Control Lever #1 Kill Switch Choke Control Cable Choke Linkage Throttle Z Bend Control Cable Throttle Control Cable...
  • Page 46 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5 Fuel System and Governor Governor Control Unit (GCU) senses engine speed by Adjustment Procedure pulse voltage inputs from the ignition modules. The The DLA must be in the fully retracted position during assembly.
  • Page 47 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5 Fuel System and Governor 5.14 www.mymowerparts.com...
  • Page 48 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5A LPG Fuel Systems CH18-740 Section 5A LPG Fuel Systems WARNING: Explosive Fuel! LPG is extremely flammable, is heavier than air, and tends to settle in low areas where a spark or flame could ignite the gas.
  • Page 49 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5A LPG Fuel Systems Operation 4. Insufficient vacuum signal, regulator not opening. a. Vacuum line between carburetor and regulator In a liquid withdrawal system, the Liquefied Petroleum cracked, leaking, kinked, or pinched.
  • Page 50 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5A LPG Fuel Systems LPG Carburetor Adjustments Engine stalls during operation 1. No fuel. 2. Faulty lock-off or blocked filter. General 3. Improper governor setting. The LPG carburetor and regulator are designed to 4.
  • Page 51 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5A LPG Fuel Systems High Altitude Operation Impco Carburetor The standard carburetor calibrations will provide 1. Turn off fuel supply at tank. proper operation up to altitudes of 1500 m (5000 ft.).
  • Page 52 See Figure 5A-6. Replace Remove the nuts, carburetor, and gaskets from with a new Kohler high pressure hose (LP rated) if the engine. Discard the gaskets. the condition is questionable in any way. Secure new hose using new clamps.
  • Page 53 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5A LPG Fuel Systems LPG Carburetor - Reassembly Idle Speed Clamp Bracket Position 1. Counting the number of turns, back the idle speed Impco Carburetor adjustment screw off (counterclockwise), so only 1.
  • Page 54 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5A LPG Fuel Systems 3. Insert a 0.025 mm (0.001 in.) feeler gauge between the side of the stop collar and the carburetor housing, then check or set the position of the stop collar. The head of the mounting screw...
  • Page 55 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5A LPG Fuel Systems 2. Manually move the governor lever, with the throttle 7. Check to be sure all system connections are tight. linkage connected, toward the carburetor as far as it will go.
  • Page 56 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5A LPG Fuel Systems Vaporizer Assembly The outer surface of the vaporizer should be kept free of dirt and debris accumulation, which will cause a loss of vaporization efficiency. Visual inspection and necessary cleaning should be performed on a regular basis, more frequently under dusty or dirty conditions.
  • Page 57 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5A LPG Fuel Systems Impco (Beam) Regulator (See Figure 5A-20) LPG vapor enters at point (A), then passes into primary area (B) at point (28), where pressure is reduced from up to 250 psi at the tank to 4.5 psi in area (B).
  • Page 58 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5A LPG Fuel Systems Nikki Regulator Primary Chamber Nikki Regulator Secondary Chamber (See Figure 5A-21) (See Figure 5A-22) The primary chamber reduces the high pressure fuel The secondary chamber further reduces the fuel...
  • Page 59 Figure 5A-23. this must be performed by qualified LP personnel only. Impco (Beam) Regulator Service Kohler repair kit 24 757 40-S should be used to service the regulator every 1500 hours, or whenever cleaning and servicing is required. Nikki Regulator Service Kohler repair kit 24 757 39-S should be used every 1500 hours.
  • Page 60 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System CH26, CH745 Section 5B Electronic Fuel Injection (EFI) Fuel System Contents Page(s) Description Initial Starting/Priming Procedure ......................5B.2 Fuel Recommendations ........................5B.2 EFI Fuel System Components ......................5B.3 Operation ..............................
  • Page 61 Gasohol (up to 10% ethyl alcohol, 90% unleaded system has been disassembled. On most engines, gasoline by volume) is approved as a fuel for Kohler that can be done similar to relieving fuel pressure, as EFI engines. Other gasoline/alcohol blends are not described above.
  • Page 62 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System EFI Fuel System Components The ECU controls the amount of fuel injected and the ignition timing by monitoring the primary sensor signals for engine temperature, speed (RPM), and throttle General position (load).

