Kohler 3000 Series SH265 Engine Service Manual

SH265

Service Manual

IMPORTANT: Read all safety precautions and instructions carefully before operating equipment. Refer to operating instruction of equipment that this engine powers.

Ensure engine is stopped and level before performing any maintenance or service.

2 Safety

3 Maintenance

5 Specifi cations

12 Tools and Aids

15 Troubleshooting

19 Air Cleaner/Intake

20 Fuel System

24 Governor System

25 Lubrication System

26 Electrical System

30 Starter System

33 Disassembly/Inspection and Service

43 Reassembly

18 690 01 Rev. C KohlerEngines.com

1

Safety

SAFETY PRECAUTIONS

WARNING: A hazard that could result in death, serious injury, or substantial property damage.

CAUTION: A hazard that could result in minor personal injury or property damage.

NOTE: is used to notify people of important installation, operation, or maintenance information.

WARNING

Explosive Fuel can cause fi res and severe burns.

Do not fi ll fuel tank while engine is hot or running.

Gasoline is extremely fl ammable and its vapors can explode if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied buildings, away from sparks or fl ames.

Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Never use gasoline as a cleaning agent.

WARNING

Rotating Parts can cause severe injury.

Stay away while engine is in operation.

Keep hands, feet, hair, and clothing away from all moving parts to prevent injury. Never operate engine with covers, shrouds, or guards removed.

WARNING

Carbon Monoxide can cause severe nausea, fainting or death.

Avoid inhaling exhaust fumes.

Engine exhaust gases contain poisonous carbon monoxide.

Carbon monoxide is odorless, colorless, and can cause death if inhaled.

WARNING

Accidental Starts can cause severe injury or death.

Disconnect and ground spark plug lead(s) before servicing.

Before working on engine or equipment, disable engine as follows: 1) Disconnect spark plug lead(s). 2) Disconnect negative (–) battery cable from battery.

WARNING

Hot Parts can cause severe burns.

Do not touch engine while operating or just after stopping.

Never operate engine with heat shields or guards removed.

WARNING

Cleaning Solvents can cause severe injury or death.

Use only in well ventilated areas away from ignition sources.

Carburetor cleaners and solvents are extremely fl ammable. Follow cleaner manufacturer’s warnings and instructions on its proper and safe use. Never use gasoline as a cleaning agent.

CAUTION

Electrical Shock can cause injury.

Do not touch wires while engine is running.

CAUTION

Damaging Crankshaft and Flywheel can cause personal injury.

Using improper procedures can lead to broken fragments. Broken fragments could be thrown from engine. Always observe and use precautions and procedures when installing fl ywheel.

WARNING

Uncoiling Spring can cause severe injury.

Wear safety goggles or face protection when servicing retractable starter.

Retractable starters contain a powerful, recoil spring that is under tension. Always wear safety goggles when servicing retractable starters and carefully follow instructions in Retractable Starter for relieving spring tension.

2

KohlerEngines.com

18 690 01 Rev. C

Maintenance

MAINTENANCE INSTRUCTIONS

WARNING




Normal maintenance, replacement or repair of emission control devices and systems may be performed by any repair establishment or individual; however, warranty repairs must be performed by a Kohler authorized dealer.

MAINTENANCE SCHEDULE

After fi rst 5 Hours

● Change oil. Lubrication System

Every 50 Hours or Annually

● Service/replace dual-element precleaner.

Every 100 Hours or Annually¹

● Clean low-profi le air cleaner element.

● Replace dual-element air cleaner element.

● Change oil.

● Clean cooling areas.

● Clean spark arrestor (if equipped).

● Replace fuel fi lter (if equipped).

Every 100 Hours

2

● Check and adjust valve clearance when engine is cold.

● Have combustion chamber decarbonized.

Air Cleaner/Intake

Air Cleaner/Intake

Air Cleaner/Intake

Lubrication System

Air Cleaner/Intake

Reassembly

Every 125 Hours or Annually¹

● Replace spark plug and set gap.

Every 200 Hours²

● Replace fuel line.

Electrical System

Fuel System

Every 300 Hours

● Replace low-profi le air cleaner element.

1

Perform these procedures more frequently under severe, dusty, dirty conditions.

2

Have a Kohler authorized dealer perform this service.

Air Cleaner/Intake

REPAIRS/SERVICE PARTS

Kohler genuine service parts can be purchased from Kohler authorized dealers. To fi nd a local Kohler authorized dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada).


3

Maintenance

OIL RECOMMENDATIONS

We recommend use of Kohler oils for best performance.

Other high-quality detergent oils (including synthetic) of API (American Petroleum Institute) service class SJ or higher are acceptable. Select viscosity based on air temperature at time of operation as shown in table below.

STORAGE

If engine will be out of service for 2 months or more follow procedure below.

1. Add Kohler PRO Series fuel treatment or equivalent to fuel tank. Run engine 2-3 minutes to get stabilized fuel into fuel system (failures due to untreated fuel are not warrantable).

2. Change oil while engine is still warm from operation.

Remove spark plug(s) and pour about 1 oz. of engine oil into cylinder(s). Replace spark plug(s) and crank engine slowly to distribute oil.

3. Disconnect negative (-) battery cable.

4. Store engine in a clean, dry place.

FUEL RECOMMENDATIONS

WARNING



Gasoline is extremely fl ammable and its vapors can explode if ignited. Store gasoline only in approved containers, in well ventilated, unoccupied buildings, away from sparks or fl ames. Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition. Never use gasoline as a cleaning agent.

NOTE: E15, E20 and E85 are NOT approved and should NOT be used; effects of old, stale or contaminated fuel are not warrantable.

Fuel must meet these requirements:

● Clean, fresh, unleaded gasoline.

● Octane rating of 87 (R+M)/2 or higher.

● Research Octane Number (RON) 90 octane minimum.

● Gasoline up to 10% ethyl alcohol, 90% unleaded is acceptable.

● Methyl Tertiary Butyl Ether (MTBE) and unleaded gasoline blend (max 15% MTBE by volume) are approved.

● Do not add oil to gasoline.

● Do not overfi ll fuel tank.

● Do not use gasoline older than 30 days.

4

KohlerEngines.com

18 690 01 Rev. C

Engine Dimensions

Dimensions in millimeters.

Inch equivalents shown in [ ].

369.40

[14.543]

113.44

[4.466]

Specifi cations

318.66

[12.545]

STRAIGHT PTO

181.60

[7.150]

SPARK

PLUG

273.97

[10.786]

110.00 [4.331]

AIR CLEANER

COVER

REMOVAL

OIL FILL

DRAIN PLUG

37.98 [1.495]

37.50 [1.476]

78.00

[3.071]

2X Ø 10.00 [0.394]

2X 10.00 X 15.50

SLOT [0.394 X 0.610]

12.50

[0.492]

GAS CAP

REMOVAL

88.00

[3.465]

342.20

[13.473]

65.05

[2.561]

32.53

[1.281]

66.00 [2.598]

32.53 [1.281]

65.05 [2.561]

162.00

[6.378]

339.90

[13.382]

30.00

[1.181]

106.00

[4.173]

METRIC FLANGE: 4X M8 X 1.25-6H THRU

SAE A FLANGE: 4X 5/16-24 UNF-2B THRU

METRIC FLANGE: 4X M8 X 1.25-6H 15.00 [0.591]

SAE A FLANGE: 4X 5/16-24 UNF-2B 15.00 [0.591]


5

Specifi cations

ENGINE IDENTIFICATION NUMBERS

Kohler engine identifi cation numbers (model, specifi cation and serial) should be referenced for effi cient repair, ordering correct parts, and engine replacement.

Model . . . . . . . . . . . . . . . . . . . . . SH265

Courage Engine

Horizontal Shaft

Numerical Designation

Specifi cation . . . . . . . . . . . . . . . SH265-0001

Serial . . . . . . . . . . . . . . . . . . . . . 4323500328

Year Manufactured Code Factory Code

2013

2014

GENERAL SPECIFICATIONS

3,6

Bore

Stroke

Displacement

Oil Capacity (refi ll)

Maximum Angle of Operation (@ full oil level)

4

SH265

68 mm (2.7 in.)

54 mm (2.1 in.)

196 cc (12.0 cu. in.)

0.6 L (0.63 U.S. qt.)

25°

TORQUE SPECIFICATIONS 3,5

Air Cleaner

Mounting Screw (into intake manifold)

SH265

8 N·m (70.8 in. lb.)

Blower Housing and Sheet Metal

M6 Shoulder Screw

M6 Nut

Carburetor

Stud

Primary Nut

Secondary Nut

Intake Cover Nut

Connecting Rod

Cap Fastener (torque in increments)

10 N·m (88.5 in. lb.)

8 N·m (70.8 in. lb.)

10 N·m (88.5 in. lb.)

8 N·m (70.8 in. lb.)

10 N·m (88.5 in. lb.)

4 N·m (35.4 in. lb.)

12 N·m (106 in. lb.)

Crankcase

Oil Drain Plug

Closure Plate Screw

Cylinder Head

Fastener (torque in 2 increments)

18 N·m (13 ft. lb.)

24 N·m (212 in. lb.) fi rst to 12 N·m (106 in. lb.) fi nally to 24 N·m (212 in. lb.)

3

Values are in Metric units. Values in parentheses are English equivalents.

4

Exceeding maximum angle of operation may cause engine damage from insuffi cient lubrication.

5

Lubricate threads with engine oil prior to assembly.

6

Any and all horsepower (hp) references by Kohler are Certifi ed Power Ratings and per SAE J1940 & J1995 hp standards. Details on Certifi ed Power Ratings can be found at KohlerEngines.com.

6

KohlerEngines.com

18 690 01 Rev. C

TORQUE SPECIFICATIONS 3,5

Flywheel

Retaining Nut

Fuel Tank

Mounting Nut

Mounting Screw

Inlet Fitting

Governor

Arm Nut

Throttle Control Lever Nut

Ignition

Spark Plug

Module Fastener

Module Screw

Oil Sentry

™

Module Screw

Muffl er

M8 Exhaust Screw

M6 Muffl er Shield Screw

M4 Muffl er Shield Screw

M5 Spark Arrestor Screw

Retractable Starter

Cover Screw

Screw

Rocker Arm

Stud

Pivot Jam Nut

Valve Cover

Fastener

Specifi cations

SH265

74 N·m (655 in. lb.)

24 N·m (212 in. lb.)

24 N·m (212 in. lb.)

1.5 N·m (13.3 in. lb.)

10 N·m (88.5 in. lb.)

4.5-6 N·m (40-53 in. lb.)

27 N·m (20 ft. lb.)

8 N·m (70.8 in. lb.)

10 N·m (88.5 in. lb.)

8 N·m (70.8 in. lb.)

24 N·m (212 in. lb.)

8 N·m (70.8 in. lb.)

2 N·m (17.7 in. lb.)

3.5 N·m (31 in. lb.)

5.4 N·m (47.8 in. lb.)

10 N·m (88.5 in. lb.)

13.6 N·m (120 in. lb.)

10 N·m (88.5 in. lb.)

8 N·m (70.8 in. lb.)

3


5



7

Specifi cations

CLEARANCE SPECIFICATIONS 3

Camshaft

End Play

Running Clearance

Bore I.D.

New

Max. Wear Limit

Connecting Rod

Crankpin End I.D. @ 21°C (70°F)

New

Max. Wear Limit

Connecting Rod-to-Crankpin Running Clearance

New

Max. Wear Limit

Connecting Rod-to-Crankpin Side Clearance

New

Max. Wear Limit

Connecting Rod-to-Piston Pin Running Clearance

Piston Pin End I.D. @ 21°C (70°F)

New

Max. Wear Limit

Crankcase

Governor Cross Shaft Bore I.D.

New

Max. Wear Limit

Crankshaft

End Play (free)

Ball Bearing

Bore (in crankcase)

New, without Main Bearing

Bore (in closure plate)

New, without Main Bearing

Flywheel End Main Bearing Journal O.D.

O.D.-New

O.D.-Max. Wear Limit

Taper

Max.

Closure Plate End Main Bearing Journal O.D.

O.D.-New


Taper

Max.

Connecting Rod Journal O.D.

O.D.-New


Max.

Max.

Width

Out-of-Round

Runout (either end)

Main Bearing I.D. (Crankcase/Closure Plate)

New (installed)

3


5


8

KohlerEngines.com

SH265

0.025/0.602 mm (0.0010/0.0237 in.)

0.016/0.052 mm (0.0006/0.0020 in.)

14.000/14.018 mm (0.5512/0.5519 in.)

14.048 mm (0.5531 in.)

30.021/30.026 mm (1.1819/1.1821 in.)

30.08 mm (1.184 in.)

0.041/0.051 mm (0.002/0.002 in.)

0.12 mm (0.005 in.)

0.58/0.60 mm (0.023/0.024 in.)

1.10 mm (0.043 in.)

0.01/0.027 mm (0.0004/0.0011 in.)

18.010/18.015 mm (0.709/0.709 in.)

18.08 mm (0.712 in.)

6.000/6.018 mm (0.2362/0.2369 in.)

6.037 mm (0.2377 in.)

0.025/0.703 mm (0.0010/0.028 in.)

0.003/0.25 mm (0.0001/0.0010 in.)

51.961/51.991 mm (2.0457/2.0469 in.)

51.961/51.991 mm (2.0457/2.0469 in.)

24.975/24.989 mm (0.9833/0.9838 in.)

24.95 mm (0.9823 in.)

0.025 mm (0.0010 in.)

0.025 mm (0.0010 in.)

24.975/24.989 mm (0.9833/0.9838 in.)

24.95 mm (0.9823 in.)

0.025 mm (0.0010 in.)

0.025 mm (0.0010 in.)

29.975/29.985 mm (1.1801/1.1805 in.)

29.920 mm (1.1779 in.)

0.025 mm (0.0010 in.)

0.025 mm (0.0010 in.)

25.02/25.08 mm (0.9850/0.9874 in.)

