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Contents
Section 1. Safety and General Information .............................................................................
Section 2. Tools & Aids .............................................................................................................
Section 3. Troubleshooting ......................................................................................................
Section 4. Air Cleaner and Air Intake System .........................................................................
Section 5. Fuel System and Governor .....................................................................................
Section 6. Lubrication System .................................................................................................
1
2
3
4
5
6
Section 7. Electrical System and Components ......................................................................
Section 8. Disassembly.............................................................................................................
Section 9. Inspection and Reconditioning ..............................................................................
Section 10. Reassembly............................................................................................................
Section 11. Emission Compliance Systems............................................................................
7
8
9
10
11
Safety and General Information
Section 1
Safety and General Information
Safety Precautions
To ensure safe operation please read the following statements and understand their meaning. Also
refer to your equipment manufacturer's manual for other important safety information. This manual
contains safety precautions which are explained below. Please read carefully.
WARNING
Warning is used to indicate the presence of a hazard that can cause severe personal injury, death,
or substantial property damage if the warning is ignored.
CAUTION
Caution is used to indicate the presence of a hazard that will or can cause minor personal injury or
property damage if the caution is ignored.
Section 1
1
NOTE
Note is used to notify people of installation, operation, or maintenance information that is important
but not hazard-related.
For Your Safety!
These precautions should be followed at all times. Failure to follow these precautions could result in injury to
yourself and others.
WARNING
Accidental Starts can cause
severe injury or death.
Disconnect and ground spark plug
leads before servicing.
Accidental Starts!
ȱǯȱȱ
ȱȱȱȱ¢ȱȱ
ǯȱBefore working on the engine
or equipment, disable the engine as
follows: 1) Disconnect the spark plug
lead(s). 2) Disconnect negative (-)
baery cable from baery.
WARNING
Rotating Parts can cause severe
injury.
Stay away while engine is in
operation.
Rotating Parts!
Keep hands, feet, hair, and clothing
away from all moving parts to prevent
injury. Never operate the engine with
covers, shrouds, or guards removed.
Hot Parts can cause severe burns.
Do not touch engine while operating
or just aer stopping.
Hot Parts!
Engine components can get extremely
hot from operation. To prevent severe
burns, do not touch these areas while
the engine is running, or immediately
aer it is turned off. Never operate
the engine with heat shields or guards
removed.
WARNING
1.1
Section 1
Safety and General Information
WARNING
Explosive Fuel can cause fires
and severe burns.
Do not fill the fuel tank while the
engine is hot or running.
Explosive Fuel!
Gasoline is extremely flammable and
its vapors can explode if ignited. Store
gasoline only in approved containers,
in well ventilated, unoccupied
buildings, away from sparks or flames.
Do not fill the fuel tank while the
engine is hot or running, since spilled
fuel could ignite if it comes in contact
with hot parts or sparks from ignition.
Do not start the engine near spilled
fuel. Never use gasoline as a cleaning
agent.
WARNING
WARNING
Carbon Monoxide can cause
severe nausea, fainting or death.
Avoid inhaling exhaust fumes, and
never run the engine in a closed
building or confined area.
Lethal Exhaust Gases!
Engine exhaust gases contain
poisonous carbon monoxide. Carbon
monoxide is odorless, colorless, and can
cause death if inhaled. Avoid inhaling
exhaust fumes, and never run the
engine in a closed building or confined
area.
WARNING
Explosive Gas can cause fires and
severe acid burns.
Charge baery only in a well
ventilated area. Keep sources of
ignition away.
Explosive Gas!
Baeries produce explosive hydrogen
gas while being charged. To prevent a
fire or explosion, charge baeries only
in well ventilated areas. Keep
sparks, open flames, and other sources
of ignition away from the baery at all
times. Keep baeries out of the reach
of children. Remove all jewelry when
servicing baeries.
Before disconnecting the negative
(-) ground cable, make sure all switches
are OFF. If ON, a spark will occur at
the ground cable terminal which could
cause an explosion if hydrogen gas or
gasoline vapors are present.
Cleaning Solvents can cause
severe injury or death.
Use only in well ventilated areas
away from ignition sources.
Flammable Solvents!
Carburetor cleaners and solvents are
extremely flammable. Keep sparks,
flames, and other sources of ignition
away from the area. Follow the
cleaner manufacturer’s warnings and
instructions on its proper and safe use.
Never use gasoline as a cleaning agent.
1.2
CAUTION
Electrical Shock can cause injury.
Do not touch wires while engine is
running.
Electrical Shock!
Never touch electrical wires or
components while the engine is
running. They can be sources of
electrical shock.
Engine Identification Numbers
When ordering parts, or in any communication
involving an engine, always give the Model,
Specification, and Serial Numbers of the engine.
The engine identification numbers appear on a decal
affixed to the engine shrouding. See Figure 1-1. An
explanation of these numbers is shown in Figure 1-2.
Section 1
Safety and General Information
1
Identification Decal
Figure 1-1. Engine Identification Decal Location.