  • Page 63: Electrical Components

    Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System Important Service Notes! Electrical Components • Cleanliness is essential and must be maintained at all times when servicing or working on the EFI Electronic Control Unit (ECU) system.
  • Page 64 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System Three different styles of ECU’s have been utilized in To prevent engine over-speed and possible failure, a EFI production. The first style is easily identified by its “rev-limiting”...
  • Page 65 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System General 6. Disconnect the speed sensor connector from The engine speed sensor is essential to engine wiring harness. It is the connector with one heavy operation; constantly monitoring the rotational speed black lead (see Figure 5B-5).
  • Page 66 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System Mounted on the throttle body/intake manifold and Throttle Position Sensor (TPS) 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.
  • Page 67 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System 4. Leave the leads connected to the pin terminals as 7. Remove the two mounting screws from the TPS. described in step 3. Rotate the throttle shaft Save the screws for reuse.
  • Page 68 (red wire), or use jumper plug (SPX Part No. Light (MIL). KO3217-9). If using the PC-based diagnostic tool and software (Kohler Part No. 25 761 23-S), go to a. The light should blink on/off quickly for “Special Tests” and follow the prompts to approximately 3 seconds and then go off and complete.
  • Page 69 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System 5. Remove the jumper wire or plug from the service Engine (Oil) Temperature Sensor connector plug in wiring harness. 6. Run the engine at full throttle (above 3000 RPM),...
  • Page 70 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System “24 Pin” (MSE 1.0) Plastic-Cased ECU: Check The tip of the sensor, protruding into the exhaust gas, between the #6 and #4 pin terminals. is hollow (see cutaway Figure 5B-12). The outer portion of the tip is surrounded by the exhaust gas, “32 Pin”...
  • Page 71 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System 1. Oxygen sensor must be hot (minimum of 400°C, connection) between that point and the previous 725°F). Run engine for about 5 minutes. With the checkpoint. For example, if the reading is too low...
  • Page 72 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System a. If there is no continuity displayed in either of Electrical Relay the tests, check the harness circuit for breaks or damage, and the connections for poor contact, moisture, or corrosion.
  • Page 73 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System 6. Attach ohmmeter leads to the #30 and #87 Terminal #87 - Terminal #85 - terminals in relay. Initially, there should be no Feed To Ignition Ignition Switch Coils, Fuel continuity.
  • Page 74 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System When the key switch is on and the relay is closed, the Service Injector problems typically fall into three general fuel rail is pressurized, and voltage is present at the categories: electrical, dirty/clogged, or leakage.
  • Page 75 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System Check all electrical connections, connectors, and wiring harness leads if resistance is incorrect. Injector leakage is very unlikely, but in those rare instances it can be internal (past the tip of the valve needle), or external (weeping around the injector body).
  • Page 76 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System 8. Thoroughly clean the area around and including than normal operating temperatures, short operating the throttle body/manifold and the injectors. intervals, and dirty, incorrect, or poor quality fuel.
  • Page 77 EFI engines are equipped with Champion RC12YC between terminal #87 and pin #1 for coil #1. (Kohler Part No. 12 132 02-S) resistor style spark Repeat the test between terminal #87 and pin #19 plugs. Equivalent alternate brand plugs can also be for coil #2.
  • Page 78 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System Fuel Components Fuel Pump Figure 5B-24. “24 Pin” (MSE 1.0) Plastic-Cased Internal External ECU Connector. Figure 5B-26. Fuel Pump Styles. General An electric fuel pump is used to transfer fuel in the EFI system.
  • Page 79 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System 1. Connect the black hose of Kohler pressure tester Fuel Pressure Regulator (SPX Part No. KO3217-4), to the test valve in the fuel rail. Route the clear hose into a portable gasoline container or the equipment fuel tank.
  • Page 80 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System Pressure Regulating Pressure Spring Regulating Chamber Diaphragm Valve Seat Valve Fuel Chamber Inlet Port Outlet Port (to fuel rail) Return Port (to tank) Figure 5B-29. Fuel Pressure Regulator Details.
  • Page 81 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System 8. Reconnect the negative (-) battery cable. General The fuel rail is a formed tube assembly that feeds fuel 9. Recheck regulated system pressure at fuel rail to the top of the injectors.
  • Page 82 Do not attempt to circumvent this compatible and must not be used! Use only Oetiker warm up period, or readjust the idle speed during this clamps (Kohler Part No. 24 237 05-S) on fuel line time. The engine must be completely warmed up for connections.
  • Page 83 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System The idle speed adjustment procedure remains the same for engines with or without a dampening spring. Typically, no periodic servicing is necessary in this Linkage area. If however, removal/replacement of the...
  • Page 84 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System If not already installed, position the governor lever on the cross shaft, but leave the clamping screw loose. Feeler Gauge Figure 5B-39. Inserting Feeler Gauge (Engines Without Stop Screw).
  • Page 85 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System 4. Verify that the governor has been set correctly. Engine starts hard or fails to start when hot With the linkage still retained in the “Full Throttle”...
  • Page 86 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System Electrical System If a fault code indicates a problem with an electrical The EFI system is a 12 VDC negative ground system, component, disconnect the ECU connector and test designed to operate down to a minimum of 7.0 volts.
  • Page 87 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System “35 Pin” (MA 1.7) Metal-Cased ECU Systems Pin # Component Ignition Coil #1 Not used Engine Speed Sensor ECU Production Test Terminal Not Used Not Used Not Used...
  • Page 88 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 www.mymowerparts.com...
  • Page 89 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System “24 Pin” (MSE 1.0) Plastic-Cased ECU Systems Pin # Function Permanent Battery Voltage Switched Ignition Voltage Safety Switch Throttle Position Sensor (TPS) and Temperature Sensor Ground Not Used...
  • Page 90 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System “32 Pin” (MSE 1.1) Plastic-Cased ECU Systems Pin # Function Permanent Battery Voltage Switched Battery Voltage TPS Set; “Auto-Learn” Initialization Terminal Throttle Position Sensor (TPS) and Temperature Sensor Ground...
  • Page 91 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 www.mymowerparts.com...
  • Page 92 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System Fault Codes Fuel System The ECU continuously monitors engine operation against preset performance limits. If the operation is WARNING: Fuel System Under Pressure! outside the limits, the ECU activates the MIL and The fuel system operates under high pressure.
  • Page 93 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System Example of Diagnostic Display 1. Diagnostic display initiated through ignition key sequencing. Long Pause Short Pauses Code 32 Long Pause Code 61 Long Pause Light remains on at end of transmission Figure 5B-43.
  • Page 94 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System 3 " " n 2 " " n 3 " " n c i l 3 " " n u l i i r c l a t...
  • Page 95 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System Code: 4. ECU/Harness Related Source: Engine Speed Sensor a. ECU-to-harness connection problem. Explanation: ECU receiving inconsistent tooth count signals from speed sensor. 5. Ignition System Related Expected Engine a.
  • Page 96 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System 3. Engine Wiring Harness Related Code: “32 Pin” (MSE 1.1) Plastic-Cased ECU: Source: Fuel Mixture or Oxygen Sensor a. Pin circuits 4, 8, and/or 18 damaged (wiring, Explanation: “System too lean.”...
  • Page 97 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System Code: 3. TPS Sensor Related Source: Oxygen Sensor a. Throttle plate position incorrectly set or Explanation: No change in the sensor output signal. registered during “Initialization.’’ Expected Engine b.
  • Page 98 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System 3. Engine Wiring Harness Related 3. System Related a. Difference in voltage between sensed voltage a. Engine is operating above the 176°C (350°F) (pin circuit 17 for metal-cased ECU, pin temperature sensor limit.
  • Page 99 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System Code: "32 Pin" (MSE 1.1) Plastic- 2. Engine Wiring Harness Related Cased ECU only. a. Broken or shorted wire in harness. ECU pin 15 Source: Injector #1 circuit open, shorted to to injector pin 2.
  • Page 100 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System Code: "32 Pin" (MSE 1.1) Plastic- Code: Cased ECU only. Source: Source: Fuel pump relay circuit open, shorted Explanation: Denotes the end of fault codes. If to ground, or shorted to battery...
  • Page 101 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System *Operate for an appropriate period of time based upon original fault codes. Figure 5B-44. 5B.43 www.mymowerparts.com...
  • Page 102 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System Flow Chart Diagnostic Aids 12. Code 52 - Injector 2, "32 Pin" (MSE 1.1) Plastic- Cased ECU only. Diagnostic Aid #1 "SYSTEM POWER" (MIL does not 13. Code 55 - MIL Light, "32 Pin" (MSE 1.1) Plastic- illuminate when key is turned “on”)
  • Page 103 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System Diagnostic Aid #4 “SPEED SENSOR” (MIL does not Diagnostic Aid #7 “IGNITION SYSTEM” (no spark) turn off during cranking). Indicates the ECU is not Possible causes: receiving a signal from the speed sensor.
  • Page 104 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 5B EFI Fuel System 5B.46 www.mymowerparts.com...
  • Page 105 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 6 Lubrication System CH18-745 Section 6 Lubrication System General NOTE: Using other than service class SG, SH, SJ or higher oil, or extending oil change intervals This engine uses a full pressure lubrication system. This...