0.025 mm (0.0010 in.)

24.994/25.000 mm (0.9840/0.9842 in.)

18 690 01 Rev. C


Cylinder Bore

Bore I.D.

New

Max. Wear Limit

Out-of-Round

Max.

Cylinder Head

Max. Out-of-Flatness

Governor

Governor Cross Shaft-to-Crankcase Running Clearance

Governor Cross Shaft O.D.

New

Max. Wear Limit

Governor Gear Shaft-to-Governor Gear Running Clearance

Governor Gear Shaft O.D.

New

Max. Wear Limit

Ignition

Spark Plug Gap

Module Air Gap

Piston, Piston Rings, and Piston Pin

Piston-to-Piston Pin Running Clearance

Piston Pin Bore I.D.

New

Max. Wear Limit

Piston Pin O.D.

New

Max. Wear Limit

Top and Center Compression Ring Side Clearance

New

Used Bore (max.)

Top and Center Compression Ring End Gap

New

Used Bore (max.)

Top and Center Compression Ring Width

New

Used Bore (max.)

Oil Control Ring-to-Groove Side Clearance

Piston Thrust Face O.D.

7

New

Max. Wear Limit

Piston Thrust Face-to-Cylinder Bore Running Clearance

New

Specifi cations

SH265

70.027/70.035 mm (2.757/2.757 in.)

70.200 mm (2.764 in.)

12.7 microns (0.0005 in.)

12.7 microns (0.0005 in.)

0.1 mm (0.0039 in.)

0.013/0.075 mm (0.0005/0.0029 in.)

5.95/5.98 mm (0.2342/0.2354 in.)

5.85 mm (0.2303 in.)

0.09/0.19 mm (0.0035/0.0074 in.)

6.028/6.043 mm (0.2373/0.2379 in.)

6.018 mm (0.2369 in.)

0.76 mm (0.030 in.)

0.254 mm (0.0100 in.)

0.009/0.016 mm (0.0003/0.0006 in.)

18.004/18.005 mm (0.7088/0.7089 in.)

18.05 mm (0.7106 in.)

17.992/17.995 mm (0.7083/0.7084 in.)

17.95 mm (0.7067 in.)

0.04 mm (0.002 in.)

0.15 mm (0.006 in.)

0.325 mm/0.4 (0.013/0.016 in.)

1.00 mm (0.039 in.)

1.5/1.51 mm (0.059/0.059 in.)

1.37 mm (0.054 in.)

0.06/0.18 mm (0.0023/0.0071 in.)

67.975/67.985 mm (2.6762/2.6766 in.)

67.85 mm (2.6712 in.)

0.057/0.075 mm (0.0022/0.0029 in.)

3


7

Measure 15 mm (0.5905 in.) above bottom of piston skirt at right angles to piston pin.


9

Specifi cations


Valves and Valve Lifters

Intake Valve Stem-to-Valve Guide Running Clearance

Exhaust Valve Stem-to-Valve Guide Running Clearance

Intake Valve Stem O.D.

New

Max. Wear Limit

Exhaust Valve Stem O.D.

New

Max. Wear Limit

Intake Valve Stem to Guide

New

Max. Wear Limit

Exhaust Valve Stem to Guide

New

Max. Wear Limit

Valve Guide Reamer Size

Intake

Standard

Valve Seat Width

Nominal Valve Face Angle

SH265

0.020/0.044 mm (0.008/0.0017 in.)

0.030/0.054 mm (0.0011/0.0021 in.)

5.480 mm (0.2157 in.)

5.32 mm (0.2094 in.)

5.47 mm (0.2153 in.)

5.305 mm (0.2088 in.)

0.024/0.039 mm (0.001/0.002 in.)

0.10 mm (0.0004 in.)

0.098/0.112 mm (0.0038/0.0044 in.)

0.12 mm (0.0005 in.)

5.506 mm (0.2168 in.)

5.506 mm (0.2168 in.)

0.800/2.00 mm (0.0315/0.787 in.)

30°, 45°, 60°

3


10

KohlerEngines.com

18 690 01 Rev. C

Specifi cations

GENERAL TORQUE VALUES

English Fastener Torque Recommendations for Standard Applications

Bolts, Screws, Nuts and Fasteners Assembled Into Cast Iron or Steel

Grade 2 or 5 Fasteners

Into Aluminum

Size Grade 2

Tightening Torque: N·m (in. lb.) ± 20%

8-32

10-24

10-32

1/4-20

2.3 (20)

3.6 (32)

3.6 (32)

7.9 (70)

1/4-28

5/16-18

5/16-24

3/8-16

3/8-24

9.6 (85)

17.0 (150)

18.7 (165)

29.4 (260)

33.9 (300)

Tightening Torque: N·m (ft. lb.) ± 20%

5/16-24 —

3/8-16

3/8-24

7/16-14

—

—

47.5 (35)

7/16-20

1/2-13

1/2-20

9/16-12

9/16-18

5/8-11

5/8-18

3/4-10

3/4-16

61.0 (45)

67.8 (50)

94.9 (70)

101.7 (75)

135.6 (100)

149.5 (110)

189.8 (140)

199.3 (147)

271.2 (200)

Grade 5

2.8 (25)

4.5 (40)

4.5 (40)

13.0 (115)

15.8 (140)

28.3 (250)

30.5 (270)

—

—

—

47.5 (35)

54.2 (40)

74.6 (55)

101.7 (75)

108.5 (80)

142.4 (105)

169.5 (125)

223.7 (165)

244.1 (180)

311.9 (230)

332.2 (245)

440.7 (325)

Grade 8

—

—

—

18.7 (165)

22.6 (200)

39.6 (350)

—

Metric Fastener Torque Recommendations for Standard Applications

Property Class

Size

4.8

5.8

8.8

10.9

Tightening Torque: N·m (in. lb.) ± 10%

M4 1.2 (11) 1.7 (15)

M5

M6

M8

2.5 (22)

4.3 (38)

10.5 (93)

3.2 (28)

5.7 (50)

13.6 (120)

2.9 (26)

5.8 (51)

9.9 (88)

24.4 (216)

4.1 (36)

8.1 (72)

14.0 (124)

33.9 (300)

Tightening Torque: N·m (ft. lb.) ± 10%

M10 21.7 (16) 27.1 (20)

M12

M14

36.6 (27)

58.3 (43)

47.5 (35)

76.4 (56)

47.5 (35)

82.7 (61)

131.5 (97)

66.4 (49)

116.6 (86)

184.4 (136)

—

—

40.7 (30)

67.8 (50)

81.4 (60)

108.5 (80)

142.5 (105)

155.9 (115)

223.7 (165)

237.3 (175)

311.9 (230)

352.6 (260)

447.5 (330)

474.6 (350)

637.3 (470)

12.9

5.0 (44)

9.7 (86)

16.5 (146)

40.7 (360)

81.4 (60)

139.7 (103)

219.7 (162)

2.3 (20)

3.6 (32)

—

7.9 (70)

—

17.0 (150)

—

—

—

33.9 (25)

61.0 (45)

94.9 (70)

—

—

—

—

—

—

—

—

—

—

—

—

—

Noncritical

Fasteners

Into Aluminum

2.0 (18)

4.0 (35)

6.8 (60)

17.0 (150)

18 690 01 Rev. C

Torque Conversions

N·m = in. lb. x 0.113

in. lb. = N·m x 8.85

N·m = ft. lb. x 1.356

ft. lb. = N·m x 0.737

KohlerEngines.com

11

Tools and Aids

Certain quality tools are designed to help you perform specifi c disassembly, repair, and reassembly procedures. By using these tools, 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 a list of tools and their source.

SEPARATE TOOL SUPPLIERS

Kohler Tools

Contact your local Kohler source of supply.

SE Tools

415 Howard St.

Lapeer, MI 48446

Phone 810-664-2981

Toll Free 800-664-2981

Fax 810-664-8181

Design Technology Inc.

768 Burr Oak Drive

Westmont, IL 60559

Phone 630-920-1300

Fax 630-920-0011

TOOLS

Description

Alcohol Content Tester

For testing alcohol content (%) in reformulated/oxygenated fuels.

Camshaft Endplay Plate

For checking camshaft endplay.

Camshaft Seal Protector (Aegis)

For protecting seal during camshaft installation.

Cylinder Leakdown Tester

For checking combustion retention and if cylinder, piston, rings, or valves are worn.

Individual component available:

Adapter 12 mm x 14 mm (Required for leakdown test on XT-6 engines)

Dealer Tool Kit (Domestic)

Complete kit of Kohler required tools.

Components of 25 761 39-S

Ignition System Tester

Cylinder Leakdown Tester

Oil Pressure Test Kit

Rectifi er-Regulator Tester (120 V AC/60Hz)

Dealer Tool Kit (International)

Complete kit of Kohler required tools.


Ignition System Tester

Cylinder Leakdown Tester

Oil Pressure Test Kit

Rectifi er-Regulator Tester (240 V AC/50Hz)

Digital Vacuum/Pressure Tester

For checking crankcase vacuum.


Rubber Adapter Plug

Electronic Fuel Injection (EFI) Diagnostic Software

For Laptop or Desktop PC.

EFI Service Kit

For troubleshooting and setting up an EFI engine.


Fuel Pressure Tester

Noid Light

90° Adapter

Code Plug, Red Wire

Code Plug, Blue Wire

Shrader Valve Adapter Hose

Wire Probe Set (2 pieces regular wire with clip; 1 piece fused wire)

Hose Removal Tool, Dual Size/End (also sold as individual Kohler tool)

Flywheel Puller

For properly removing fl ywheel from engine.

Source/Part No.

Kohler 25 455 11-S

SE Tools KLR-82405

SE Tools KLR-82417

Kohler 25 761 05-S


DTI-731-03

Kohler 25 761 39-S

Kohler 25 455 01-S

Kohler 25 761 05-S

Kohler 25 761 06-S

Kohler 25 761 20-S

Kohler 25 761 42-S

Kohler 25 455 01-S

Kohler 25 761 05-S

Kohler 25 761 06-S

Kohler 25 761 41-S


DTI-721-01


DTI-721-10

Kohler 25 761 23-S

Kohler 24 761 01-S


DTI-019

DTI-021

DTI-023

DTI-027

DTI-029

DTI-037

DTI-031

DTI-033

SE Tools KLR-82408

12 KohlerEngines.com

18 690 01 Rev. C

Tools and Aids

TOOLS

Description

Hose Removal Tool, Dual Size/End (also available in EFI Service Kit)

Used to properly remove fuel hose from engine components.

Hydraulic Valve Lifter Tool

For removing and installing hydraulic lifters.

Ignition System Tester

For testing output on all systems, including CD.

Inductive Tachometer (Digital)

For checking operating speed (RPM) of an engine.

Offset Wrench (K and M Series)

For removing and reinstalling cylinder barrel retaining nuts.

Oil Pressure Test Kit

For testing/verifying oil pressure on pressure lubricated engines.

Rectifi er-Regulator Tester (120 volt current)

Rectifi er-Regulator Tester (240 volt current)

For testing rectifi er-regulators.

Components of 25 761 20-S and 25 761 41-S

CS-PRO Regulator Test Harness

Special Regulator Test Harness with Diode

Spark Advance Module (SAM) Tester

For testing SAM (ASAM and DSAM) on engines with SMART-SPARK

™

.

Starter Servicing Kit (All Starters)

For removing and reinstalling drive retaining rings and brushes.


Starter Brush Holding Tool (Solenoid Shift)

Triad/OHC Timing Tool Set

For holding cam gears and crankshaft in timed position while installing timing belt.

Valve Guide Reamer (K and M Series)

For properly sizing valve guides after installation.

Valve Guide Reamer O.S. (Command Series)

For reaming worn valve guides to accept replacement oversize valves. Can be used in low-speed drill press or with handle below for hand reaming.

Reamer Handle

For hand reaming using Kohler 25 455 12-S reamer.

Source/Part No.

Kohler 25 455 20-S

Kohler 25 761 38-S

Kohler 25 455 01-S


DTI-110

Kohler 52 455 04-S

Kohler 25 761 06-S

Kohler 25 761 20-S

Kohler 25 761 41-S


DTI-031R

DTI-033R

Kohler 25 761 40-S

SE Tools KLR-82411

SE Tools KLR-82416

Kohler 28 761 01-S


DTI-K828

Kohler 25 455 12-S


DTI-K830

AIDS

Description

Camshaft Lubricant (Valspar ZZ613)

Dielectric Grease (GE/Novaguard G661)

Dielectric Grease

Kohler Electric Starter Drive Lubricant (Inertia Drive)

Kohler Electric Starter Drive Lubricant (Solenoid Shift)

RTV Silicone Sealant

Loctite

®

5900

®

Heavy Body in 4 oz. aerosol dispenser.

Only oxime-based, oil resistant RTV sealants, such as those listed, are approved for use. Permatex

®

the Right Stuff

®

1 Minute Gasket™ or Loctite

®

Nos. 5900

®

or

5910

®

are recommended for best sealing characteristics.

Spline Drive Lubricant

Source/Part No.

Kohler 25 357 14-S

Kohler 25 357 11-S

Loctite

®

51360

Kohler 52 357 01-S

Kohler 52 357 02-S

Kohler 25 597 07-S

Loctite

®

5910

®

Loctite

®

Ultra Black 598™

Loctite

®

Ultra Blue 587™

Loctite

®

Ultra Copper 5920™

Permatex

®

the Right Stuff

®

1

Minute Gasket™

Kohler 25 357 12-S


13

Tools and Aids

FLYWHEEL HOLDING TOOL ROCKER ARM/CRANKSHAFT TOOL

A fl ywheel holding tool can be made out of an old junk fl ywheel ring gear and used in place of a strap wrench.

1. Using an abrasive cut-off wheel, cut out a six tooth segment of ring gear as shown.

2. Grind off any burrs or sharp edges.

3. Invert segment and place it between ignition bosses on crankcase so tool teeth engage fl ywheel ring gear teeth. Bosses will lock tool and fl ywheel in position for loosening, tightening, or removing with a puller.