A. Model No.
Courage Vertical Shaft Engine
Numerical Designation
B. Spec. No.
Engine Model
Model
69
69
69
69
69
69
69
69
C. Serial No.
Year Manufactured Code
Code Year
SV 540 S
Version Code
6 (OHFWULF6WDUW
SV540-0001
First spec
written in this
model series
3205810334
Factory Code
Figure 1-2. Explanation of Engine Identification Numbers.
1.3
Section 1
Safety and General Information
Oil Recommendations
Using the proper type and weight of oil in the
crankcase is extremely important, as is checking oil
daily and changing oil regularly. Failure to use the
correct oil or using dirty oil causes premature engine
wear and failure.
Oil Type
Use high-quality detergent oil of API (American
Petroleum Institute) service class SJ or higher. Select
the viscosity based on the air temperature at the time
of operation as shown below.
RECOMMENDED SAE VISCOSITY GRADES
10W-30
**
5W-20, 5W-30
°F -20 0 20 32 40 60 80 100
°C -30 -20 -10 0 10 20 30 40
TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE
* Use of synthetic oil having 5W-20 or 5W-30 rating is acceptable,
up to 4°C (40°F)
** Synthetic oils will provide better starting in extreme cold below
23°C (-10°F)
NOTE: Using other than service class SJ or higher
oil or extending oil change intervals longer
than recommended can cause engine
damage.
NOTE: Synthetic oils meeting the listed
classifications may be used with oil changes
performed at the recommended intervals.
However to allow piston rings to properly
seat, a new or rebuilt engine should be
operated for at least 50 hours using standard
petroleum based oil before switching to
synthetic oil.
A logo or symbol on oil containers identifies the API
service class and SAE viscosity grade. See Figure 1-3.
Figure 1-3. Oil Container Logo.
*
E
S
I
P
A
SAE
10W-30
V
R
I
Kohler 10W-30
C
E
S
J
Refer to Section 6 - Lubrication System for detailed
oil check, oil change, and oil filter change procedures.
Fuel Recommendations
WARNING: Explosive Fuel!
Gasoline is extremely flammable and its vapors can
explode if ignited. Store gasoline only in approved
containers, in well ventilated, unoccupied buildings, away
from sparks or flames. Do not fill the fuel tank while the
engine is hot or running, since spilled fuel could ignite if
it comes in contact with hot parts or sparks from ignition.
Do not start the engine near spilled fuel. Never use
gasoline as a cleaning agent.
General Recommendations
Purchase gasoline in small quantities and store
in clean, approved containers. A container with a
capacity of 2 gallons or less with a pouring spout is
recommended. Such a container is easier to handle
and helps eliminate spillage during refueling.
Do not use gasoline le over from the previous
season, to minimize gum deposits in your fuel
system and to ensure easy starting.
Do not add oil to the gasoline.
Do not overfill the fuel tank. Leave room for the fuel
to expand.
Fuel Type
For best results use only clean, fresh, unleaded
gasoline with a pump sticker octane rating of 87
(R+M)/2 or higher. In countries using the Research
Octane Number (RON), it should be 90 octane
minimum. Leaded gasoline is not recommended and
must not be used on EFI engines or on other models
where exhaust emissions are regulated.
Gasoline/Alcohol Blends
Gasohol (up to 10% ethyl alcohol, 90% unleaded
gasoline by volume) is approved as a fuel for Kohler
engines. Other gasoline/alcohol blends including E20
and E85 are not to be used and not approved. Any
failures resulting from use of these fuels will not be
warranted.
Gasoline/Ether Blends
Methyl Tertiary Butyl Ether (MTBE) and unleaded
gasoline blends (up to a maximum of 15% MTBE by
volume) are approved as a fuel for Kohler engines.
Other gasoline/ether blends are not approved.
1.4
Periodic Maintenance
Section 1
Safety and General Information
WARNING: Accidental Starts!
ȱǯȱȱȱȱȱȱ¢ȱȱǯȱBefore working on the engine or equipment,
disable the engine as follows: 1) Disconnect the spark plug lead(s). 2) Disconnect negative (-) baery cable from baery.
Maintenance Schedule
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
service center.
Maintenance RequiredFrequency
• Fill fuel tank.
Daily or Before
Starting Engine
Annually
or Every 25 Hours
Annually or
Every 100 Hours
Every 200 Hours
• Check oil level.
• Check air cleaner for dirty¹, loose, or damaged parts.
• Check air intake and cooling areas, clean as necessary¹.
• Service precleaner element¹ (if equipped).
• Service air cleaner element¹ (if not equipped with precleaner).
• Replace air cleaner element¹ (if equipped with precleaner).
• Change oil and filter (more frequently under severe conditions).
• Remove cooling shroud and clean cooling areas.
• Check that all fasteners are in place and components are properly secured.
• Replace fuel filter.
• Check spark plug condition and gap.
• Have valve lash checked/adjusted2.
1
Every 500 Hours
¹Perform these maintenance procedures more frequently under extremely dusty, dirty conditions.
²Have a Kohler Engine Service Dealer perform this service.
Storage
If the engine will be out of service for two months or
more, use the following storage procedure:
1. Clean the exterior surfaces of the engine.
2. Change the oil and oil filter while the engine is
still warm from operation. See Change Oil and
Oil Filter in Section 6.