  • Page 106: Section 6 Lubrication System

    Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 6 Lubrication System NOTE: To prevent extensive engine wear or damage, Checking Oil Level always maintain the proper oil level in the The importance of checking and maintaining the crankcase. Never operate the engine with the proper oil level in the crankcase cannot be oil level below the ‘‘L”...
  • Page 107 Replace the oil filter at least every other oil change additional 2/3-1 turn. (every 200 hours of operation). Always use a genuine Kohler oil filter. Change the filter as follows. See Figure 8. Remove the oil fill cap and fill the engine with the 6-6.
  • Page 108 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 6 Lubrication System Service Oil Cooler Oil Sentry ™ Some engines are equipped with an oil cooler. One style of oil cooler mounts on the engine crankcase and General has the oil filter on it. The other style of oil cooler is...
  • Page 109 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 6 Lubrication System 2. Gradually increase the pressure to the switch. As To install the switch, follow these steps: ® ® the pressure increases through the range of 1. Apply pipe sealant with Teflon (Loctite 59241 or equivalent) to the threads of the switch.
  • Page 110 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 6 Lubrication System www.mymowerparts.com...
  • Page 111 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 7 Retractable Starter CH18-745 Section 7 Retractable Starter WARNING: Spring Under Tension! Retractable starters contain a powerful, recoil spring that is under tension. Always wear safety goggles when servicing retractable starters and carefully follow instructions in this section for relieving spring tension.