A spanner wrench to lift rocker arms or turn crankshaft may be made out of an old junk connecting rod.

1. Find a used connecting rod from a 10 HP or larger engine. Remove and discard rod cap.

2. Remove studs of a Posi-Lock rod or grind off aligning steps of a Command rod, so joint surface is fl at.

3. Find a 1 in. long capscrew with correct thread size to match threads in connecting rod.

a capscrew and approximately 1 in. O.D. Assemble capscrew and washer to joint surface of rod.


18 690 01 Rev. C

Troubleshooting

TROUBLESHOOTING GUIDE

When troubles occur, be sure to check simple causes which, at fi rst, may seem too obvious to be considered. For example, a starting problem could be caused by an empty fuel tank.

Some general common causes of engine troubles are listed below and vary by engine specifi cation. Use these to locate causing factors.

Engine Cranks But Will Not Start

● Battery connected backwards.

● Blown fuse.

● Carburetor solenoid malfunction.

● Choke not closing.

● Clogged fuel line or fuel fi lter.

● Diode in wiring harness failed in open circuit mode.

● DSAI or DSAM malfunction.

● Empty fuel tank.

● Faulty electronic control unit.

● Faulty ignition coil(s).

● Faulty spark plug(s).

● Fuel pump malfunction-vacuum hose clogged or leaking.

● Fuel shut-off valve closed.

● Ignition module(s) faulty or improperly gapped.

● Insuffi cient voltage to electronic control unit.

● Interlock switch is engaged or faulty.

● Key switch or kill switch in OFF position.

● Low oil level.

● Quality of fuel (dirt, water, stale, mixture).

● SMART-SPARK

TM

malfunction.

● Spark plug lead(s) disconnected.

Engine Starts But Does Not Keep Running

● Faulty carburetor.

● Faulty cylinder head gasket.

● Faulty or misadjusted choke or throttle controls.


● Intake system leak.

● Loose wires or connections that intermittently ground ignition kill circuit.


● Restricted fuel tank cap vent.

Engine Starts Hard

● Clogged fuel line or fuel fi lter.

● Engine overheated.

● Faulty ACR mechanism.

● Faulty or misadjusted choke or throttle controls.


● Flywheel key sheared.




● Low compression.


● Weak spark.

Engine Will Not Crank

● Battery is discharged.

● Faulty electric starter or solenoid.

● Faulty key switch or ignition switch.



● Pawls not engaging in drive cup.

● Seized internal engine components.

Engine Runs But Misses

● Carburetor adjusted incorrectly.



● Ignition module(s) faulty or improperly gapped.

● Incorrect crankshaft position sensor air gap.




● Spark plug lead(s) disconnected.

● Spark plug lead boot loose on plug.

● Spark plug lead loose.

Engine Will Not Idle



● Idle fuel adjusting needle(s) improperly set.

● Idle speed adjusting screw improperly set.

● Inadequate fuel supply.



● Restricted fuel tank cap vent.

Engine Overheats

● Cooling fan broken.

● Excessive engine load.

● Fan belt failed/off.

● Faulty carburetor.

● High crankcase oil level.

● Lean fuel mixture.

● Low cooling system fl uid level.

● Low crankcase oil level.

● Radiator, and/or cooling system components clogged, restricted, or leaking.

● Water pump belt failed/broken.

● Water pump malfunction.

Engine Knocks


● Hydraulic lifter malfunction.

● Incorrect oil viscosity/type.

● Internal wear or damage.




15

Troubleshooting

Engine Loses Power

● Dirty air cleaner element.



● Restricted exhaust.


● High crankcase oil level.

● Incorrect governor setting.

● Low battery.




Engine Uses Excessive Amount of Oil

● Loose or improperly torqued fasteners.

● Blown head gasket/overheated.

● Breather reed broken.

● Clogged, broken, or inoperative crankcase breather.

● Crankcase overfi lled.

● Incorrect oil viscosity/type.

● Worn cylinder bore.

● Worn or broken piston rings.

● Worn valve stems/valve guides.

Oil Leaks from Oil Seals, Gaskets

● Breather reed broken.

● Clogged, broken, or inoperative crankcase breather.

● Loose or improperly torqued fasteners.

● Piston blow by, or leaky valves.

● Restricted exhaust.

16

EXTERNAL ENGINE INSPECTION

NOTE: It is good practice to drain oil at a location away from workbench. Be sure to allow ample time for complete drainage.

Before cleaning or disassembling engine, make a thorough inspection of its external appearance and condition. This inspection can give clues to what might be found inside engines (and cause) when it is disassembled.

● Check for buildup of dirt and debris on crankcase, cooling fi ns, grass screen, and other external surfaces.

Dirt or debris on these areas can cause overheating.

● Check for obvious fuel and oil leaks, and damaged components. Excessive oil leakage can indicate a clogged or inoperative breather, worn or damaged seals or gaskets, or loose fasteners.

● Check air cleaner cover and base for damage or indications of improper fi t and seal.

● Check air cleaner element. Look for holes, tears, cracked or damaged sealing surfaces, or other damage that could allow unfi ltered air into engine. A dirty or clogged element could indicate insuffi cient or improper maintenance.

● Check carburetor throat for dirt. Dirt in throat is further indication that air cleaner was not functioning properly.

● Check if oil level is within operating range on dipstick.

If it is above, sniff for gasoline odor.

● Check condition of oil. Drain oil into a container; it should fl ow freely. Check for metal chips and other foreign particles.

Sludge is a natural by-product of combustion; a small accumulation is normal. Excessive sludge formation could indicate over rich fuel settings, weak ignition, overextended oil change interval or wrong weight or type of oil was used.

CLEANING ENGINE

WARNING

Cleaning Solvents can cause severe injury or death.

Use only in well ventilated areas away from ignition sources.

Carburetor cleaners and solvents are extremely fl ammable. Follow cleaner manufacturer’s warnings and instructions on its proper and safe use. Never use gasoline as a cleaning agent.

After inspecting external condition of engine, clean engine thoroughly before disassembly. Clean individual components as engine is disassembled. Only clean parts can be accurately inspected and gauged for wear or damage. There are many commercially available cleaners that will quickly remove grease, oil, and grime from engine parts. When such a cleaner is used, follow manufacturer’s instructions and safety precautions carefully.

Make sure all traces of cleaner are removed before engine is reassembled and placed into operation. Even small amounts of these cleaners can quickly break down lubricating properties of engine oil.

KohlerEngines.com

18 690 01 Rev. C

Troubleshooting

CRANKCASE VACUUM TEST

WARNING

Carbon Monoxide can cause severe nausea, fainting or death.

Avoid inhaling exhaust fumes.

Engine exhaust gases contain poisonous carbon monoxide. Carbon monoxide is odorless, colorless, and can cause death if inhaled.

WARNING

Rotating Parts can cause severe injury.

Stay away while engine is in operation.

Keep hands, feet, hair, and clothing away from all moving parts to prevent injury. Never operate engine with covers, shrouds, or guards removed.

A partial vacuum should be present in crankcase when engine is operating. Pressure in crankcase (normally caused by a clogged or improperly assembled breather) can cause oil to be forced out at oil seals, gaskets, or other available spots.

Crankcase vacuum is best measured with either a water manometer or a vacuum gauge. Complete instructions are provided in kits.

To test crankcase vacuum with manometer:

1. Insert rubber stopper into oil fi ll hole. Be sure pinch clamp is installed on hose and use tapered adapters to connect hose between stopper and one manometer tube. Leave other tube open to atmosphere. Check that water level in manometer is at 0 line. Make sure pinch clamp is closed.

2. Start engine and run no-load high speed.

3. Open clamp and note water level in tube.

Level in engine side should be a minimum of 10.2 cm (4 in.) above level in open side.

If level in engine side is less than specifi ed (low/no vacuum), or level in engine side is lower than level in open side (pressure), check for conditions in table below.

4. Close pinch clamp before stopping engine.

To test crankcase vacuum with vacuum/pressure gauge:

1. Remove dipstick or oil fi ll plug/cap.

2. Install adapter into oil fi ll//dipstick tube opening, upside down over end of a small diameter dipstick tube, or directly into engine if a tube is not used.

Insert barbed gauge fi tting into hole in stopper.

3. Run engine and observe gauge reading.

Analog tester–needle movement to left of 0 is a vacuum, and movement to right indicates a pressure.

Digital tester–depress test button on top of tester.

Crankcase vacuum should be a minimum of 10.2 cm

(4 in.) of water. If reading is below specifi cation, or if pressure is present, check table below for possible causes and conclusions.

Piston blow by or leaky valves (confi rm by inspecting components).

Restricted exhaust.

Condition

Crankcase breather clogged or inoperative.

Seals and/or gaskets leaking. Loose or improperly torque fasteners.

Conclusion

NOTE: If breather is integral part of valve cover and cannot be serviced separately, replace valve cover and recheck pressure.

Disassemble breather, clean parts thoroughly, check sealing surfaces for fl atness, reassemble, and recheck pressure.

Replace all worn or damaged seals and gaskets. Make sure all fasteners are tightened securely. Use appropriate torque valves and sequences when necessary.

Recondition piston, rings, cylinder bore, valves and valves guides.

Check exhaust screen/spark arrestor (if equipped). Clean or replace as needed. Repair or replace any other damaged/restricted muffl er or exhaust system parts.


17

Troubleshooting

COMPRESSION TEST

For Command Twins:

A compression test is best performed on a warm engine. Clean any dirt or debris away from base of spark plug(s) before removing them. Be sure choke is off, and throttle is wide open during test. Compression should be at least 160 psi and should not vary more than 15% between cylinders.

All other models:

These engines are equipped with an automatic compression release (ACR) mechanism. It is diffi cult to obtain an accurate compression reading because of ACR mechanism. As an alternative, use cylinder leakdown test described below.

CYLINDER LEAKDOWN TEST

A cylinder leakdown test can be a valuable alternative to a compression test. By pressurizing combustion chamber from an external air source you can determine if valves or rings are leaking, and how badly.

Cylinder leakdown tester is a relatively simple, inexpensive leakdown tester for small engines. This tester includes a quick-connect for attaching adapter hose and a holding tool.

1. Run engine for 3-5 minutes to warm it up.

2. Remove spark plug(s) and air fi lter from engine.

3. Rotate crankshaft until piston (of cylinder being tested) is at top dead center (TDC) of compression stroke. Hold engine in this position while testing. Holding tool supplied with tester can be used if PTO end of crankshaft is accessible. Lock holding tool onto crankshaft. Install a 3/8 in. breaker bar into hole/slot of holding tool, so it is perpendicular to both holding tool and crankshaft PTO.

fl ywheel end is more accessible, use a breaker bar and socket on fl ywheel nut/screw to hold it in position. An assistant may be needed to hold breaker bar during testing. If engine is mounted in a piece of equipment, it may be possible to hold it by clamping or wedging a driven component. Just be certain that engine cannot rotate off of

TDC in either direction.

4. Install adapter into spark plug hole, but do not attach it to tester at this time.

5. Turn regulator knob completely counterclockwise.

6. Connect an air source of at least 50 psi to tester.

7. Turn regulator knob clockwise (increase direction) until gauge needle is in yellow set area at low end of scale.

8. Connect tester quick-connect to adapter hose. While fi rmly holding engine at TDC, gradually open tester valve.

Note gauge reading and listen for escaping air at combustion air intake, exhaust outlet, and crankcase breather.

Condition

Air escaping from crankcase breather.

Air escaping from exhaust system.

Air escaping from intake.

Gauge reading in low (green) zone.

Gauge reading in moderate (yellow) zone.

Gauge reading in high (red) zone.

Conclusion

Ring or cylinder worn.

Defective exhaust valve/improper seating.

Defective intake valve/improper seating.

Piston rings and cylinder in good condition.

Engine is still usable, but there is some wear present.

Customer should start planning for overhaul or replacement.

Rings and/or cylinder have considerable wear. Engine should be reconditioned or replaced.


18 690 01 Rev. C

Air Cleaner/Intake

AIR CLEANER

These systems are CARB/EPA certifi ed and components should not be altered or modifi ed in any way.

Dual-Element Air Cleaner Components

A

B

D

NOTE: Operating engine with loose or damaged air cleaner components could cause premature wear and failure. Replace all bent or damaged components.

NOTE: Paper element cannot be blown out with compressed air.

Dual-Element

Remove wing nut and air cleaner cover.

Precleaner

1. Remove precleaner from paper element.

2. Replace or wash precleaner in warm water with detergent. Rinse and allow to air dry.

3. Reinstall precleaner over paper element.

Paper Element

1. Remove wing nut (if equipped) and paper element with precleaner.

2. Separate precleaner from element; service precleaner and replace element.

3. Reinstall precleaner over paper element; secure with wing nut (if equipped).

Reinstall air cleaner cover and secure with wing nut.

E

A

C

A

C

E

Wing Nut

Precleaner

Air Cleaner Base

B

D

Air Cleaner Cover

Paper Element

Low-Profi le Air Cleaner Components

F

F

Air Cleaner Base

H

Air Cleaner Cover

G

I

I

G

H

Foam Element

Screw

Low-Profi le

1. Remove screw and air cleaner cover.

2. Remove foam element from base.

3. Wash foam element in warm water with detergent.

Rinse and allow to air dry.

4. Lightly oil foam element with new engine oil; squeeze out excess oil.

5. Reinstall foam element into base.

6. Reinstall cover and secure with screw.

BREATHER TUBE

Make sure both ends of breather tube are properly connected.

AIR COOLING

WARNING

Hot Parts can cause severe burns.

Do not touch engine while operating or just after stopping.

Never operate engine with heat shields or guards removed.

Proper cooling is essential. To prevent over heating, clean screens, cooling fi ns, and other external surfaces of engine. Avoid spraying water at wiring harness or any electrical components. Refer to Maintenance Schedule.