3. The fuel system must be completely emptied,
or the gasoline must be treated with a stabilizer
to prevent deterioration. If you choose to
use a stabilizer, follow the manufacturer’s
recommendations, and add the correct amount
for the capacity of the fuel system. Fill the fuel
tank with clean, fresh gasoline. Run the engine
for 2-3 minutes to get stabilized fuel into the
carburetor.
• Have bendix starter drive serviced².
• Replace spark plug.
To empty the system, run the engine until the
tank and system are empty.
4. Due to the deep recess around the spark plug,
blow out the cavity with compressed air. Remove
the spark plug. The spark plug is most accessible
when the blower housing is removed for
cleaning.
Add one tablespoon of engine oil into the spark
plug hole. Install the plug, but do not connect
the plug lead. Crank the engine two or three
revolutions. Connect the plug lead.
5. Reinstall the blower housing, if removed
previously, and torque the blower housing screws
to 7.5 N·m (65 in. lb.).
6. Store the engine in a clean, dry place.
1.5
Section 1
Safety and General Information
VALVE COVER VIEW
Dimensions in millimeters. Inch equivalents shown in ().
Figure 1-4. Typical Engine Dimensions.
1.6
Safety and General Information
General Specifications¹
Power (@ 3600 RPM, exceeds Society of Automotive Engineers-Small Engine Test Code J1940)
SV470 ............................................................................................................. 11.2 kW (15 HP)
SV480 ............................................................................................................. 11.9 kW (16 HP)
SV530 ............................................................................................................. 12.7 kW (17 HP)
SV540 .............................................................................................................. 13.4 kW (18 HP)
SV590 ............................................................................................................. 14.1 kW (19 HP)
SV600 .............................................................................................................. 14.9 kW (20 HP)
SV610 .............................................................................................................. 15.7 kW (21 HP)
SV620 .............................................................................................................. 16.4 kW (22 HP)
Bore
SV470, SV480 (Early Models Only) ............................................................. 84 mm (3.30 in.)
SV470, SV480, SV530, SV540 ........................................................................89 mm (3.50 in.)
SV590, SV600, SV610, SV620 ........................................................................94 mm (3.70 in.)
Stroke ...................................................................................................................... 86 mm (3.38 in.)
Displacement
SV470, SV480 (Early Models Only) ............................................................. 477 cc (29.1 cu. in.)
SV470, SV480, SV530, SV540 ........................................................................535 cc (32.6 cu. in.)
SV590, SV600, SV610, SV620 ........................................................................597 cc (36.4 cu. in.)
Section 1
1
Compression Ratio
SV470, SV480, SV530, SV540 ........................................................................9.4:1
SV590, SV600, SV610, SV620 ........................................................................8.5:1
Dry Weight .............................................................................................................35.8 kg (79 lb.)
Oil Capacity (with filter) .....................................................................................1.04-1.30 L (1.1-1.4 qt.)
Angle of Operation - Maximum (at Full Oil Level) All Directions ...............25° Intermient
Air Cleaner Base
Hex Nut Fastener Torque .................................................................................... 5.5 N·m (48 in. lb.)
Mounting Screw Fastener Torque (Install Dry - DO NOT OIL) ....................8.0 N·m (70 in. lb.) Into new as-cast hole
5.5 N·m (48 in. lb.) Into used hole
Blower Housing and Sheet Metal
M6 Fasteners Torque ..................................................................11.6 N·m (99 in. lb.) Into new as-cast hole
7.7 N·m (68 in. lb.) Into used hole
Cam Lever
Cam Lever Fastener Torque ...................................................... 8.0-10.5 N·m (70-94.0 in. lb.) Into new as-cast hole
7.1-8.6 N·m (61.8-74.8 in. lb.) Into used hole
Cam Gears
End Play .............................................................................................................. 0.5/1.5 mm (0.019/0.059 in.)
Running Side Clearance .................................................................................... 0.02/0.13 mm (0.001/0.005 in.)
Cam Gear-to-Cam Sha Running Assembly ................................................. 0.02/0.10 mm (0.001/0.004 in.)
Carburetor
Fuel Bowl Retaining Screw Torque ................................................................. 5.1-6.2 N·m (45-55 in. lb.)
1
Values are in metric units. Values in parentheses are English equivalents. Lubricate threads with engine oil prior
to assembly, EXCEPT for air cleaner base thread forming screw - install dry.
1.7
Section 1
Safety and General Information
Closure Plate
Closure Plate Fastener Torque ........................................................................ 24.5 N·m (216 in. lb.)
Balance Weight Guide Channel Width
New .............................................................................................................. 17.95/18.05 mm (0.707/0.711 in.)
Max. Wear Limit ......................................................................................... 18.13 mm (0.714 in.)
Connecting Rod
Cap Fastener Torque (torque in 2 increments).............................................. 5.5, 11.5 N·m (50, 100 in. lb.)
Connecting Rod-to-Crankpin Running Clearance
New ............................................................................................................... 0.03/0.055 mm (0.0012/0.0022 in.)
Max. Wear Limit .......................................................................................... 0.07 mm (0.0025 in.)