  • Page 112: Section 7 Retractable Starter

    Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 7 Retractable Starter Keep Pulley Rope Slipknot Handle Guide from Rotating Bushing Rope Hole Knot in Pulley Rope Retainer Figure 7-3. Installing Rope. Figure 7-2. Removing Starter Handle. 10. Tie a slipknot approximately 12 in. from the free 3.
  • Page 113 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 7 Retractable Starter Disassembly Brake Spring and WARNING: Spring Under Tension! Brake Washer Do not remove the center screw from the starter until the spring tension is released. Removing the center...
  • Page 114 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 7 Retractable Starter 8. Note the position of the spring and keeper Reassembly assembly in the pulley. See Figure 7-7. 1. Make sure the spring is well lubricated with grease. Place the spring and keeper assembly Remove the spring and keeper assembly from the inside the pulley (with spring towards pulley).
  • Page 115 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 7 Retractable Starter 4. Place the brake washer in the recess in starter 7. Tension the spring and install the rope and handle pulley; over the center shaft. as instructed in steps 6 through 12 under “Rope Replacement”...
  • Page 116 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 7 Retractable Starter www.mymowerparts.com...
  • Page 117 RC12YC (Kohler Part No. 12 132 02-S). A high-performance spark plug, Champion ® Platinum 3071 (used on Pro Series engines, Kohler Part No. 25 132 12-S) is also available. Equivalent alternate brand plugs can also be used. Gap: 0.76 mm (0.030 in.)

  • Page 118: Section 8 Electrical System And Components

    Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components Normal: A plug taken from an engine operating under Wet Fouled: A wet plug is caused by excess fuel or oil normal conditions will have light tan or gray colored in the combustion chamber.
  • Page 119 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components Battery 2. Keep the cables, terminals, and external surfaces of the battery clean. A build-up of corrosive acid or grime on the external surfaces can cause the General battery to self-discharge.
  • Page 120 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components Electronic CD Ignition Systems Carburetor Solenoid Starter and Ignition Spark Pressure Carburetor Module Advance Safety Green Solenoid Input Module Input (Optional) White Oil Pressure B+ and...
  • Page 121 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components Kill Switch or Ignition ‘‘Off’’ Position of Modules Key Switch Spark Plug Magnet (0.28/0.33 mm) 0.011/0.013 in. Air Gap Flywheel Figure 8-4. Capacitive Discharge (Fixed Timing) Ignition System.
  • Page 122 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components 12 Volt Battery Green Key Switch or ‘‘Off’’ Position of Key Switch Spark Advance Module White Spark Spark Plug Plug 0.28/0.33 mm Ignition Module (0.011/0.013 in.)
  • Page 123 2. Test for spark on both cylinders with Kohler ignition tester, SPX Part No. KO1046 (formerly Kohler Part CAUTION: High-Energy Electric Spark! No.