19

Fuel System

Typical carbureted fuel system and related components include:

● Fuel tank.

● Fuel lines.

● In-line fuel fi lter.

● Fuel tank fi lter.

● Carburetor.

● Fuel strainer screen in carburetor.

Fuel tank outlet is located above carburetor inlet, allowing gravity to feed fuel through in-line fi lter and fuel line to carburetor.

Fuel then enters carburetor through a fuel shut-off valve and a fi ne screen/sediment bowl, and then to carburetor fl oat bowl. Fuel is drawn into carburetor body and is mixed with air. This fuel-air mixture is then burned in engine combustion chamber.

FUEL RECOMMENDATIONS

Refer to Maintenance.

FUEL LINE

Low permeation fuel line must be installed on carbureted

Kohler Co. engines to maintain EPA and CARB regulatory compliance.

FUEL FILTER

Fuel Tank Filter

A serviceable fuel tank fi lter is located under fuel tank cap, in fi ller neck.

Daily or as required clean fi lter of any accumulation as follows:

1. Remove fuel tank cap and fi lter.

Fuel Shut-Off

WARNING




Engines are equipped with a fuel shut-off located at carburetor. It controls fuel fl ow from tank to carburetor.

2. Turn fuel shut-off lever to OFF position.

3. Remove fuel shut-off cup.

4. Clean fuel shut-off cup with solvent and wipe dry.

5. Inspect for worn or damaged O-ring; replace as necessary.

6. Place O-ring on fuel shut-off cup. Install fuel shut-off cup and O-ring; rotate until fi nger tight. Turn with a wrench 1/2 to 3/4 full turn.

7. Turn fuel shut-off lever to ON position and check for leaks. If fuel shut-off cup leaks, repeat steps 5 and 6.

8. Tighten fuel tank cap securely.

4. Tighten fuel tank cap securely.

FUEL SYSTEM TESTS

When engine starts hard or turns over but will not start, fuel system might be causing problems. Test fuel system by performing following test.

1. Check for fuel in combustion chamber.

a. Disconnect and ground spark plug lead.

b. Use an approved fuel container to catch fuel, and hold line below bottom of tank to observe fuel fl ow.

b. Close choke on carburetor.

3. Check operation of fuel shut-off valve.

c. Crank engine several times.

d. Remove spark plug and check for fuel at tip.

a. Remove fuel sediment bowl under inlet fi tting of carburetor.

2. Check for fuel fl ow from tank to carburetor.

a. Remove fuel line from inlet fi tting of carburetor.

b. Turn fuel shut-off valve ON and OFF and observe operation.

Condition

Fuel at tip of spark plug.

No fuel at tip of spark plug.

Fuel fl ows from fuel line.

No fuel fl ow from fuel line.

Fuel fl ows from valve.

No fuel fl ows from valve.

Conclusion

Fuel is reaching combustion chamber.

Check fuel fl ow from fuel tank (step 2).

Check operation of fuel shut-off valve (step 3).

Check fuel tank vent, in-line fi lter threaded into tank, and fuel line. Correct any observed problem and reconnect line.

Check for dirt and water in sediment bowl and screen.

Clean bowl and screen as needed. Check for faulty carburetor, refer to Carburetor.

Check for a restriction in fuel shut-off valve or inlet elbow.


18 690 01 Rev. C

Fuel System

CARBURETOR

WARNING



Typical One-Barrel Carburetor Components

F

C

A

B

I

K

D

J

G

H

E

M

L


These engines are equipped with a fi xed main jet carburetor. Carburetor is designed to deliver correct fuelto-air mixture to engine under all operating conditions.

Idle mixture is set at factory and cannot be adjusted.

Troubleshooting Checklist

When engine starts hard, runs rough, or stalls at low idle speed, check these areas before adjusting or disassembling carburetor.

1. Make sure fuel tank is fi lled with clean, fresh gasoline.

2. Make sure fuel tank cap vent is not blocked and is operating properly.

3. Make sure fuel is reaching carburetor. This includes checking fuel shut-off valve, fuel tank fi lter screen, in-line fuel fi lter, fuel lines and fuel pump for restrictions or faulty components as necessary.

4. Make sure air cleaner base and carburetor are securely fastened to engine using gaskets in good condition.

5. Make sure air cleaner element (including precleaner if equipped) is clean and all air cleaner components are fastened securely.

6. Make sure ignition system, governor system, exhaust system, and throttle and choke controls are operating properly.

N

O

P

A

Fuel Shut-Off

B

Wave Washer

C

E

Fuel Shut-Off Valve

Idle Jet

D

Low Idle Speed

Adjusting Screw

F

Fuel Shut-Off Gasket

G

Main Nozzle Tube

H

I

K

M

Bowl Gasket

Spring

Float

N

J

L

Main Jet

Fuel Inlet Needle

Hinge Pin

Fuel Bowl

P

Bowl Retaining Screw


21

Fuel System

Troubleshooting-Carburetor Related Causes

Condition

Engine starts hard, runs rough, or stalls at idle speed.

Engine runs rich (indicated by black, sooty exhaust smoke, misfi ring, loss of speed and power, governor hunting, or excessive throttle opening).

Engine runs lean (indicated by misfi ring, loss of speed and power, governor hunting, or excessive throttle opening).

Fuel leaks from carburetor.

Possible Cause

Low idle fuel mixture (some models)/ speed improperly adjusted.

Clogged air cleaner.

Choke partially closed during operation.

Dirt under fuel inlet needle.

Bowl vent or air bleeds plugged.

Leaky, cracked, or damaged fl oat.

Intake air leak.

Idle holes plugged; dirt in fuel delivery channels.

Float damaged.

Dirt under fuel inlet needle.

Bowl vents plugged.

Conclusion

Adjust idle speed screw or clean carburetor.

Clean or replace air cleaner.

Check choke lever/linkage to ensure choke is operating properly.

Remove needle; clean needle and seat and blow with compressed air.

Clean vent, ports, and air bleeds.

Blow out all passages with compressed air.

Submerge fl oat to check for leaks.

Check if carburetor is loose or one of intake gaskets is leaking.

Clean main fuel jet and all passages; blow out with compressed air.

Submerge fl oat to check for leaks.

Replace fl oat.

Remove needle; clean needle and seat and blow with compressed air.

Blow out with compressed air.

Carburetor bowl gasket leaks.

Replace gasket.

Carburetor Circuits

Float

Fuel level in bowl is maintained by fl oat and fuel inlet needle. Buoyant force of fl oat stops fuel fl ow when engine is at rest. When fuel is being consumed, fl oat will drop and fuel pressure will push inlet needle away from seat, allowing more fuel to enter bowl. When demand ceases, buoyant force of fl oat will again overcome fuel pressure, rising to predetermined setting and stop fl ow.

Slow and Mid-Range

At low speeds engine operates only on slow circuit. As a metered amount of air is drawn through slow air bleed jets, fuel is drawn through main jet and further metered through slow jet. Air and fuel are mixed in body of slow jet and exit to idle progression (transfer port) chamber.

From idle progression chamber, air fuel mixture is metered through idle port passage. At low idle air/fuel mixture is controlled by setting of idle fuel adjusting screws. This mixture is then mixed with main body of air and delivered to engine. As throttle plate opening increases, greater amounts of air/fuel mixture are drawn in through fixed and metered idle progression holes.

As throttle plate opens further, vacuum signal becomes great enough at venturi so main circuit begins to work.

Main (high-speed)

At high speeds/loads engine operates on main circuit.

As a metered amount of air is drawn through air jet, fuel is drawn through main jet. Air and fuel are mixed in main nozzles then enters main body of airflow where further mixing of fuel and air occurs. This mixture is then delivered to combustion chamber. Carburetor has a fixed main circuit; no adjustment is possible.

22

Carburetor Adjustments

NOTE: Carburetor adjustments should be made only after engine has warmed up.

Carburetor is designed to deliver correct fuel-to-air mixture to engine under all operating conditions. Main fuel jet is calibrated at factory and is not adjustable. Idle fuel adjusting needles are also set at factory and are not adjustable.

Low Idle Speed (RPM) Adjustment

NOTE: Actual low idle speed depends on application.

Refer to equipment manufacturer’s recommendations. Low idle speed for basic engines is 1800 RPM.

1. Place throttle control into idle or slow position. Turn low idle speed adjusting screw in or out to obtain allow idle speed of 1800 RPM (± 75 RPM).

Carburetor Servicing



WARNING

Before working on engine or equipment, disable engine as follows: 1) Disconnect spark plug lead(s). 2)

Disconnect negative (–) battery cable from battery.

NOTE: Main and slow jets are fixed and size specific and can be removed if required. Fixed jets for high altitudes are available.

KohlerEngines.com

18 690 01 Rev. C

• Inspect carburetor body for cracks, holes, and other wear or damage.

• Inspect float for cracks, holes, and missing or damaged float tabs. Check float hinge and shaft for wear or damage.

• Inspect fuel inlet needle and seat for wear or damage.

1. Perform removal procedures for appropriate air cleaner and carburetor outlined in Disassembly.

2. Clean exterior surfaces of dirt or foreign material before disassembling carburetor. Remove bowl retaining screws, and carefully separate fuel bowl from carburetor. Do not damage fuel bowl O-rings.

Transfer any remaining fuel into an approved container. Save all parts. Fuel can also be drained prior to bowl removal by loosening/removing bowl drain screw.

float pin and inlet needle. Seat for inlet needle is not serviceable and should not be removed.

4. Clean carburetor bowl and inlet seat areas as required.

5. Carefully remove main jet from carburetor. After main jet is removed, main nozzles can be removed through bottom of main towers. Note orientation/ direction of nozzles. End with 2 raised shoulders should be out/down adjacent to main jets.

6. Save parts for cleaning and reuse unless a jet kit is also being installed. Clean slow jets using compressed air or carburetor cleaner, do not use wire.

NOTE: There are 2 O-rings on body of idle jet.

Carburetor is now disassembled for appropriate cleaning and installation of parts in overhaul kit. See instructions provided with repair kits for more detailed information.

High Altitude Operation

Engines may require a high altitude carburetor kit to ensure correct engine operation at altitudes above

1219 meters (4000 ft.). To obtain high altitude kit information or to fi nd a Kohler authorized dealer visit

KohlerEngines.com or call1-800-544-2444 (U.S. and

Canada).

This engine should be operated in its original confi guration below 1219 meters (4000 ft.) as damage may occur if high altitude carburetor kit is installed and operated below 1219 meters (4000 ft.).


Fuel System

23

Governor System

GOVERNOR

Governor Components

A

I

K

J

H

I

F

G

E

D

C

B

A

E

I

Control Assembly

Dampening Spring

Washer

B

F

J

Nut

Throttle Control Lever

Governor Gear

Governed speed setting is determined by position of throttle control. It can be variable or constant, depending on engine application.

Governor is designed to hold engine speed constant under changing load conditions. Most engines are equipped with a centrifugal fl yweight mechanical governor. Governor gear/fl yweight mechanism of mechanical governor is mounted inside crankcase and is driven off gear on crankshaft.

This governor design works as follows:

● Centrifugal force acting on rotating governor gear assembly causes fl yweights to move outward as speed increases. Governor spring tension moves them inward as speed decreases.

● As fl yweights move outward, they cause regulating pin to move outward.

● Regulating pin contacts tab on cross shaft causing shaft to rotate.

● One end of cross shaft protrudes through crankcase.

Rotating action of cross shaft is transmitted to throttle lever of carburetor through external throttle linkage.

● When engine is at rest, and throttle is in fast position, tension of governor spring holds throttle plate open.

When engine is operating, governor gear assembly is rotating. Force applied by regulating pin against cross shaft tends to close throttle plate. Governor spring tension and force applied by regulating pin balance each other during operation, to maintain engine speed.

C

G

Governor Spring

Governor Lever

K

Governor Gear Shaft

D

H

Throttle Link

Cup

● When load is applied and engine speed and governor gear speed decreases, governor spring tension moves governor arm to open throttle plate wider. This allows more fuel into engine, increasing engine speed. As speed reaches governed setting, governor spring tension and force applied by regulating pin will again offset each other to hold a steady engine speed.

Governor Adjustments

Initial Adjustment Procedure

NOTE: Make sure carburetor is mounted and secured in place when adjustment is being made/checked.

Make this initial adjustment whenever governor lever is loosened or removed from cross shaft. To ensure proper setting, make sure throttle linkage is connected to governor lever and to carburetor throttle lever.

Adjust as follows:

1. Close fuel shut-off valve.

2. Remove air cleaner outer cover. Then either reposition fuel tank to access governor shaft and lever joint, or disconnect fuel line and remove tank from engine.

3. Loosen governor lever mounting nut.

4. Move governor lever clockwise until it stops.

5. Rotate governor shaft clockwise until it stops.

6. Hold both in this position and torque governor lever nut to 10 N·m (88.5 in. lb.).


18 690 01 Rev. C

Lubrication System

These engines use a splash lubrication system, supplying necessary lubrication to crankshaft, camshaft, connecting rod and valve train components.

Lubrication Components

A

B

C

C

A

Dipstick

B

OIL RECOMMENDATIONS

Refer to Maintenance.

CHECK OIL LEVEL

NOTE: To prevent extensive engine wear or damage, never run engine with oil level below or above operating range indicator on dipstick.

Ensure engine is cool. Clean oil fi ll/dipstick areas of any debris.

1. Remove dipstick; wipe oil off.

2. Reinsert dipstick into tube; rest on oil fi ll neck; turn counterclockwise until cap drops down to lowest point of thread leads; do not thread cap onto tube.

a. Remove dipstick; check oil level. Level should be at top of indicator on dipstick.

or

Remove fi ll plug. Level should be up to point of overfl owing fi ller neck.

3. If oil is low, add oil up to point of overfl owing fi ller neck.

4. Reinstall dipstick or oil fi ll plug and tighten securely.

Oil Fill Plug

C

Oil Drain Plug

CHANGE OIL

Change oil while engine is warm.