Connecting Rod-to-Crankpin Side Clearance ................................................ 0.25/0.59 mm (0.0098/0.0232 in.)
Connecting Rod-to-Piston Pin Running Clearance ....................................... 0.015/0.028 mm (0.0006/0.0011 in.)
Piston Pin End I.D.
New ............................................................................................................... 22.015/22.023 mm (0.8667/0.8670 in.)
Max. Wear Limit .......................................................................................... 22.036 mm (0.8675 in.)
Crankcase
Governor Cross Sha Bore I.D.
New ............................................................................................................... 6.025/6.05 mm (0.2372/0.2382 in.)
Max. Wear Limit .......................................................................................... 6.063 mm (0.2387 in.)
Oil Drain Plug Torque ....................................................................................... 14.0 N·m (125 in. lb.)
Crankshaft
End Play (free) .................................................................................................... 0.225/1.025 mm (0.0089/0.040 in.)
Cranksha Bore in Crankcase I.D.
New .............................................................................................................. 41.965/41.990 mm (1.6521/1.6531 in.)
Max. Wear Limit ......................................................................................... 42.016 mm (1.654 in.)
Cranksha Bore in Closure Plate I.D.
New .............................................................................................................. 44.965/44.990 mm (1.7703/1.7713 in.)
Max. Wear Limit ......................................................................................... 45.016 mm (1.7723 in.)
Flywheel End Main Bearing Journal O.D.
New - Before Serial No. 3703200003 ....................................................... 44.913/44.935 mm (1.7682/1.7691 in.)
New - Aer Serial No. 3703200013 ......................................................... 44.870/44.895 mm (1.7665/1.7675 in.)
O.D. - Max. Wear Limit ............................................................................. 44.84 mm (1.765 in.)
Max. Taper .................................................................................................. 0.0220 mm (0.0009 in.)
Max. Out of Round .................................................................................... 0.025 mm (0.001 in.)
PTO End Main Bearing Journal O.D.
New - Before Serial No. 3703200003 ........................................................ 41.913/41.935 mm (1.6501/1.6510 in.)
New - Aer Serial No. 3703200013 .......................................................... 41.855/41.880 mm (1.6478/1.6488 in.)
O.D. - Max. Wear Limit ............................................................................. 41.83 mm (1.647 in.)
Max. Taper .................................................................................................. 0.020 mm (0.0008 in.)
Max. Out of Round .................................................................................... 0.025 mm (0.001 in.)
1.8
Section 1
Safety and General Information
Crankshaft (Continued)
Cranksha Bore in Closure Plate Running Clearance
New - Before Serial No. 3703200003 ........................................................ 0.030/0.077 mm (0.0012/0.0030 in.)
New - Aer Serial No. 3703200013 .......................................................... 0.070/0.120 mm (0.0027/0.0047 in.)
Cranksha Bore in Crankcase Running Clearance
New - Before Serial No. 3703200003 ........................................................ 0.030/0.077 mm (0.0012/0.0030 in.)
New - Aer Serial No. 3703200013 .......................................................... 0.085/0.135 mm (0.0033/0.0053 in.)
Connecting Rod Journal O.D.
New .............................................................................................................. 40.982/41.000 mm (1.6134/1.6141 in.)
Max. Wear Limit ......................................................................................... 40.964 mm (1.612 in.)
Max. Taper .................................................................................................. 0.012 mm (0.0005 in.)
Max. Out of Round .................................................................................... 0.025 mm (0.001 in.)
Cranksha T.I.R.
PTO End, Cranksha in Engine ............................................................... 0.15 mm (0.0059 in.)
Entire Cranksha, in V-Blocks ................................................................. 0.10 mm (0.0039 in.)
Cranksha Eccentrics O.D.
New .............................................................................................................. 66.940/66.970 mm (2.6354/2.6366 in.)
Max. Wear Limit ......................................................................................... 66.89 mm (2.633 in.)
1
Balance Weight
Balance Weight Bearing Surface I.D.
New .............................................................................................................. 67.011/67.086 mm (2.6382/2.6412 in.)
Max. Wear Limit ......................................................................................... 67.140 mm (2.6430 in.)
Balance Weight Pin O.D.
New .............................................................................................................. 11.950/11.975 mm (0.4705/0.4715 in.)
Max. Wear Limit ......................................................................................... 11.900 mm (0.4685 in.)
Guide Shoe Width - Before Serial No. 3618000003
New ............................................................................................................. 17.85/17.90 mm (0.703/0.705 in.)
Max. Wear Limit ......................................................................................... 17.75 mm (0.6988 in.)
Guide Shoe Hole I.D.
New .............................................................................................................. 12.000/12.025 mm (0.4724/0.4734 in.)
Max. Wear Limit ......................................................................................... 12.050 mm (0.4744 in.)
Linkage Pin O.D. (Crankcase) - Aer Serial No. 3618000013
New .............................................................................................................. 11.964/11.975 mm (0.4710/0.4715 in.)
Max. Wear Limit ......................................................................................... 11.900 mm (0.4685 in.)