  • Page 124: Section 2 Special Tools

    *NOTE: Ignition tester (SPX Part No. KO1046 formerly Kohler Part No. 24 455 02-S) must be used 2. Crank the engine over, establishing a minimum of to test ignition on these engines. Use of any 550-600 RPM, and observe tester(s) for spark.
  • Page 125 24 584 11 or 24 584 15-S. For small modules with vendor numbers MA-2C or MA-2D (Kohler Part No. 24 584 11), or the larger style modules (24 584 15-S and 24 584 36-S), use a digital ohmmeter to check the resistance values and compare them to the table following.
  • Page 126 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components Ignition Module Resistance Table 4) Position a 0.33 mm (0.013 in.) feeler gauge between the magnet and all three 24 584 03 or 24 584 15-S or legs of the module.
  • Page 127 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components terminal of the ground lead or the ground To Test – screw/bolt. Check the voltage with the key NOTE: SAM must be at room temperature (to the switch in both the “START”...
  • Page 128 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components 3. Disconnect the yellow and brown tester leads from the long module leads. Connect the brown tester lead to the short brown module lead. Connect the yellow tester lead to the short yellow (or pink) module lead.
  • Page 129 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components Battery Charging System • Make sure the battery polarity is correct. A negative (-) ground system is used. General • Disconnect the rectifier-regulator plug and/or the...
  • Page 130 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components 15/20/25 amp Regulated Charging System Figure 8-14. Wiring Diagram - 15/20/25 amp Regulated Battery Charging System. Figure 8-15. 15 amp Stator and Rectifier-Regulator. Figure 8-16. 20 amp Stator and Rectifier-Regulator.
  • Page 131 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components 1st Style 25 Amp Stator 2nd Style Figure 8-17. 25 amp Stator and Rectifier-Regulators. 3 amp Unregulated Charging System Ground-To-Kill Lead (White) Light Ignition (Blue) Modules...
  • Page 132 AC terminals. See Figure 8-21. Rectifier- Regulator Ground Strap (or lead) Figure 8-20. Rectifier-Regulator. Testing of the rectifier-regulator may be performed as Figure 8-21. follows, using the Rectifier-Regulator Tester (SPX Part No. KO3221, formerly Kohler Part No. 25 761 20-S). 8.16 www.mymowerparts.com...
  • Page 133 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components 20/25 Amp Rectifier-Regulators 3. Plug the tester into a 110 volt AC outlet supply and turn on the power switch. See Figure 8-22. 1. Connect the single lead adapter in between the The ‘‘POWER’’...
  • Page 134 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components 6. Press the ‘‘TEST’’ button until a ‘‘click’’ is heard and then release. See Figure 8-23. Momentarily one of the four lights will illuminate indicating the partial condition of the part.
  • Page 135 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components 4. Press the ‘‘TEST’’ button until a “click” is heard and then release. See Figure 8-23. Momentarily either the ‘‘HIGH’’, ‘‘LOW’’, or ‘‘SHORT’’ light will flash.
  • Page 136 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components Troubleshooting Guide 15/20/25 amp Battery Charging Systems When problems occur in keeping the battery charged or the battery charges at too high a rate, the problem can usually be found somewhere in the charging system or with the battery.
  • Page 137 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components Troubleshooting Guide 3 amp Battery Charging System with 70 Watt Lighting Stator NOTE: Zero ohmmeters on each scale to ensure accurate readings. Voltage tests should be made with engine running at 3000 RPM - no load.
  • Page 138 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components Electric Starting Motors NOTE: If the starter does not crank the engine, shut off the starter immediately. Do not make Some engines in this series use inertia drive starting further attempts to start the engine until the motors while most use solenoid shift starters.
  • Page 139 4. Clean the splines on drive shaft thoroughly with solvent. Dry the splines thoroughly. 5. Apply a small amount of Kohler electric starter drive lubricant, Part No. 52 357 01-S, to the splines. The use of other lubricants may cause the drive pinion to stick or bind.
  • Page 140 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components Style ‘‘B’’ Drive Service 1. The rubber dust cover has a molded lip on the inside that snaps into a groove in the dust cover spacer (see Figure 8-31). Turn the drive pinion clockwise until it reaches the fully extended position.
  • Page 141 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components Retaining Ring Installation 2. Locate the small raised line on the edge of the 1. Position the retaining ring in the groove in one of drive end cap. On starters with Style ‘‘A’’...
  • Page 142 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components NOTE: Use a brush holder tool to keep the 2. Insert the armature into the starter frame. Make brushes in the pockets. A brush holder sure the magnets are closer to the drive shaft end tool can easily be made from thin sheet of armature.
  • Page 143 7. Lubricate the drive shaft with Kohler bendix starter with the ring gear into the retracted position. drive lubricant (Part No. 52 357 01-S). Install the drive components following the instructions for servicing the starter drive.
  • Page 144 2. Remove the hex. nuts securing the solenoid, and disassembled, cleaned and relubricated. Apply starter remove the solenoid from the starter assembly. lubricant (Kohler Part No. 52 357 02-S) to the lever and shaft. Failure to do so could result in an 3. Remove the two thru bolts.
  • Page 145 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components Phillips Head Screws Torx Head Screws Figure 8-41. Removing Solenoid Screws. Figure 8-42. Solenoid Removed from Starter. 3. If the solenoid was mounted with Phillips head screws, separate the solenoid and plunger spring from the drive end cap.
  • Page 146 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components 7. Remove the drive lever pivot bushing and backing plate from the end cap. See Figure 8-47. Figure 8-44. Removing Thru Bolts. 5. Remove the commutator end plate assembly, Figure 8-47.
  • Page 147 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components Figure 8-49. Retaining Ring Detail. Figure 8-50. Removing Retaining Ring. 11. Remove the retainer from the armature shaft. 12. Remove the drive pinion assembly from the Save the stop collar.
  • Page 148 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components Inspection Commutator O.D. 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.
  • Page 149 Brush Replacement Starter Service The brushes and springs are serviced as a set (4). Clean the drive lever and armature shaft. Apply Kohler Use Brush and Spring Kit, Kohler Part No. electric starter drive lubricant Part No. 52 357 02-S 25 221 01-S, if replacement is necessary.
  • Page 150 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components 7. Install the backup washer, followed by the rubber grommet, into the matching recess of the drive end cap. The molded recesses in the grommet should be “out”, matching and aligned with those in the end cap.
  • Page 151 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components Figure 8-62. Installing Thrust Washer. Figure 8-64. Removing Retaining Clips. 10. Starter reassembly when replacing the Brushes/ b. Position each of the brushes back in their slots Brush Holder Assembly: so they are flush with the I.D.
  • Page 152 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 8 Electrical System and Components Figure 8-66. Installing Brush Holder Assembly Figure 8-68. Torquing Brush Holder Screws. using Tool with Extension. 13. Hook the plunger behind the upper end of the 11.
  • Page 153 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 9 CH18-745 Disassembly Section 9 Disassembly 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.