1. Clean area around oil fi ll plug/dipstick and drain plug.

2. Remove drain plug and oil fi ll plug/dipstick. Drain oil completely.

3. Reinstall drain plug. Torque 18 N·m (13 ft. lb.).

4. Fill crankcase with new oil, up to point of overfl owing fi ller neck.

6. Dispose of used oil in accordance with local ordinances.

OIL SENTRY

™

(if equipped)

This switch is designed to prevent engine from starting in a low oil or no oil condition. Oil Sentry

™

may not shut down a running engine before damage occurs. In some applications this switch may activate a warning signal.

Read your equipment manuals for more information. For testing procedures refer to Electronic Ignition Systems and Oil Sentry

™

Tests.


25

Electrical System

SPARK PLUGS

CAUTION

Electrical Shock can cause injury.

Do not touch wires while engine is running.

Spark Plug Component and Details

A

B

Inspection

Inspect each spark plug as it is removed from cylinder head. Deposits on tip are an indication of general condition of piston rings, valves, and carburetor.

Normal and fouled plugs are shown in following photos:

Normal

Plug taken from an engine operating under normal conditions will have light tan or gray colored deposits. If center electrode is not worn, plug can be set to proper gap and reused.

Worn

C

D

A

Wire Gauge

B

C

Ground Electrode

D

Spark Plug

Gap

NOTE: Do not clean spark plug in a machine using abrasive grit. Some grit could remain in spark plug and enter engine causing extensive wear and damage.

Engine misfi re or starting problems are often caused by a spark plug that has improper gap or is in poor condition.

Engine is equipped with following spark plugs:

Gap 0.76 mm (0.03 in.)

Thread Size 14 mm

Reach 19.1 mm (3/4 in.)

Hex Size 15.9 mm (5/8 in.)

Refer to Maintenance for Repairs/Service Parts.

Service

Clean out spark plug recess. Remove plug and replace.

1. Check gap using wire feeler gauge. Adjust gap to

0.76 mm (0.03 in.).

2. Install plug into cylinder head.

3. Torque plug to 27 N·m (20 ft. lb.).

On a worn plug, center electrode will be rounded and gap will be greater than specifi ed gap. Replace a worn spark plug immediately.

Wet Fouled

A wet plug is caused by excess fuel or oil in combustion chamber. Excess fuel could be caused by a restricted air cleaner, a carburetor problem, or operating engine with too much choke. Oil in combustion chamber is usually caused by a restricted air cleaner, a breather problem, worn piston rings, or valve guides.


18 690 01 Rev. C

Carbon Fouled


ELECTRONIC IGNITION SYSTEM

Inductive Discharge Ignition System Components

J

Soft, sooty, black deposits indicate incomplete combustion caused by a restricted air cleaner, over rich carburetion, weak ignition, or poor compression.

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

A 12 volt battery (not furnished) with a minimum current rating of 230 cold cranking amps/18 amp hours should be suffi cient for cranking most electric start engine models. Actual cold cranking requirement depends on engine size, application and starting temperatures.

Cranking requirements increase as temperatures decrease and battery capacity shrinks. Refer to equipment's operating instructions for specifi c battery requirements.

If battery charge is insuffi cient to turn over engine, recharge battery.

Battery Maintenance

Regular maintenance is necessary to prolong battery life.

Battery Test

To test battery, follow manufacturer's instructions.

F

I

H

B

D

E

C

A

G

B

C

E

Flywheel

Ignition Module

D

F

G

Kill Terminal

H

I

Spark Plug Terminal

J

Air Gap 0.254 mm

(0.010 in.)

Magnet

Spark Plug

Lamination

Spark Plug Boot

These engines are equipped with a dependable magneto breakerless ignition. In such a system, electrical energy is generated by cutting of magnetic fl ux lines generated from ignition magnet on engine fl ywheel via prescribed air gap as it passes ignition module.

This energy is transferred through ignition module laminations and is then converted in module electronics and stored in module primary coil, as a current. Stored energy is transferred at correct moment by triggering a semiconductor switch inside module. Electrical break by switch initiates energy transfer by causing collapse of magnetic fi eld at coil primary. This includes a voltage at coil primary that is amplifi ed via transformer action at coil secondary. Amplitude of voltage at coil secondary is suffi cient to jump gap at spark plug, igniting fuel air mixture in gap and initiating combustion. Note that by design, these modules only will provide proper function if mounted in correct orientation.

This ignition system is designed to be trouble free for life of engine. Other than periodically checking/replacing spark plugs, no maintenance or timing adjustments are necessary or possible. Mechanical systems do occasionally fail or break down. Refer to Troubleshooting to determine root of a reported problem.

Reported ignition problems are most often due to poor connections. Before beginning test procedure, check all external wiring. Be certain all ignition-related wires are connected, including spark plug leads. Be certain all terminal connections fi t snugly. Make sure ignition switch is in run position.


27


Electronic Ignition Systems and Oil Sentry

™

Tests

1. Disconnect cap from spark plug and attach it to terminal end of spark tester. Attach tester spring clip to a good ground, not to spark plug. Turn ignition/key switch ON and crank engine while observing fi ring tip of tester.

Condition

Tester is fi ring.

Tester doesn't fi re.

Conclusion

Ignition system is good.

Install a new spark plug and try to start engine. If it still will not start, check other possible causes

(fuel, compression, etc.).

Go to step 2.

4. Set an ohmmeter to Rx1 scale and zero meter.

Connect one ohmmeter lead to Oil Sentry

™

fl oat switch lead (yellow with green sleeve) and touch other lead to a bare spot on crankcase (ground).

Drain oil from crankcase and repeat test.

With oil at proper level, no continuity should have been indicated. After oil was drained, continuity should have been indicated.

Condition

No continuity indicated.

Conclusion

Remove closure plate from engine and remove fl oat switch for further testing (steps 4a and 4b).

2. Trace yellow lead wire from Oil Sentry module to Oil Sentry

™

™

control connector where it joins lead from Oil Sentry switch (yellow lead wire). Repeat spark test.

™

fl oat

Condition

Spark is now present.

Still no spark.

Conclusion

Control module or fl oat switch is faulty. Test control module (step 3) and fl oat switch (step 4).

Test ignition module (step

5).

3. Connect a jumper lead from yellow lead terminal to a bare spot on crankcase (ground). Turn ignition switch ON, crank engine, and observe red LED indicator lamp.

Condition

Indicator lamp was not fl ashing.

Indicator lamp fl ashes during cranking.

Conclusion

Trace black lead from ignition switch. Separate bullet connector where switch lead joins double red harness lead. Crank engine, again observing red LED indicator lamp.

Control module is functioning, proceed to step 5. If lamp was not fl ashing initially but did fl ash in step 3, control module is good, but ignition switch is probably faulty. Test fl oat switch

(step 4) and ignition switch (step 6).

a. If continuity was indicated with and without oil above, check if insulation has been scraped off fl oat switch lead.

Condition

Lead wire is bare.

Conclusion

Allow it to short, repair with electrical tape, or replace fl oat switch.

With ohmmeter lead to fl oat switch lead terminal and connect other lead to mounting bracket. Test resistance with switch in normal position and inverted. Repeat test 2 or 3 times in each direction.

Condition

Switch continuity should be as indicated.

Conclusion

If not, replace it.

5. Set an ohmmeter to Rx1K or Rx10K scale and zero.

Connect one ohmmeter lead to kill lead (black/white) terminal and connect other lead into spark plug cap.

a. Remove cap from spark plug lead and test b. If resistances are other than specifi ed, remove

Ignition Module

Cap resistance of cap alone.

blower housing and remove ignition module. With kill lead and spark plug cap removed, test resistance from small spade terminal to core of spark plug lead wire. If resistance is not in this range, replace module.

Spade Terminal to Spark

Plug Lead Wire

Resistance Chart

13.5-18.0 K ohms

4-6 K ohms

9.5-12.9 K ohms


18 690 01 Rev. C

6. Set an ohmmeter to Rx1 scale and zero meter. Test ignition/key switch as follows.

a. Trace two black leads from on/off switch and separate them from any connections. Connect ohmmeter leads to switch leads, and check for continuity in both switch positions.

Condition

Continuity should be indicated when and only when switch is in OFF position.

Conclusion

Replace switch for any other results.

General Wiring Diagram

A

B

C

F

E

D

A

C

Ignition Module

Optional Red

Ignition Switch

E

Oil Alert Control Unit

F

B

D

Spark Plug

Oil Sensor

Optional Micro

Shut Down Switch



29

Starter System

NOTE: Do not crank engine continuously for more than 10 seconds. Allow a 60 second cool down period between starting attempts. Failure to follow these guidelines can burn out starter motor.

NOTE: If engine develops suffi cient speed to disengage starter but does not keep running (a false start), engine rotation must be allowed to come to a complete stop before attempting to restart engine. If starter is engages while fl ywheel is rotating, starter pinion and fl ywheel ring gear may clash, resulting in damage of starter.

NOTE: If starter does not crank engine, shut off starter immediately. Check condition of inline fuse and do not make further attempts to start engine until condition is corrected.

NOTE: Do not drop starter or strike starter housing. Doing so can damage starter.

Engines in this series use inertia drive electric starters or retractable starters. Inertia drive electric starters are not serviceable.

Troubleshooting-Starting Diffi culties

Condition

Starter does not energize.

Starter energizes but turns slowly.

Possible Cause

Battery

Wiring

Starter Switch or Solenoid

Battery

Wiring

Transmission or

Engine

Conclusion

Check specifi c gravity of battery. If low, recharge or replace battery as necessary.

Check fuse condition.

Clean corroded connections and tighten loose connections.

Replace wires in poor condition and with frayed or broken insulation.

Check switch or relay operation. If starter cranks normally, replace faulty components.

Check specifi c gravity of battery. If low, recharge or replace battery as necessary.

Check for corroded connections, poor ground connection.

Make sure clutch or transmission is disengaged or placed in neutral. This is especially important on equipment with hydrostatic drive. Transmission must be exactly in neutral to prevent resistance which could keep engine from starting.

Check for seized engine components such as bearings, connecting rod, and piston.

Electric Starting System Tests

1. Test battery on unit.

a. Connect a DC voltmeter across battery terminals and read battery voltage (key switch OFF).

b. Turn key switch to start position and read battery voltage again. Turn switch OFF.

Condition Conclusion

Voltage less than 12 volts. Charge battery.

Battery voltage should not fall below 9 volts during cranking.

If it does, battery may be faulty or there may be a short in starting circuit.

Have battery load tested.

If battery passes load test, check circuitry.

2. Remove electric starter cover panel and check fuse inside plastic holder. Fuse outside holder is a spare.

Condition

Fuse is blown.

Conclusion

Check for a wiring problem (bare wire, short circuit). Correct problem and replace fuse. Try to start engine. If it still won’t start, go to step 3.

3. Disconnect blue relay lead. Be sure transmission is in neutral and PTO is OFF. Connect one end of a jumper lead to positive terminal of battery. Connect other end to terminal of relay.

Condition

Relay engages and starter begins to crank.

Conclusion

Key switch is faulty, or there is a wiring problem to/from key switch. Check wiring and test key switch circuits with an ohmmeter.


18 690 01 Rev. C

4. Use a known, good, fully-charged battery and jumper cables to test starter motor. Be sure transmission is in neutral and PTO is OFF.

Remove heavy lead from post terminal on starter.

Connect one end of positive jumper cable to post terminal and connect other end to positive terminal of battery.

Connect one end of negative jumper cable to negative terminal of battery. Touch other end of negative jumper cable to a bare surface on crankcase or to starter housing.

Condition

Relay engages and starter begins to crank.

Conclusion

Key switch is faulty, or there is a wiring problem to/from key switch. Check wiring and test key switch circuits with an ohmmeter.

5. Disconnect leads from starter relay and remove it from starter for testing.

a. Set an ohmmeter on Rx1 scale and zero meter.

Connect one ohmmeter lead to terminal of blue lead from relay. Connect other ohmmeter lead to relay mounting bracket.

Condition

Meter reading less than

3.4 ohms, or an open circuit is indicated (infi nity ohms).

Conclusion

Relay is faulty and must be replaced.

b. With ohmmeter still on Rx1 scale, connect leads to two large post terminals. Meter should indicate an open circuit (infi nity ohms, no continuity).

c. Leave ohmmeter leads connected to large terminals. Connect a jumper lead from positive terminal of battery to terminal of blue relay lead.

Connect another jumper lead from negative terminal of battery to relay mounting bracket.

Condition

When circuit is completed, applying 12 volts to energizing coil, an audible click should be heard as relay engages, and ohmmeter should then indicate continuity between large terminals.

Conclusion

Results are other than indicated, replace relay.


Starter System

31

Starter System

RETRACTABLE STARTERS

WARNING

Uncoiling Spring can cause severe injury.

Wear safety goggles or face protection when servicing retractable starter.

Retractable Starter Components

Retractable starters contain a powerful, recoil spring that is under tension. Always wear safety goggles when servicing retractable starters and carefully follow instructions in

Retractable Starter for relieving spring tension.

A

B

A

Kit, Pawl Repair

Remove Starter

1. Remove screws securing starter to blower housing.

2. Remove starter assembly.

Rope Replacement

NOTE: Do not allow pulley/spring to unwind. Enlist aid of a helper if necessary.

Rope can be replaced without complete starter disassembly.

1. Remove starter assembly from engine.

2. Pull rope out approximately 12 in. and tie a temporary (slip) knot in it to keep it from retracting into starter.

3. Pull knot end out of handle, untie knot, and slide handle off. pulley rotate slowly as spring tension is released.

5. When all spring tension on starter pulley is released, remove rope from pulley.

6. Tie a double left-hand knot in one end of new rope.

7. Rotate pulley counterclockwise to pre-tension spring

(approximately 4 full turns of pulley).

8. Continue rotating pulley counterclockwise until rope hole in pulley is aligned with rope guide bushing of starter housing.