Balance Weight Linkage- Aer Serial No. 3618000013
New .............................................................................................................. 11.985/12.010 mm (0.4719/0.4728 in.)
Max. Wear Limit ......................................................................................... 12.035 mm (0.4738 in.)
Balance Weight Screw Torque ......................................................................... 10.9-13.2 N·m (95.0-115.0 in. lb.)
1.9
Section 1
Safety and General Information
Cylinder Bore
Cylinder Bore I.D.
New
SV470, SV480-00XX .................................................................................. 84.000/84.025 mm (3.307/3.308 in.)
SV470, SV480-01XX .................................................................................. 89.000/89.025 mm (3.504/3.505 in.)
SV530, SV540 ............................................................................................. 89.000/89.025 mm (3.504/3.505 in.)
SV590, SV600, SV610, SV620 ................................................................... 94.010/94.035 mm (3.701/3.702 in.)
Max. Wear Limit
SV470, SV480-00XX .................................................................................. 84.073 mm (3.310 in.)
SV470, SV480-01XX .................................................................................. 84.073 mm (3.310 in.)
SV530, SV540 ............................................................................................. 89.073 mm (3.507 in.)
SV590, SV600, SV610, SV620 ................................................................... 94.073 mm (3.704 in.)
Max. Taper .................................................................................................. 0.05 mm (0.002 in.)
Max. Out of Round .................................................................................... 0.12 mm (0.0047 in.)
Cylinder Head
Cylinder Head Fastener Torque (torque in 2 increments) .......................... 20.5, 41.0 N·m (180, 360 in. lb.)
Max. Out-of-Flatness ........................................................................................ 0.8 mm (0.003 in.)
Rocker Arm Pivot Stud Torque ....................................................................... 13.5 N·m (120 in. lb.)
Rocker Arm Adjustment Nut Set Screw ........................................................ 5.5 N·m (50 in. lb.)
Electric Starter
Thru Bolt Torque ............................................................................................... 3.3-3.9 N·m (30-35 in. lb.)
Mounting Nut Torque ...................................................................................... 3.6 N·m (32 in. lb.)
Nut (Top) Positive (+) Brush Lead Terminal ................................................. 1.6-2.8 N·m (15-25 in. lb.)
Nut (Flange) Positive (+) Brush Lead Terminal ............................................ 2.2-4.5 N·m (20-40 in. lb.)
Fan/Flywheel
Flywheel Retaining Screw Torque M12 ......................................................... 88.0 N·m (65 . lb.)
Flywheel Retaining Screw Torque M10 ......................................................... 66.5 N·m (49 . lb.)
Governor
Governor Cross Sha-to-Crankcase Running Clearance ........................... 0.013/0.075 mm (0.0005/0.003 in.)
Governor Cross Sha O.D.
New .............................................................................................................. 5.975/6.012 mm (0.2352/0.2367 in.)
Max. Wear Limit ......................................................................................... 5.962 mm (0.2347 in.)
Governor Gear Sha-to-Governor Gear Running Clearance ..................... 0.09/0.16 mm (0.0035/0.0063 in.)
Governor Gear Sha O.D.
New ............................................................................................................. 5.99/6.00 mm (0.2358/0.2362 in.)
Max. Wear Limit ........................................................................................ 5.977 mm (0.02353 in.)
Ignition
Spark Plug Type (Champion® or Equivalent) ............................................... RC12YC or QC12YC
Spark Plug Gap .................................................................................................. 0.76 mm (0.030 in.)
1.10
Section 1
Safety and General Information
Ignition (Continued)
Spark Plug Torque............................................................................................. 24-30 N·m (18-22 . lb.)
Ignition Module Air Gap ................................................................................ 0.203/0.305 mm (0.008/0.012 in.)
Ignition Module Fastener Torque ................................................................... 6.0 N·m (55 in. lb.) Into new as-cast hole
4.0 N·m (35 in. lb.) Into used hole
Muffler
Muffler Retaining Nuts Torque ...................................................................... 24.4 N·m (216 in. lb.)
Oil Filter
Oil Filter Torque ................................................................................................ refer to the oil filter for instructions.
Oil Filter Pad Pipe Plug
1/8” N.P.T.F. Torque .......................................................................................... 4.5-5.0 N·m (40-46 in. lb.)
Oil Pump
Mounting Screw Torque .............................................................5.0-7.5 N·m (44.4-66.0 in. lb.) Into new as-cast hole
3.8-4.6 N·m (33.3-40.3 in. lb.) Into used hole
Pump Gears-to-Crankcase Side Clearance .................................................... 0.165/0.315 mm (0.0065/0.0124 in.)
1
Oil Sentry
Pressure Switch Torque .................................................................................... 4.5-5.0 N·m (40-45 in. lb.)
Piston, Piston Rings, and Piston Pin
Piston Pin Bore I.D.
New .............................................................................................................. 22.006/22.012 mm (0.8685/0.8666 in.)
Max. Wear Limit ......................................................................................... 22.025 mm (0.8671 in.)
Piston Pin O.D.
New .............................................................................................................. 21.995/22.0 mm (0.8659/0.8661 in.)
Max. Wear Limit ......................................................................................... 21.994 mm (0.8658 in.)