  • Page 154: Section 9 Disassembly

    Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 9 Disassembly 3. Remove and discard the oil filter. See Figure 9-5. Figure 9-2. Removing Dipstick from Tube. Figure 9-5. Removing Oil Filter. Figure 9-3. Removing Oil Fill Cap from Cover.
  • Page 155 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 9 Disassembly 4. Remove the hex. flange screws securing the bracket and base. See Figure 9-8. Two additional rear screws must be removed if the engine contains a rear air cleaner support bracket. See Figure 9-9.
  • Page 156 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 9 Disassembly Figure 9-11. Removing Tube from Breather Cover. Figure 9-13. Disconnecting Pulse Line from Crankcase. 6. Remove the rubber breather tube from the breather cover. See Figure 9-11. Remove Fuel Pump...
  • Page 157 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 9 Disassembly Figure 9-15. Removing Screws Holding Fuel Pump Figure 9-17. Mechanical Fuel Pump. (Metal Bodied Pump Shown). Remove Control Panel (If So Equipped) 4. Note or mark the orientation of the fuel pump, 1.
  • Page 158 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 9 Disassembly Remove External Governor Controls 1. Loosen the hex. flange nut and remove the governor lever from the cross shaft. See Figure 9-22. Leave lever attached to the throttle linkage and lay assembly on the top of the crankcase.
  • Page 159 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 9 Disassembly 3. Remove the carburetor, throttle linkage and Remove Electric Starter Motor governor lever as an assembly. See Figure 9-24. 1. Disconnect the leads from the starter. 2. Remove the two hex. flange screws. See Figure 9-26.
  • Page 160 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 9 Disassembly 4. Remove the three (each side) hex. flange screws securing the outer baffles. Note the location of any lifting strap and position of the two short screws (one each side on bottom) for reassembly.
  • Page 161 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 9 Disassembly Figure 9-32. Removing Metal Grass Screen. Figure 9-34. Removing Fasteners Holding Baffle and Breather Cover. 7. Remove the lower blower housing screw and washer securing the rectifier-regulator ground 2. Remove both inner baffles. See Figure 9-35.
  • Page 162 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 9 Disassembly 7. Remove the hex. flange screw, breather reed retainer and breather reed. See Figure 9-39. Figure 9-36. Breaking Breather Cover Seal. 5. Remove the breather cover and gasket (if used).
  • Page 163 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 9 Disassembly Remove Ignition Modules 3. Leave the wiring harness attached to the manifold. 1. Disconnect the lead(s)* from each ignition module. See Figure 9-41. *Modules for non- SMART-SPARK ignition systems have only one Aluminum ™...
  • Page 164 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 9 Disassembly Remove Spark Plugs Hex. Flange Screw 1. Remove the spark plug from each cylinder head. Hex. Flange Nut and Washer Figure 9-45. Removing Spark Plugs. Remove Cylinder Heads and Hydraulic Lifters NOTE: Cylinder heads are retained using either hex.
  • Page 165 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 9 Disassembly Figure 9-48. Removing Hydraulic Lifter. Figure 9-47. Removing Cylinder Head Assembly. Figure 9-49. Mark Position of Hydraulic Lifters. 4. Remove the lifters from the lifter bores. Use Hydraulic Lifter Tool (SPX Part No. KO1044) Do not use a magnet to remove lifters.
  • Page 166 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 9 Disassembly Disassemble Cylinder Heads 3. Once the valve spring is compressed, remove the following items. See Figures 9-53 and 9-54. 1. Remove the two hex. flange screws, rocker arm pivots and rocker arms from the cylinder head.

  • Page 167: Flywheel Strap Wrench

    Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 9 Disassembly Figure 9-55. Removing Plastic Type Grass Screen. Figure 9-57. Removing Flywheel Fastener Using Strap Wrench. 2. Remove the four hex. flange screws and fan. See Figure 9-56. 2. Remove the hex. flange screw and washer.
  • Page 168 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 9 Disassembly 2. Locate the three splitting tabs that are cast into the perimeter of the closure plate. Insert the drive end of a 1/2" breaker bar between the top splitting tab and the crankcase.
  • Page 169 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 9 Disassembly Remove Camshaft 1. Remove the camshaft and shim. See Figure 9-64. Camshaft Shim Figure 9-66. Mark End Cap with Cylinder Number Before Removal. Figure 9-64. Removing Camshaft (Note Shim).
  • Page 170 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 9 Disassembly Remove Crankshaft 1. Carefully pull the crankshaft from the crankcase. See Figure 9-68. Note thrust washers and shims if used. Figure 9-70. Removing Governor Cross Shaft Retainer (8 mm Shaft Design).
  • Page 171 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 10 CH18-745 Inspection and Reconditioning Section 10 Inspection and Reconditioning This section covers the operation, inspection, and Automatic Compression Release (ACR) repair/reconditioning of major internal engine Some engines are equipped with the optional components.