9. Insert unknotted end of new rope through rope hole in starter pulley and rope guide bushing of housing.

10. Tie a slipknot approximately 12 in. from free end of rope. Hold pulley fi rmly and allow it to rotate slowly until slipknot reaches guide bushing of housing.

B

Kit, Starter Rope with Handle

11. Insert starter rope through starter handle and tie a double, left-hand knot at end of starter rope. Insert knot into hole in handle.

12. Untie slip knot and pull on starter handle until starter rope is fully extended. Slowly retract starter rope into starter assembly. If recoil spring is properly tensioned, starter rope will retract fully and starter handle will stop against starter housing.

Pawls (dogs) Replacement

1. Install a clamp to hold pulley in starter housing and prevent it from rotating.

2. Unscrew center screw and lift off drive plate.

3. Note positions of pawls and pawl springs before removing. Remove parts from pulley.

4. Install pawl springs and pawls into pawl slots of pulley. All parts must by dry.

5. Position drive plate over pawls, aligning actuating slots in place with raised sections on each drive pawl. Torque center screw to 5-6 N·m (44-54 in. lb.).

6. Remove clamp and pull starter rope out part way to check operation of pawls.

Install Starter

1. Install retractable starter onto blower housing leaving screws slightly loose.

2. Pull starter handle out until pawls engage in drive cup. Hold handle in this position and tighten screws securely.


18 690 01 Rev. C

Disassembly/Inspection and Service

WARNING




External Engine Components

K

J

E

I

F

G

C

D

H

A

E

I

Oil Drain Plug

Air Cleaner Cover

Fuel Tank

B

B

Oil Fill Plug

C

F

Element/Precleaner

G

J

Fuel Tank Filter

K

A

Muffl er Assembly

Air Cleaner Base

Low-Profi le Air

Cleaner

D

H

Breather Hose

Carburetor Cover


33


Clean all parts thoroughly as engine is disassembled.

Only clean parts can be accurately inspected and gauged for wear or damage. There are many commercially available cleaners that will quickly remove grease, oil, and grime from engine parts. When such a cleaner is used, follow manufacturer’s instructions and safety precautions carefully.

Make sure all traces of cleaner are removed before engine is reassembled and placed into operation. Even small amounts of these cleaners can quickly break down lubricating properties of engine oil.

Disconnect Spark Plug Lead

NOTE: Pull on boot only, to prevent damage to spark plug lead.

1. Disconnect spark plug lead from spark plug.

2. Push fuel shut-off lever left to close fuel valve.

Drain Oil From Crankcase

1. Remove 1 oil drain plug and 1 oil fi ll plug.

2. Allow ample time for oil to drain from crankcase.

Remove Muffl er and Heat Shield Assembly

1. Remove nuts, lock washers, and fl at washers.

Blower Housing/Control Panel Components

3. Remove exhaust gasket from exhaust outlet.

Remove Air Cleaner Assembly

Remove air cleaner base from engine as follows:

1. Remove screws securing base of air cleaner assembly to engine.

2. Disconnect breather hose and remove base of air cleaner assembly.

3. Remove nuts and carburetor cover.

4. Loosely install nuts on studs (to temporarily hold carburetor on engine).

Remove Fuel Tank

1. Ensure fuel tank is empty.

2. Loosen clamp and disconnect fuel line from inlet of shut-off valve.

4. Remove screw and fuel tank while guiding fuel hose through engine bracket.

F

E

D

C

G

A

B

I

M

L

K

J

H

34

A

E

Governor Lever

Dampening Spring

I

On/Off Wiring

Harness Bullet

Connector

M

Oil Sentry

™

Bracket

B

F

J

Nut

Control Assembly

Blower Housing

C

G

K

Governor Spring

Carburetor

Oil Sentry

™

Wiring

Harness Bullet

Connector

D

H

L

Throttle Link

Retractable Starter

Oil Sentry

™

Module

KohlerEngines.com

18 690 01 Rev. C


Remove External Throttle, Governor and Choke

Linkage

1. Mark hole in which governor spring is attached and loosen nut securing governor lever arm to governor shaft. Lift off governor lever and remove carburetor throttle link, dampening spring, and governor spring from governor lever.

2. Remove nut securing throttle control lever. Unhook spring and remove throttle control lever.

3. Remove screws and throttle plate.

Remove Carburetor

WARNING




Remove air cleaner gasket and slide carburetor off mounting studs while disconnecting throttle linkage and dampening spring. Remove carburetor to insulator gasket, insulator, and insulator to cylinder head gasket.

Remove Retractable Starter

Remove screws securing retractable starter assembly to blower housing.

Remove Electric Starter (if equipped)

Remove screws securing electric starter to blower housing.

Remove Blower Housing

1. Remove screws securing blower housing.

2. Release wiring harness bundle clamp and disconnect ON/OFF wiring harness bullet connectors.

3. Remove blower housing.

Remove Oil Sentry

™

Module

Disconnect wiring harness bullet connector between Oil

Sentry

™

switch and module. Remove screw securing module to bracket.

Cylinder Head Components

M

N

L

I

H G

K

F

E

D

C

B

A

I

M

A

E

J

Valve Cover

Push Rod Guide

Intake Valve Stem

Seal

Dowel Pins

J

N

B

F

Adjusting Nut

Push Rod

Cylinder Shroud

Cylinder Head

C

G

K


Rocker Arm

Valve Keeper

Valve

D

H

L

Rocker Arm Stud

Valve Spring

Spark Plug

35


Remove Valve Cover/Breather, Rocker Arms, Push

Rods and Cylinder Head Assembly

NOTE: Mark location of push rods and any other part removed that will be reused.

Valve Cover with Gasket

1. Remove screws and remove valve cover and gasket from engine. Breather assembly is inside valve cover.

2. Remove screws securing cylinder shroud and remove cylinder shroud.

3. Loosen and remove rocker arm lock nuts and adjuster nuts. Remove rocker arms and push rods.

4. Remove spark plug.

5. Remove screws securing cylinder head.

6. Remove cylinder head, dowel pins, and cylinder head gasket.

Valve Cover with RTV Sealant

NOTE: Valve cover is sealed to cylinder head using

RTV silicone sealant. When removing valve cover, use care not to damage gasket surfaces of cover and cylinder head. To break RTV seal, hold block of wood against 1 fl at surface of valve cover. Strike wood fi rnly with mallet. If seal doesn't break loose after 1 or 2 attempts, repeat procedure on other side.

1. Remove screws and remove valve cover from engine. Breather assembly is inside valve cover.

2. Using a brass wire brush and gasket remover or similar solvent, clean old RTV from surface of cylinder head and valve cover.

3. Remove screws securing cylinder shroud and remove cylinder shroud.

4. Loosen and remove rocker arm lock nuts and adjuster nuts. Remove rocker arms and push rods.

5. Remove spark plug.

6. Remove screws securing cylinder head.

7. Remove cylinder head, dowel pins, and cylinder head gasket.

Remove Valves

NOTE: Mark location of any part removed that will be reused.

1. Supporting head of valve from below, depress valve keeper and valve spring until keeper can be released from valve stem. Remove valve spring and valve from head. Repeat this procedure for remaining valve.

2. Remove and replace intake valve stem seal whenever cylinder head is serviced or disassembled.


18 690 01 Rev. C


Valve Details

B

C

D

Item

A

B

C

D

E

A

E

Dimension

Head Diameter—Specifi cation

Head Diameter—Maximum

Head Diameter—Service Limit

Stem Diameter—Specifi cation

Stem Diameter—Maximum

Stem Diameter—Service Limit

Valve Length—Specifi cation

Valve Length—Maximum

Valve Length—Service Limit

Face/Seat Width—Maximum

Face/Seat Angle

Stem to Guide—Specifi cation

Stem to Guide—Maximum

Stem to Guide—Service Limit

Stem to Guide Running Clearance—Specifi cation

Stem to Guide Running Clearance—Maximum

Stem to Guide Running Clearance—Service Limit

Valve Guide – Specifi cation

Valve Guide – Maximum

D

Intake

25 mm + 0.1 mm

(0.9842 in. + 0.0039 in.)

25.1 mm (0.9881 in.)

24.9 mm (0.9803 in.)

5.5 mm (0.217 in.)

5.491 mm (0.216 in.)

5.340 mm (0.210 in.)

64 mm + 0.15 mm

(2.5197in. + 0.0059 in.)

64.15 mm (2.5256 in.)

64.15 mm (2.5256 in.)

2.0 mm (0.079 in.)

90°-90.5°/89.5°-90°

0.024 mm (0.0009 in.)

0.039 mm (0.0015 in.)

0.10 mm (0.0039 in.)

0.020 mm (0.0008 in.)

0.044 mm (0.0017 in.)

0.10 mm (0.0039 in.)

5.5 mm (0.2165 in.)

5.512 mm (0.2170 in.)

D

Exhaust

24 mm + 0.1 mm

(0.9449 in. + 0.0039 in.)

24.1 mm (0.9488 in.)

23.9 mm (0.9409 in.)

5.438 mm (0.214 in.)

5.430 mm (0.214 in.)

5.280 mm (0.208 in.)

62 mm + 0.15 mm

(2.4409 in. + 0.0059 in.)

62.15 mm (2.4468 in.)

62.15 mm (2.4468 in.)

2.0 mm (0.079 in.)

90-90.5°/89.5°-90°

0.098 mm (0.0038 in.)

0.112 mm (0.0044 in.)

0.12 mm (0.0047 in.)

0.030 mm (0.0008 in.)

0.054 mm (0.0021 in.)

0.12 mm (0.0047 in.)

5.5 mm (0.2165 in.)

5.512 mm (0.2170 in.)


37


Inspection and Service

After cleaning, check fl atness of cylinder head and corresponding top surface of crankcase, using a surface plate or piece of glass and feeler gauge. Maximum allowable out of fl atness is 0.1 mm (0.0039 in.).

Carefully inspect valve mechanism parts. Inspect valve springs and related hardware for excessive wear or distortion. Check valves and valve seats for evidence of deep pitting, cracks, or distortion. Check running clearance between valve stems and guides.

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 valves fi rst. After removal, clean valve heads, faces, and stems with a power wire brush.

Then, carefully inspect each valve for defects such as warped head, excessive corrosion, or worn stem end.

Replace valves found to be in bad condition.

Valve Guides

If a valve guide is worn beyond specifi cations, it will not guide valve in a straight line. This may result in burned valve faces or seats, loss of compression, and excessive oil consumption.

To check valve guide-to-valve stem clearance, thoroughly clean valve guide and, using a split-ball gauge, measure inside diameter of guide. Then, using an outside micrometer, measure diameter of valve stem at several points on stem where it moves in valve guide.

Use largest stem diameter to calculate clearance by subtracting stem diameter from guide diameter. If intake or exhaust clearance exceeds specifi cations in Valve

Specifi cation table, determine whether valve stem or guide is responsible for excessive clearance.

If guides are within limits but valve stems are worn beyond limits, install new valves.

Valve Seat Inserts

Hardened steel alloy intake and exhaust valve seat inserts are press-fi tted into cylinder head. Inserts are not replaceable but can be reconditioned if not too badly pitted or distorted. If cracked or badly warped, cylinder head should be replaced.

Recondition valve seat inserts following instructions provided with valve seat cutter being used. Cutting proper valve face angle, as specifi ed in Clearance

Specifi cations table and proper valve seat angle (89.5°-

90°) will achieve desired 0° (1° full cut) interference angle where maximum pressure occurs on outside diameters of valve face and seat.

Lapping Valves

Reground or new valves must be lapped in, to provide proper fi t. Use a hand valve grinder with a suction cup for fi nal lapping. Lightly coat valve face with a fi ne grade of grinding compound, then rotate valve on seat with grinder. Continue grinding until a smooth surface is obtained on seat and on valve face. Thoroughly clean cylinder head in hot, soapy water to remove all traces of grinding compound. After drying cylinder head, apply a light coating of SAE 10 oil to prevent rusting.

Intake Valve Stem Seal

Some engines use a valve stem seal on intake valve.

Always use a new seal when valves are removed from cylinder head. Seals should also be replaced if deteriorated or damaged in any way. Never reuse an old seal.

Flywheel/Ignition Components

A

A

C

E

B

C

D

Flywheel Retaining

Nut

Flywheel Fan

Flywheel Shield

F

B

D

F

E

Drive Cup

Flywheel

Ignition Module

Remove Ignition Module

Remove screws securing ignition module to crankcase.

Remove module.

Remove Flywheel

NOTE: Whenever possible, an impact wrench should be used to loosen fl ywheel retaining nut. A fl ywheel strap wrench may be used to hold fl ywheel when loosening or tightening fl ywheel retaining nut.

NOTE: Always use a puller to remove fl ywheel from crankshaft. Do not strike fl ywheel or crankshaft as these parts could become cracked or damaged.

2. Remove drive cup and fan from fl ywheel.

3. Remove screw and shield on right side of fl ywheel

(required for use of puller in next step).

4. Remove puller.

Inspection

Inspect fl ywheel for cracks and fl ywheel keyway for damage. Replace fl ywheel if it is cracked. Replace fl ywheel, crankshaft, and key if fl ywheel key is sheared or keyway is damaged.


18 690 01 Rev. C


Crankcase Components

S

T

U

O

P

Q

R

N

V

F

H

G

I

J

K

L

M

E

A

B

C

D

A

E

I

M

Q

U

Closure Plate Oil Seal

Camshaft

Connecting Rod

Piston Ring Set

Governor Shaft

Crankcase Oil Seal

B

F

J

N

R

V

Closure Plate Bearing

Crankshaft

C

G

Closure Plate

Oil Sentry

™

Switch

Float

D

H

Piston Pin Retainer

K

Tappet

O

Governor Gear

Dowel Pin

Piston Pin

Governor Cup

L

P

S

Governor Cross Shaft

T

Remove Closure Plate

NOTE: Do not pry on gasket surface of crankcase or closure plate, as this can cause damage and leakage.