Top Compression Ring-to-Groove Side Clearance ..................................... 0.04 mm (0.0016 in.)
Middle Compression Ring-to-Groove Side Clearance ............................... 0.04 mm (0.0016 in.)
Top and Middle Compression Ring End Gap
New Bore
Top Ring .................................................................................................... 0.15/0.40 mm (0.006/0.016 in.)
Middle Ring .............................................................................................. 0.30/0.55 mm (0.012/0.022 in.)
Used Bore (max.) ........................................................................................ 0.77 mm (0.030 in.)
Piston Thrust Face O.D.²
SV470, SV480-00XX
New ............................................................................................................ 83.948/83.962 mm (3.3050/3.3056 in.)
Max. Wear Limit ....................................................................................... 83.828 mm (3.3003 in.)
SV470, SV480-01XX
New ............................................................................................................ 88.948/88.962 mm (3.5018/3.5024 in.)
Max. Wear Limit ....................................................................................... 88.828 mm (3.4972 in.)
²Measure 8 mm (0.314 in.) above the boom of the piston skirt at right angles to the piston pin.
1.11
Section 1
Safety and General Information
Piston, Piston Rings, and Piston Pin (Continued)
SV530, SV540
New ............................................................................................................ 88.948/88.962 mm (3.5018/3.5024 in.)
Max. Wear Limit ....................................................................................... 88.828 mm (3.4972 in.)
SV590, SV600, SV610, SV620
New ............................................................................................................ 93.928/93.942 mm (3.6980/3.6985 in.)
Max. Wear Limit ....................................................................................... 93.828 mm (3.6940 in.)
2
Piston Thrust Face-to-Cylinder Bore
SV470, SV480, SV530, SV540 .................................................................... 0.045 mm (0.0018 in.)
SV560, SV590, SV600, SV610, SV620 ....................................................... 0.0880 mm (0.0035 in.)
Rectifier-Regulator
Mounting Screw Torque ................................................................................... 6.0 N·m (55 in. lb.) Into new as cast hole
4.0 N·m (35 in. lb.) Into used hole
Speed Control
Speed Control Bracket Assembly Fastener Torque ......................................11.0 N·m (95 in. lb.) Into new as-cast hole
7.5 N·m (65 in. lb.) Into used hole
Stator
Stator Mounting Screw Torque ....................................................................... 6.0 N·m (55 in. lb.) Into new as-cast hole
4.0 N·m (35 in. lb.) Into used hole
Throttle/Choke Controls
Governor Control Lever Fastener Torque ..................................................... 7.0-8.5 N·m (60-75 in. lb.)
Running Clearance
Valve Cover
Valve Cover Fastener Torque........................................................................... 11.0 N·m (95 in. lb.) Into new as-cast hole
7.5 N·m (65 in. lb.) Into used hole
Valves and Valve Lifters
Intake Valve Lash3 ............................................................................................. 0.127 mm (0.005 in.)
Exhaust Valve Lash3 .......................................................................................... 0.178 mm (0.007 in.)
Intake Valve Minimum Li ............................................................................. 8.9 mm (0.350 in.)
Exhaust Valve Minimum Li .......................................................................... 8.9 mm (0.350 in.)
Nominal Valve Seat Angle ............................................................................... 45°
Intake Valve Stem-to-Valve Guide Running Clearance ............................... 0.038/0.076 mm (0.0015/0.003 in.)
Exhaust Valve Stem-to-Valve Guide Running Clearance ............................ 0.050/0.88 mm (0.0020/0.0035 in.)
Intake Valve Guide I.D.
New .............................................................................................................. 6.038/6.058 mm (0.2377/0.2385 in.)
Max. Wear Limit ......................................................................................... 6.135 mm (0.2415 in.)
2
Measure 8 mm (0.314 in.) above the boom of the piston skirt at right angles to the piston pin.
3
Check valve lash every 200 hours, adjust as required.
1.12
Section 1
Safety and General Information
Valves and Valve Lifters (Continued)
Intake Valve Stem Diameter
New .............................................................................................................. 5.982/6.0 mm (0.2355/0.2362 in.)
Exhaust Valve Guide I.D.
New .............................................................................................................. 6.038/6.058 mm (0.2377/0.2385 in.)
Max. Wear Limit ......................................................................................... 6.160 mm (0.2425 in.)
Exhaust Valve Stem Diameter
New .............................................................................................................. 5.970/5.988 mm (0.235/0.2357 in.)