  • Page 172: Section 10 Inspection And Reconditioning

    Procedure to Install New Plug: 1. Use a single cylinder camshaft pin, Kohler Part Inspect the crankpin for score marks or metallic No. 47 380 09-S as a driver and tap the plug into pickup.
  • Page 173 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 10 Inspection and Reconditioning Check the cylinder bore wall for scoring. In severe NOTE: Kohler pistons are custom-machined to cases, unburned fuel can cause scuffing and scoring exacting tolerances. When oversizing a of the cylinder wall.
  • Page 174 Before installing the piston into the cylinder bore, it is necessary that the clearance be accurately checked. Inspect the ring gear for cracks or damage. Kohler This step is often overlooked, and if the clearances are does not provide the ring gear as a serviceable part.
  • Page 175 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 10 Inspection and Reconditioning EXHAUST INTAKE VALVE VALVE EXHAUST INSERT INTAKE INSERT Dimension Intake Exhaust 89° Seat Angle 89° Insert O.D. 36.987/37.013 mm (1.4562/1.4572 in.) 32.987/33.013 mm (1.2987/1.2997 in.) 4 mm (0.1575 in.) Guide Depth 6.5 mm (0.2559 in.)
  • Page 176 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 10 Inspection and Reconditioning Normal: Even after long hours of operation a valve Leakage: A poor grind on face or seat of valve will can be reconditioned and reused if the face and allow leakage resulting in a burned valve on one side margin are in good shape.
  • Page 177 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 10 Inspection and Reconditioning Stem Corrosion: Moisture in fuel or from Excessive Combustion Temperatures: The white condensation are the most common causes of valve deposits seen here indicate very high combustion stem corrosion.
  • Page 178 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 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 Valve Seat Cutter excessive oil consumption.
  • Page 179 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 10 Inspection and Reconditioning Ring failure is usually indicated by excessive oil Detonation damage occurs when a portion of the fuel consumption and blue exhaust smoke. When rings charge ignites spontaneously from heat and pressure fail, oil is allowed to enter the combustion chamber shortly after ignition.
  • Page 180 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 10 Inspection and Reconditioning Replacement pistons are available in STD bore size, and in 0.25 mm (0.010 in.), and 0.50 mm (0.020 in.) oversize. Replacement pistons include new piston ring sets and new piston pins.
  • Page 181 Check the base surface of the hydraulic lifters for wear Piston or damage. If the lifters need to be replaced, apply a liberal coating of Kohler lubricant 25 357 14-S to the base of each new lifter before it is installed. Compression Ring “Bleeding”...
  • Page 182 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 10 Inspection and Reconditioning Disassembly Reassembly The governor gear must be replaced once it is 1. Install the locking tab thrust washer on the removed from the closure plate. governor gear shaft with the tab down.
  • Page 183 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 10 Inspection and Reconditioning 3. Install the rotor. 4. Install the oil pump body to the closure plate and secure with the two hex. flange screws. Torque the hex. flange screws as follows: First Time Installation: 10.7 N·m (95 in.
  • Page 184 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 10 Inspection and Reconditioning 10.14 www.mymowerparts.com...
  • Page 185 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 CH18-745 Reassembly Section 11 Reassembly 17. Install fuel pump. General 18. Install carburetor. NOTE: Make sure the engine is assembled using all 19. Install external governor controls. specified torque values, tightening sequences 20.