1. Remove screws securing closure plate to crankcase.

2. Remove closure plate, gasket, and dowel pins (if required) from crankcase.

Gasket

End Cap

Piston

Governor Washer

Crankcase Bearing

Inspection

Inspect oil seal in closure plate and remove it if it is worn or damaged. New oil seal can be installed after closure plate is assembled to crankcase. See Reassembly for oil seal installation instructions.

Inspect main bearing surface for wear or damage (refer to Specifi cations). Replace closure plate if required.


39


Remove Camshaft and Valve Tappets

1. Remove camshaft by pulling it straight out of crankcase.

2. Remove valve tappets by pulling straight out of crankcase. Mark their positions.


Inspect gear teeth of camshaft. If teeth are badly worn or chipped, or if some are missing, replacement of camshaft will be necessary. If unusual wear or damage is evident on either camshaft lobes or mating tappets camshaft and both tappets must be replaced. Check condition and operation of Automatic Compression

Release (ACR) mechanism.

Automatic Compression Release (ACR)

ACR Operation Details

B

C

A

E

D

A

C

Camshaft

Decompression

Weight

Arm

B

D

Exhaust Cam Lobe

Return Spring

E

These engines are equipped with an ACR mechanism.

ACR lowers compression at cranking speeds to make starting easier.

Operation

ACR mechanism consists of a decompression weight and arm mounted to camshaft, and activated by a return spring. When engine is rotating at low cranking speeds

(1000 RPM or less), decompression weight holds arm so it protrudes above heel of exhaust lobe. This holds exhaust valve off its seat during fi rst part of compression stroke.

After engine speed increases above approximately 1000

RPM, centrifugal force causes decompression weight to move outward, causing arm to retract. When in this position, arm has no effect on exhaust valve and engine operates at FULL compression and power.

Benefi ts

As a result of reduced compression at cranking speeds, several important benefi ts are obtained:

1. Manual (retractable) starting is much easier. Without

ACR, manual starting would be virtually impossible.

2. Electric start models can use a smaller starter and battery that are more practical for application.

3. ACR eliminates need for a spark retard/advance mechanism. A spark retard/advance mechanism would be required on engines without ACR to prevent kickback that would occur during starting.

ACR eliminates this kickback, making manual starting safer.

4. Choke control setting is less critical with ACR. If fl ooding occurs, excess fuel is blown out opened exhaust valve and does not hamper starting.

5. Engines with ACR start much faster in cold weather than engines without ACR.

6. Engines with ACR can be started with spark plugs that are worn or fouled. Engines without ACR are more diffi cult to start with those same spark plugs.

Remove Piston, Connecting Rod, and Crankshaft

NOTE: If a carbon ridge is present at top of cylinder bore, use a ridge reamer to remove it before attempting to remove piston.

1. Remove screws securing end cap to connecting rod.

Remove end cap. While guiding connecting rod, slide piston and connecting rod from cylinder bore.

2. Remove crankshaft from crankcase.

Connecting Rod Inspection and Service

Check bearing area (big end) for excessive wear, score marks, running and side clearances. Replace connecting rod and end cap if scored or excessively worn.

Service replacement connecting rods are available in

STD size.

Pistons and Rings Inspection

Scuffi ng and scoring of pistons and cylinder walls occurs when internal engine temperatures approach welding point of piston. Temperatures high enough to do this are created by friction, which is usually attributed to improper lubrication and/or overheating of engine.

Normally, very little wear takes place in piston boss or piston pin area. If original piston and connecting rod can be reused after new rings are installed, original pin can also be reused but new piston pin retainers are required.

Piston pin is included as part of piston assembly; if pin boss in piston or pin itself is worn or damaged, a new piston assembly is required.

Ring failure is usually indicated by excessive oil consumption and blue exhaust smoke. When rings fail, oil is allowed to enter combustion chamber where it is burned along with fuel. High oil consumption can also occur when piston ring end gap is incorrect, because ring cannot properly conform to cylinder wall under this condition. Oil control is also lost when ring gaps are not staggered during installation.

When cylinder temperatures get too high, lacquer and varnish collect on pistons, causing rings to stick, which results in rapid wear. A worn ring usually takes on a shiny or bright appearance.

Scratches on rings and pistons are caused by abrasive material such as carbon, dirt, or pieces of hard metal.


18 690 01 Rev. C


Detonation damage occurs when a portion of fuel charge ignites spontaneously from heat and pressure shortly after ignition. This creates 2 fl ame fronts, which meet and explode to create extreme hammering pressures on a specifi c area of piston. Detonation generally occurs from using low octane fuels.

Preignition or ignition of fuel charge before timed spark can cause damage similar to detonation. Preignition damage is often more severe than detonation damage.

Preignition is caused by a hot spot in combustion chamber such as glowing carbon deposits, blocked cooling fi ns, an improperly seated valve, or wrong spark plug.

Replacement pistons are available in STD bore size.

Replacement pistons include new piston ring sets and new piston pins.

Replacement ring sets are also available separately for STD pistons. Always use new piston rings when installing pistons. Never use old rings.

Some important points to remember when servicing piston rings:

1. Cylinder bore must be deglazed before service ring sets are used.

2. If cylinder bore does not need reboring and if old piston is within wear limits and free of score or scuff marks, old piston may be reused.

3. Remove old rings and clean up grooves. Never reuse old rings.

4. Before installing new rings on piston, place top 2 rings, each in turn, in its running area in cylinder bore and check end gap. Compare ring gap to

Clearance Specifi cations.

5. After installing new compression (top and middle) rings on piston, check piston-to-ring side clearance.

Compare clearance to Clearance Specifi cations. If side clearance is greater than specifi ed, a new piston must be used.

Measuring Piston-to-Bore Clearance

Piston Detail

1. Use a micrometer and measure diameter of piston

2. Use an inside micrometer, telescoping gauge, or

3. Piston-to-bore clearance is difference between bore

Install New Piston Rings

A

C

E

15 mm (0.5905 in.) above bottom of piston skirt and perpendicular to piston pin.

bore gauge and measure cylinder bore. Take measurement approximately 7.0 mm (0.2756 in.) below top of bore and perpendicular to piston pin.

diameter and piston diameter (step 2 minus step 1).

Top Compression

Ring

Oil Control Ring

Expander Ring

Piston Ring Orientation

B

D

E

F

C

B

D

F

A

B

C

Middle Compression

Ring

Top Rail

Bottom Rail

D

A

E

A

A

15 mm (0.5905 in.)

NOTE: Do not use a feeler gauge to measure piston-tobore clearance, it will yield inaccurate measurements. Always use a micrometer.

Before installing piston into cylinder bore, it is necessary that clearance be accurately checked. This step is often overlooked, and if clearances are not within specifi cations, engine failure will usually result.

Use following procedure to accurately measure pistonto-bore clearance:


A

Intermediate

Compression Ring

Gap

B

Top Compression

Ring Gap

C

E

Bottom Oil Rail Gap

Expander Ring

D

F

Oil Ring Expander

Gap

Bottom Rail

NOTE: Rings must be installed correctly. Install oil control ring assembly (bottom groove) fi rst, middle compression ring (center groove) second, and top compression ring (top groove) last. Oil control ring assembly is a three-piece design, and consists of a top rail, expander ring, and bottom rail.

To install new piston rings, proceed as follows:

Use a piston ring expander to install rings.

41


1. Oil control ring assembly (bottom groove): Install expander fi rst then bottom rail and top rail last. Make sure ends of expander are not overlapped. Adjust ring gaps.

2. Middle compression ring (center groove): Install middle compression ring using a piston ring expander tool. Make sure identifi cation mark is up or colored dye stripe (if contained) is left of end gap.

Adjust ring gaps.

3. Top compression ring (top groove): Install top compression ring using a piston ring expander tool.

Make sure identifi cation mark is up or colored dye stripe (if contained) is left of end gap. Adjust ring gaps.

Crankshaft Inspection and Service

Inspect gear teeth of crankshaft and ACR gear. If any teeth are badly worn or chipped, or if some are missing, replacement of crankshaft will be necessary.

Inspect crankshaft bearing surfaces for scoring, grooving, etc. Measure running clearance between crankshaft journals and their respective bearing bores.

Use an inside micrometer or telescoping gauge to measure inside diameter of both bearing bores in vertical and horizontal planes. Use an outside micrometer to measure outside diameter of crankshaft main bearing journals. Subtract journal diameters from their respective bore diameters to get running clearances.

Check results against values in specifi cation tables. If running clearances are within specifi cation, and there is no evidence of scoring, grooving, etc., no further reconditioning is necessary. If bearing surfaces are worn or damaged, crankcase and/or closure plate will need to be replaced.

Inspect crankshaft keyway. If worn or chipped, replacement of crankshaft will be necessary.

Inspect crankpin for score marks or metallic pickup.

Slight score marks can be cleaned with crocus cloth soaked in oil. If wear limits in Specifi cations are exceeded, it will be necessary to replace crankshaft.

Remove Oil Sentry

™

System

1. Remove nut securing Oil Sentry assembly to crankcase.

™

lead wire grommet

2. Pull grommet assembly from crankcase on inside.

3. Remove screws securing Oil Sentry

™ crankcase. Remove Oil Sentry

™

fl oat switch to

fl oat switch.

Remove Governor Assembly

NOTE: Mark location of all parts as governor assembly is removed.

1. Remove hitch pin from governor cross shaft.

2. Remove governor cross shaft from inside crankcase.

3. Remove cup and washer from governor gear.

4. Using a suitable drift, drive governor gear shaft from crankcase.

Inspection

Inspect governor gear teeth. Replace gear if it is worn, chipped, or if any teeth are missing. Inspect governor weights. They should move freely in governor gear.

42

Remove Crankcase and Closure Plate Seals and

Bearings

1. Remove oil seal from crankcase.

2. Using a suitable press, drive crankshaft bearing from crankcase.

3. Remove oil seal from closure plate.

4. Using a suitable press, drive crankshaft bearing from closure plate.

Crankcase

Cylinder Bore Details


Check all gasket surfaces to make sure they are free of gasket fragments. Gasket surfaces must also be free of deep scratches or nicks.

Check cylinder bore for scoring. In severe cases, unburned fuel can cause scuffi ng and scoring of cylinder wall. It washes necessary lubricating oils off piston and cylinder wall. As raw fuel seeps down cylinder wall, piston rings make metal-to-metal contact with wall.

Scoring of cylinder wall can also be caused by localized hot spots resulting from blocked cooling fi ns or from inadequate or contaminated lubrication.

If cylinder bore is badly scored, excessively worn, tapered, or out-of-round, replacement is necessary. Use an inside micrometer to determine amount of wear.

Breather Design

Breather system is designed to control amount of oil in head area and still maintain necessary vacuum in crankcase.

When pistons moves downward, crankcase gases are pushed past reed through mesh fi lter into intake system.

Upward travel of pistons closes reed and creates a low vacuum in lower crankcase. Any oil separated out through fi lter drains back into crankcase.

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18 690 01 Rev. C

Reassembly

Crankcase Components

S

T

A

V

W

A

O

P

Q

R

N

U

F

H

G

I

J

K

L

M

E

A

B

C

D

A

E

Q

U

I

M

Oil Seal

Camshaft

Connecting Rod

Piston Ring Set

Governor Shaft

Dowel Pin

R

V

J

N

B

F

Closure Plate Bearing

Crankshaft

C

G

Closure Plate

Oil Sentry

™

Switch

Float

D

H

Piston Pin Retainer

K

Tappet

O

Governor Gear

Oil Seal Depth

S

W

Piston Pin

Governor Cup

Governor Cross Shaft

Outer Surface

T

L

P

Gasket

End Cap

Piston

Governor Washer

Crankcase Bearing

NOTE: Make sure engine is assembled using all specifi ed torque values, tightening sequences, and clearances. Failure to observe specifi cations could cause severe engine wear or damage.

Always use new gaskets.

Install Crankcase Bearings and Oil Seals

NOTE: Oil bearings liberally with engine oil when installing.

NOTE: In steps 3 and 4, position oil seals with manufacturer’s identifi cation marks visible and facing you.

18 690 01 Rev. C

1. Make sure there are no nicks, burrs, or damage in bores for bearings. Crankcase and closure plate must be clean.

2. Use an arbor press to make sure bearings are installed straight into their respective bore, until fully seated.

3. Using an appropriate seal driver, install oil seal into closure plate to a depth of 5.5 mm (0.217 in.) from outer surface.

4. Using an appropriate seal driver, install oil seal into crankcase to a depth of 0.0-1.0 mm (0.0-0.039 in.) from outer surface.

KohlerEngines.com

43

Reassembly

5. Apply a light coating of lithium grease to seal lips after installing.

Install Governor Assembly

1. Install governor shaft through gear and add thrust washer to shaft.

2. Install governor gear assembly into crankcase using a press, or a drift with light taps, until tip of shaft is

78.862 mm (3.105 in.) below machined gasket surface of crankcase.

3. Install thrust washer and cup on governor gear shaft.

4. Install thrust washer onto governor cross shaft and slide shaft up through inside of crankcase.

second so fl at index end of shaft faces left (9 o'clock position). Insert hitch pin so end of pin comes in contact with raised boss on housing, limiting inward movement of shaft.

Install Oil Sentry

™

System

1. Mount Oil Sentry

™

fl oat into crankcase using screws.

2. Route wire lead grommet assembly through crankcase housing.

3. Install nut onto grommet assembly external stud and tighten securely.

Install Crankshaft

Carefully slide fl ywheel end of crankshaft through main bearing and seal.

Install Connecting Rod with Piston and Rings

Connecting Rod Details

A

NOTE: Install oil control ring assembly fi rst, middle compression ring second, and top compression ring last. Oil control ring assembly is a threepiece design, and consists of a top rail, expander ring, and bottom rail.

1. Install piston with index mark on piston to connecting rod with dipper of end cap down.

2. Install connecting rod with offset down and oil hole in

4 o’clock position shown. Match marks should align as shown.