General Torque Values
Metric Fastener Torque Recommendations for Standard Applications
Tightening Torque: N·m (in. lb.) + or - 10%
1
Property Class
Noncritical
4.8
Size
M4 1.2 (11) 1.7 (15) 2.9 (26) 4.1 (36) 5.0 (44) 2.0 (18)
M5 2.5 (22) 3.2 (28) 5.8 (51) 8.1 (72) 9.7 (86) 4.0 (35)
M6 4.3 (38) 5.7 (50) 9.9 (88) 14.0 (124) 16.5 (146) 6.8 (60)
M8 10.5 (93) 13.6 (120) 24.4 (216) 33.9 (300) 40.7 (360) 17.0 (150)
5.8 8.8 10.9 12.9
Fasteners
Into Aluminum
Tightening Torque: N·m (ft. lb.) + or - 10%
Property Class
4.8
M10 21.7 (16) 27.1 (20) 47.5 (35) 66.4 (49) 81.4 (60) 33.9 (25)
M12 36.6 (27) 47.5 (35) 82.7 (61) 116.6 (86) 139.7 (103) 61.0 (45)
M14 58.3 (43) 76.4 (55) 131.5 (97) 184.4 (136) 219.7 (162) 94.9 (70)
5.8 8.8 10.9 12.9
Oil Drain Plugs Tightening Torque: N•m (English)
Size
1/8" NPT
1/4"
3/8"
1/2"
3/4"
X-708-1
Into Cast Iron
–
17.0 (150 in. lb.)
20.3 (180 in. lb.)
27.1 (20 . lb.)
33.9 (25 . lb.)
27.1/33.9 (20/25 . lb.)
Into Aluminum
4.5 (40 in. lb.)
11.3 (100 in. lb.)
13.6 (120 in. lb.)
17.6 (13 . lb.)
21.7 (16 . lb.)
27.1/33.9 (20/25 . lb.)
Conversions
N·m = in. lb. x 0.113
N·m = . lb. x 1.356
in. lb. = N·m x 8.85
. lb. = N·m x 0.737
Noncritical
Fasteners
Into Aluminum
Torque
1.13
Section 1
Safety and General Information
1.14
Section 2
Tools & Aids
Section 2
Tools & Aids
Certain quality tools are designed to help you perform specific disassembly, repair, and reassembly procedures.
By using tools designed for the job, you can properly service engines easier, faster, and safer! In addition, you’ll
increase your service capabilities and customer satisfaction by decreasing engine downtime.
Here is the list of tools and their source.
Separate Tool Suppliers:
Kohler Tools
Contact your source
of supply.
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
2
Tools
Description Source/Part No.
Balance Gear Timing Tool (K & M Series)
To hold balance gears in timed position when assembling engine.
Camsha Endplay Plate
For checking camsha endplay.
Camsha Seal Protector (Aegis)
To protect seal during camsha installation.
Cylinder Leakdown Tester
For checking combustion retention and if cylinder, piston, rings, or valves are worn.
Electronic Fuel Injection (EFI) Diagnostic Soware
Use with Laptop or Desktop PC.
EFI Service Kit
For troubleshooting and seing up an EFI engine.
Individual Components Available
Pressure Tester
Noid Light
90° Adapter
Oetiker Clamp Pliers
Code Plug, Red Wire
Code Plug, Blue Wire
Flywheel Holding Tool (CS Series) SE Tools KLR-82407
Flywheel Puller
To remove flywheel from engine.
Flywheel Strap Wrench
To hold flywheel during removal.
Kohler 25 455 06-S
(Formerly Y-357)
SE Tools KLR-82405
SE Tools KLR-82417
Kohler 25 761 05-S
Kohler 25 761 23-S
Kohler 24 761 01-S
Design Technology Inc.
DTI-019
DTI-021
DTI-023
DTI-025
DTI-027
DTI-029
SE Tools KLR-82408
SE Tools KLR-82409
2.1
Section 2
Tools & Aids
Tools (Continued)
Description Source/Part No.
Hydraulic Valve Lier Tool
To remove and install hydraulic liers.
Ignition System Tester
For testing output on all systems, except CD.
For testing output on capacitive discharge (CD) ignition system.
Offset Wrench (K & M Series)
To remove and reinstall cylinder barrel retaining nuts.
Oil Pressure Test Kit
To test and verify oil pressure.
Rectifier-Regulator Tester (120 volt current)
Rectifier-Regulator Tester (240 volt current)
Used to test rectifier-regulators.
Kohler 25 761 38-S
Kohler 25 455 01-S
Kohler 24 455 02-S
SE Tools KLR-82410
Kohler 25 761 06-S
Kohler 25 761 20-S
Kohler 25 761 41-S
Individual Components Available
CS-PRO Regulator Test Harness
Special Regulator Test Harness with Diode
Spark Advance Module (SAM) Tester
To test the SAM (ASAM and DSAM) on engines with SMART-SPARK™.
Starter Retaining Ring Tool (Inertia Drive)
To remove and reinstall drive retaining rings (excluding FASCO starters).
Starter Servicing Kit (All Starters)
To remove and reinstall drive retaining rings and brushes.
Individual Component Available
Starter Brush Holding Tool (Solenoid Shift)
Tachometer (Digital Inductive)
For checking operating speed (RPM) of an engine.
Vacuum/Pressure Tester
Alternative to a water manometer.
Valve Guide Reamer (K & M Series)
For sizing valve guides after installation.
Design Technology Inc.
DTI-031
DTI-033
Kohler 25 761 40-S
Kohler 25 761 18-S
SE T ools KLR-8241 1
SE T ools KLR-82416
Design T echnology Inc.
DTI-110
Kohler 25 761 22-S
SE T ools KLR-1 1843
2.2
Section 2
Tools & Aids
Aids
Description Source/Part No.