  • Page 186: Section 11 Reassembly

    Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly Figure 11-2. Installing Oil Seal. Figure 11-4. Installing Governor Cross Shaft Hitch Pin (6 mm Shaft). Install Governor Cross Shaft 1. Lubricate the governor cross shaft bearing surfaces in the crankcase with engine oil.
  • Page 187 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly 3. Lubricate the crankshaft journals and connecting rod bearing surfaces with engine oil. 4. Make sure the “Fly” stamping on piston is facing towards the flywheel side of the engine. Use a hammer with a rubber grip and gently tap the piston into the cylinder as shown in Figure 11-9.
  • Page 188 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly Torque these to 22.7 N·m (200 in. lb.) 8 mm Straight Shank Torque these to 14.7 N·m (130 in. lb.) 8 mm Step-Down Torque these to 11.3 N·m (100 in. lb.) Figure 11-12.
  • Page 189 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly 5. Reinstall the end play checking tool and recheck the end play. Oil Pump Assembly The oil pump is mounted inside the closure plate. If service was required, and the oil pump was removed, refer to the assembly procedures under “Oil Pump...
  • Page 190 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly Remove the closure plate. If end play requires adjustment, remove the original spacer and install the Thrust Shim appropriate size shim spacer in its place. Then follow the procedure under “Install Closure Plate Assembly.”...
  • Page 191 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly 3. Apply a 1.5 mm (1/16 in.) bead of sealant to the 6. Install the ten hex. flange screws securing the closure plate to the crankcase. Torque fasteners sealing surface of the closure plate. See Figure 11-19 for sealant pattern.
  • Page 192 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly Install Flywheel WARNING: Damaging Crankshaft and Flywheel Can Cause Personal Injury! Using improper procedures to install the flywheel can crack or damage the crankshaft and/or flywheel. This not only causes extensive engine damage, but can also cause personal injury, since broken fragments could be thrown from the engine.
  • Page 193 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly Install Flywheel Fan 1. Install the fan onto the flywheel using the four hex. flange screws. NOTE: Position the ears located at rear perimeter of the fan in the recesses of the flywheel.
  • Page 194 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly Install Supports for the Metal Grass Screen 1. If a metal grass screen is used, with threaded individual supports, install a spacer washer on the external threads. Apply blue Loctite No.
  • Page 195 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly Valve Keepers Retainer Figure 11-36. Match Numbers on Cylinder Barrel and Spring Head. Figure 11-38. Valve Components. Intake Valve Seal Figure 11-37. Intake Valve Seal Location. Figure 11-39. Installing Valves with Valve Spring Valve Stem Seals Compressor.
  • Page 196 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly Heads secured with hex. flange screws: 2. Install a new cylinder head gasket, (with printing up). Figure 11-42. Cylinder Head Fastener Torque Sequence. Heads secured with mounting studs, nuts, and washers: Figure 11-40.
  • Page 197 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly NOTE: Push rods should always be installed in the same position as before disassembly. 1. Note the mark or tag identifying the push rod as either intake or exhaust and cylinder #1 or #2. Dip...
  • Page 198 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly 5. Repeat the above steps for the remaining cylinder. Do not interchange parts from the cylinder heads. Figure 11-49. Installing Ignition Module. 2. On engines equipped with SMART-SPARK both ™...
  • Page 199 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly Sealant Figure 11-50. Setting Ignition Module Air Gap. Figure 11-52. Sealant Applied to Terminals. 6. Torque the screws to 4.0 N·m (35 in. lb.). NOTE: If the wires were disconnected from the ignition modules on engines with SMART- 7.
  • Page 200 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly Figure 11-54. Connecting Kill Leads on Standard Figure 11-56. Installing Breather Reed Assembly. Ignition Modules. 4. Insert the breather filter into position in the crankcase. Make sure no filter strands are on the sealing surface.
  • Page 201 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly Install Blower Housing and Outer Baffles NOTE: Do not completely tighten screws until all items are installed to allow shifting for hole alignment. 1. Connect the plug to the key switch in the blower housing (if so equipped).
  • Page 202 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly 4. If the rectifier-regulator was not removed, attach the ground wire or metal grounding bracket for the rectifier-regulator, using the silver colored screw and washer, to the lower blower housing hole.
  • Page 203 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly Figure 11-67. Breather Cover Fastener Torque Figure 11-69. Installing B+ Lead into Plug. Sequence. Reconnect Rectifier-Regulator 1. Install the rectifier-regulator in the blower housing, if removed previously, then connect the rectifier-...
  • Page 204 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly 3. On models with a solenoid shift starter, connect the leads to the solenoid. See Figure 11-73. Cylinder Baffle Mounting Location Figure 11-73. Connecting Leads to Starting Motor. NOTE: If the engine uses a side mount muffler on the...
  • Page 205 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly Metal-Cased Pulse Fuel Pump Figure 11-75. Installing Carburetor Assembly. Plastic-Cased Pulse Fuel Pump Figure 11-74. Reinstalled Fuel Pump. Install Carburetor Figure 11-76. Ground Lead on Carburetor Mounting Screw. WARNING: Explosive Fuel! 3.
  • Page 206 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly 2. Make sure the throttle linkage is connected to the governor lever and the throttle lever on the carburetor. 3. Move the governor lever toward the carburetor as far as it will go (wide-open throttle) and hold in position.
  • Page 207 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly 3. Connect the governor spring from the main control bracket to the appropriate hole in the governor lever as indicated in the following charts. Note that hole positions are counted from the pivot point of the governor lever.
  • Page 208 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly 8 mm Governor Lever and Hole Position/RPM Charts Governor Lever CH18 Engines Intended Non-Accelerator Accelerator Maximum RPM Pump Carburetor Pump Carburetor Governor Shaft Configuration High Idle Spring Color Hole No.
  • Page 209 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly Item Description Bracket, speed control Clamp, cable (some applications) Kill Switch (some applications) Lever, choke (top position) Lever, throttle control (middle) Linkage, choke control Lever, throttle actuator (bottom) Screw, M5x0.8x20...
  • Page 210 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly Install Valve Covers Gasket/RTV style cover ..... 3.4 N·m (30 in. lb.) Black O-Ring style cover Three valve cover designs have been used. The with shoulder screws ... 5.6 N·m (50 in. lb.) earliest type used a gasket and RTV sealant between with screws and spacers ..
  • Page 211 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly 3. Secure the air cleaner base and bracket using the hex. flange screws. Position the bracket with the hole toward the breather hose. Be careful not to drop screws into the carburetor. If a rear air cleaner bracket is used, install the two M5 screws through the rear of the base.
  • Page 212 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly Install Oil Cooler 1. Reinstall the oil cooler on the engine (if equipped). Install a new gasket between the cooler and the closure plate. Torque nipple adapter to 27 N·m (20 ft.
  • Page 213 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly Prepare the Engine for Operation The engine is now completely reassembled. Before starting or operating the engine, be sure to do the following. 1. Make sure all hardware is tightened securely.
  • Page 214 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 11 Reassembly 11.30 www.mymowerparts.com...
  • Page 215 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 12 Clutch CH18-745 Section 12 Clutch Clutch General Some engines are equipped with a “wet” disc type clutch. See Figure 12-1 for exploded view of clutch. Nameplate Shifting Lever Gasket Clutch...

  • Page 216: Section 12 Clutch

    Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 Section 12 Clutch Service 2. After adjustment is made, engage clutch and On this type, an oil “splash” type lubrication system is check to make sure rollers go over center to lock used.
  • Page 217 Kohler Engine Parts Call K&T 606-678-9623 or 606-561-4983 FORM NO.: TP-2428-B ISSUED: 4/92 REVISED: 6/04 MAILED: 7/04 LITHO IN U.S.A. FOR SALES AND SERVICE INFORMATION IN U.S. AND CANADA, CALL 1-800-544-2444 ENGINE DIVISION, KOHLER CO., KOHLER, WISCONSIN 53044 www.mymowerparts.com...

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