3. Install and stagger piston rings in grooves.

4. Lubricate cylinder bore, piston, piston pin, and piston rings with engine oil. Compress rings using a piston ring compressor.

5. Lubricate crankshaft journal and connecting rod bearing surfaces with engine oil.

6. Be sure index mark on piston is facing down toward base of engine. Use a hammer handle or rounded wood dowel and gently tap piston into cylinder. Be careful oil ring rails do not spring free between bottom of ring compressor and top of cylinder.

7. Install connecting rod end cap to connecting rod so dipper is down and match marks are aligned.

8. Torque connecting rod screws in increments to

12 N·m (106 in. lb.).

Install Valve Tappets and Camshaft

Crankshaft and Camshaft Timing Marks

A

A

D

A

C

B

A

C

Match Marks

Dipper

B

D

Offset

Oil Hole

NOTE: If piston and/or connecting rod has been changed or removed, be sure piston index mark and end cap dipper orientation are correct before installation.

44

A

1. Identify valve tappets as to their proper locations.

Lubricate face and stem of each tappet with engine oil. Install each into its respective bore.

2. Lubricate camshaft bearing surfaces and cam lobes as well as camshaft bore in crankcase with engine oil.

marks on gears.

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Timing Marks

3. Rotate crankshaft to TDC so timing mark (dimple) on crankgear (smaller gear) is in 4 o’clock position.

Install camshaft into crankcase, aligning timing

18 690 01 Rev. C

Reassembly

Install Closure Plate

Torque Sequence

1

Install Flywheel

CAUTION

Damaging Crankshaft and Flywheel can cause personal injury.

6

4

5

3

NOTE: Make sure governor lever is against cup on governor gear assembly.

1. Check to be sure sealing surfaces of crankcase and closure plate are clean and free of nicks or burrs.

2. Install dowel pins and install a new closure plate gasket (dry) onto dowel pins.

3. Install closure plate to crankcase. Carefully seat ends of camshaft and balance shaft into their mating bearings. Rotate crankshaft slightly to help engage governor gear teeth.

4. Install screws securing closure plate to crankcase.

Torque screws in sequence shown to 24 N·m

(212 in. lb.).

Flywheel/Ignition Components

A

A

C

E

B

C

2

D

Flywheel Retaining

Nut

Flywheel Fan

Flywheel Shield

18 690 01 Rev. C

F

B

D

F

Using improper procedures can lead to broken fragments. Broken fragments could be thrown from engine. Always observe and use precautions and procedures when installing fl ywheel.

NOTE: Before installing fl ywheel make sure crankshaft taper and fl ywheel hub bore are clean, dry, and completely free of lubricants. Presence of lubricants can cause fl ywheel to be over stressed and damaged when nut is torqued to specifi cation.

NOTE: Make sure fl ywheel key is installed properly in keyway. Flywheel can become cracked or damaged if key is not installed properly.

1. Install woodruff key into keyway of crankshaft. Be sure that key is properly seated and parallel with taper of shaft.

fl ywheel onto crankshaft, being careful not to shift position of woodruff key.

4. Install fan bosses into matching holes in fl ywheel.

5. Position drive cup on fl ywheel, engaging boss on its base with corresponding hole on fl ywheel. Hold in position and install nut. Finger tighten to keep cup indexed.

a tighten fl ywheel nut. Torque nut to 74 N·m

(655 in. lb.).

E

Drive Cup

Flywheel

Ignition Module

Install Ignition Module

NOTE: Ensure ignition module is correctly oriented.

fl ywheel so magnet is away from location where ignition module will be installed.

2. Install ignition module loosely to bosses with screws.

Move module as far away from fl ywheel as possible, then tighten screws just enough to hold it in position.

fl ywheel in a clockwise direction until magnet is under 1 leg of ignition module.

4. Insert a 0.254 mm (0.010 in.) fl at feeler gauge between leg of module and magnet. Loosen nearest screw, allowing magnet to draw module against feeler gauge. Push against module to hold leg tight against feeler gauge while tightening screw.

fl ywheel until magnet is under other leg of module. Loosen nearest screw, allowing magnet to draw module against feeler gauge. Push against module to hold leg tight against feeler gauge while tightening screw.

6. Torque both module screws to 8 N·m (70.8 in. lb.).

fl ywheel back and forth, checking to make sure magnet does not strike module.

KohlerEngines.com

45

Reassembly

8. Connect kill wire to ignition module bottom blade terminal and route wire lead across top of crankcase.

Cylinder Head Components

3

1

M

O

2 4

N

L

I

H G

K

F

E

D

C

B

A

I

M

A

E

Valve Cover

Push Rod Guide

Intake Valve Stem

Seal

J

Dowel Pins

B

F

J

N

Adjusting Nut

Push Rod

Cylinder Shroud

Cylinder Head

C

G

K

O

Rocker Arm

Valve Keeper

Valve

Torque Sequence

D

H

L

Rocker Arm Stud

Valve Spring

Spark Plug

Assemble Cylinder Head

NOTE: Engine utilizes a valve stem seal on intake valve. Always use a new seal when valves are installed in cylinder head. Never reuse an old seal.

1. Install valves into their respective positions.

2. Install a new valve seal on stem of intake valve.

3. Install valve springs and retainers into their respective locations in cylinder head. Using hand pressure, compress each valve spring and slide each retainer onto valve stem to lock in place.

Install Cylinder Head

1. Check to make sure there are no nicks or burrs on sealing surfaces of cylinder head or crankcase.

2. Rotate crankshaft to position piston at TDC on compression stroke.

3. Install dowel pins into recesses around lower cylinder head bolt holes and install a new cylinder head gasket.

4. Install cylinder head and start screws. Tighten screws initially to a torque of 12 N·m (106 in. lb.) in several increments using sequence shown. Tighten to a fi nal torque of 24 N·m (212 in. lb.).


Install Push Rods and Rocker Arms

NOTE: Push rods should always be installed in original location.

1. Install push rod guide plate, aligning holes for rocker arm studs. Install rocker arm studs and torque to

13.6 N·m (120 in. lb.).

2. Dip ends of push rods in engine oil and install them in their respective locations, seating each into tappet socket.

3. Assemble rocker arms, adjusters, and locknuts onto rocker arm studs and push rods.

4. Adjust valve tappet clearance as follows: a. Be sure piston is still at top of compression stroke.

Insert valve stem. Recommended valve to rocker arm clearance for intake is 0.1 mm (0.0040 in.) and

0.15 mm (0.0060 in.) for exhaust.

c. Adjust clearance as required by loosening locknut and tightening adjuster.

Turn clockwise to decrease clearance.

Turn counterclockwise to increase clearance.

18 690 01 Rev. C

Reassembly

d. Hold adjuster from turning and tighten locknut.

Torque locknut to 10 N·m (88.5 in. lb.).

e. Recheck that clearance is correct.

5. Set gap of new spark plug to 0.76 mm (0.030 in.).

6. Install spark plug in cylinder head and torque to

27 N·m (20 ft. lb.).

Install Valve Cover

Valve Cover Torque Sequence

3

2

Valve Cover with RTV

1 4

Valve Cover with Gasket

1. Make sure sealing surfaces of valve cover and cylinder head are clean, and free of any nicks or burrs.

2. Install a new valve cover gasket, followed by valve cover on head with screws and torque to 8.0 N·m

(71 in. lb.) using sequence shown.

A

A

RTV Sealant

NOTE: Always use fresh sealant. Using outdated sealant can result in leakage. Refer to Tools and

Aids for important information on sealant dispenser.

NOTE: To ensure proper adhesion of sealant to both surfaces, perform step 3 immediately (5 minutes maximum) after application of RTV.

1. Prepare sealing surface of cylinder head and valve cover.

2. Apply a 1.5 mm (1/16 in.) bead of sealant to valve cover as shown.

3. Position cover on cylinder head and start mounting screws.

4. Torque screws to 8.0 N·m (71 in. lb.) using sequence shown.


47

Reassembly

Blower Housing/Control Panel Components

F

E

D

C

G

A

B

I

M

L

K

J

H

A

E

I

Governor Lever

Dampening Spring

On/Off Wiring

Harness Bullet

Connector

M

Oil Sentry

™

Bracket

B

F

J

Nut

Control Assembly

Blower Housing

C

G

K

Governor Spring

Carburetor

Oil Sentry

™

Wiring

Harness Bullet

Connector

D

H

L

Throttle Link

Retractable Starter

Oil Sentry

™

Module

Install Throttle Plate

Install throttle plate with screws.

Install Engine Air Shroud

Install cylinder shroud. Torque screws to 8 N·m

(70.8 in. lb.).

Install Carburetor

1. Install a new insulator to cylinder head gasket onto carburetor studs, followed by insulator, carburetor to insulator gasket, carburetor, and air cleaner gasket.

2. Connect throttle link and dampening spring into their respective holes on throttle lever.

Install Blower Housing

1. Position spark plug lead in molded clip in carburetor insulator.

2. Install blower housing on crankcase with screws.

Torque screws to 10 N·m (88.5 in. lb.).

Install Electric Starter and Control Panel (if equipped)

1. Align and mount electric starter onto crankcase.

Install and torque screws to 24 N·m (212 in. lb.).

2. Connect electrical leads for Oil Sentry module, key switch, relay, and starter.

™

, ignition

3. Mount control panel to crankcase and secure with screws. Ensure ground wires are placed between screw and bracket. Torque screws to 24 N·m

(212 in. lb.).


18 690 01 Rev. C

Reassembly

Install Retractable Starter

1. Install retractable starter on blower housing using screws. Finger tighten screws only.

2. Pull rope handle to engage pawls and center starter to drive cup. Hold in this position and torque screws to

5.4 N·m (47.8 in. lb.).

External Engine Components

K

J

E

I

F

G

C

D

H

A

E

I

Oil Drain Plug

Air Cleaner Cover

Fuel Tank

B

B

Oil Fill Plug

C

F

Element/Precleaner

G

J

Fuel Tank Filter

K

A

Muffl er Assembly

Air Cleaner Base

Low-Profi le Air

Cleaner

D

H

Breather Hose

Carburetor Cover


49

Reassembly

Install Throttle Lever, Governor Lever, Throttle Link, Dampening Spring, and Governor Spring

1. Install nylon washer and wave spring to throttle plate.

2. Connect spring to throttle lever and throttle plate. Install throttle lever to throttle plate. Install tabbed washer (with tab engaged in slot) and secure with nut.

3. Torque nut to 5.4 N·m (47.8 in. lb.).

4. Install governor lever onto shaft.

5. Connect dampening spring and throttle link to governor lever. Connect governor spring to governor lever and to throttle lever.

6. Move governor lever clockwise until it stops. Rotate governor shaft clockwise until it stops. Hold both in this position and torque governor lever nut to 10 N·m (88.5 in. lb.).


18 690 01 Rev. C

Reassembly

18 690 01 Rev. C

Spring Color

Spring Color

Spring Color

Spring Color

Spring Color

Spring Color

Spring Color

KohlerEngines.com

51

Reassembly

Install Oil Sentry

TM

Module

1. Install Oil Sentry

™

module and secure with screw.

2. Connect electrical leads for Oil Sentry

™

module.

Install Fuel Tank

1. Route fuel line across top of engine toward carburetor while positioning fuel tank on mounting brackets.

2. Secure with screw on inner mounting bracket.

3. Install nuts on fuel tank studs.

4. Torque fuel tank screw and nuts to 24 N·m

(212 in. lb.).

5. Position fuel line in clip at carburetor and connect fuel line to shut-off valve on carburetor. Secure clamp.

Install Carburetor Cover

Install outer air cleaner cover onto studs and secure with nuts.

Install Muffl er and Heat Shield Assembly

1. Install a new exhaust gasket with muffl er and heat shield assembly. Secure muffl er and heat shield assembly with nuts.

2. Torque nuts to 8 N·m (70.8 in. lb.).

Install Air Cleaner Base, Element, and Cover

Dual-Element

1. Install air cleaner base and secure with screws.

2. Install paper element with precleaner onto air cleaner stud and secure with washer and wing nut (if equipped).

3. Install air cleaner cover and secure with wing nut.

Low-Profi le

1. Install air cleaner base and secure with screws.

2. Install foam element (lightly oiled) into base.

3. Install cover and secure with screw.

Prepare Engine for Operation

Engine is now reassembled. Before starting or operating engine be sure to do following:

1. Make sure all hardware is properly torqued.

2. Make sure oil drain plugs, oil fi ll plugs, and Oil

Sentry

™

wire lead bullet connectors are tightened securely.

3. Fill crankcase with correct oil. Refer to Maintenance and Lubrication System for oil recommendations and procedures.

Testing Engine

NOTE: Do not adjust maximum no-load high-idle engine speed beyond 3950 RPM maximum.

It is recommended engine be operated on a test stand or bench prior to installation on a piece of equipment.

1. Set engine up on a test stand. Check gas and oil levels. Start engine and run for 5-10 minutes between idle and midrange. Adjust low-speed idle screw so low idle speed is set to 1800 RPM (± 150) or application specifi cations.

2. Adjust high-speed stop screw as necessary to

3850 + 100 RPM (typical RPM).


18 690 01 Rev. C


53


18 690 01 Rev. C


55

© 2015 by Kohler Co. All rights reserved.


18 690 01 Rev. C

Kohler 3000 Series SH265 Engine Service Manual

Assistant Bot

SH265

Service Manual

WARNING

Key Features

Frequently Answers and Questions

What are the recommended fuel types for the 3000 Series SH265?

How often should I change the oil in the 3000 Series SH265?

What are the symptoms of a clogged or inoperative breather in the 3000 Series SH265?

Related manuals

Table of contents

Kohler 3000 Series SH265 Engine Service Manual

Assistant Bot

SH265

Service Manual

WARNING

Key Features

Frequently Answers and Questions

What are the recommended fuel types for the 3000 Series SH265?

How often should I change the oil in the 3000 Series SH265?

What are the symptoms of a clogged or inoperative breather in the 3000 Series SH265?

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