Camsha Lubricant (Valspar ZZ613) Kohler 25 357 14-S
Dielectric Grease (GE/Novaguard G661) Kohler 25 357 11-S
Dielectric Grease (Fel-Pro) Lubri-Sel
Electric Starter Drive Lubricant (Inertia Drive) Kohler 52 357 01-S
Electric Starter Drive Lubricant (Solenoid Shi) Kohler 52 357 02-S
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. Loctite® Nos. 5900 or 5910 are recommended for best sealing characteristics.
Loctite® 5910
Loctite® Ultra Black 598
Loctite® Ultra Blue 587
Loctite® Ultra Copper
Spline Drive Lubricant Kohler 25 357 12-S
Kohler 25 597 07-S
2
2.3
Section 2
Tools & Aids
Special Tools You Can Make
Flywheel Holding Tool
A flywheel holding tool can be made out of an old
junk flywheel ring gear as shown in Figure 2-1, and
used in place of a strap wrench.
1. Using an abrasive cut-off wheel, cut out a six
tooth segment of the ring gear as shown.
2. Grind off any burrs or sharp edges.
3. Invert the segment and place it between the
ignition bosses on the crankcase so that the tool
teeth engage the flywheel ring gear teeth. The
bosses will lock the tool and flywheel in
position for loosening, tightening or removing
with a puller.
2. Remove the studs of a Posi-Lock rod or grind off
the aligning steps of a Command rod, so the joint
surface is flat.
3. Find a 1 in. long capscrew with the correct thread
size to match the threads in the connecting rod.
4. Use a flat washer with the correct I.D. to slip on
the capscrew and approximately 1” O.D. (Kohler
Part No. 12 468 05-S). Assemble the capscrew
and washer to the joint surface of the rod, as
shown in Figure 2-2.
Figure 2-1. Flywheel Holding Tool.
Rocker Arm/Crankshaft Tool
A spanner wrench to li the rocker arms or turn the
cranksha 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 the rod cap.
Figure 2-2. Rocker Arm/Crankshaft Tool.
2.4
Section 3
Troubleshooting
Troubleshooting Guide
When troubles occur, be sure to check the simple
causes which, at first, may seem too obvious to be
considered. For example, a starting problem could be
caused by an empty fuel tank.
Some common types of engine troubles are listed
below. Use these to help locate the possible cause(s).
Engine Cranks But Will Not Start
1. Empty fuel tank.
2. Fuel shut-off valve closed.
3. Poor fuel, dirt or water in the fuel system.
4. Clogged fuel line.
5. Spark plug lead disconnected.
6. Kill switch in off position.
7. Faulty spark plug.
8. Faulty ignition module.
9. Fuel solenoid malfunction.
10. Choke not closing.
11. Baery connected backwards.
12. Safety interlock system engaged.
Engine Starts But Does Not Keep Running
1. Restricted fuel tank cap vent.
2. Poor fuel, dirt or water in the fuel system.
3. Faulty or misadjusted choke or throle controls.
4. Loose wires or connections that short the kill
terminal of ignition module to ground.
5. Faulty cylinder head gasket.
6. Faulty carburetor.
7. Intake system leak.
Engine Starts Hard
1. PTO drive is engaged.
2. Poor fuel, dirt or water in the fuel system.
3. Clogged fuel line.
4. Loose or faulty wires or connections.
5. Faulty or misadjusted choke or throle controls.
6. Faulty spark plug.
7. Low compression.
8. Faulty ACR mechanism.
9. Weak spark.
10. Fuel pump malfunction causing lack of fuel.
Section 3
Troubleshooting
3
11. Engine overheated-cooling/air circulation
restricted.
12. Flywheel key sheared.
13. Intake system leak.
Engine Will Not Crank
1. PTO drive is engaged.
2. Baery is discharged.
3. Safety interlock switch is engaged.
4. Loose or faulty wires or connections.
5. Faulty key switch or ignition switch.
6. Faulty electric starter.
7. Seized internal engine components.
Engine Runs But Misses
1. Dirt or water in the fuel system.
2. Spark plug faulty or fouled.
3. Poor quality of fuel.
4. Spark plug lead boot loose on plug.
5. Loose wires or connections that intermiently
short the kill terminal of ignition module to
ground.
6. Engine overheated.
7. Faulty ignition module or improperly gapped.
8. Carburetor adjusted incorrectly.
Engine Will Not Idle
1. Dirt or water in the fuel system.
2. Stale fuel and/or gum in carburetor.
3. Faulty spark plug.
4. Fuel supply inadequate.
5. Idle fuel adjusting needle improperly set.
6. Idle speed adjusting screw improperly set.
7. Low compression.
8. Restricted fuel tank cap vent.
9. Engine overheated-cooling system/air circulation
problem.
3.1
Section 3
Troubleshooting
Engine Overheats
1. Air intake/grass screen, cooling fins, or cooling
shrouds clogged.
2. Excessive engine load.
3. Low crankcase oil level.
4. High crankcase oil level.
5. Faulty carburetor.
6. Lean fuel mixture.
Engine Knocks
1. Excessive engine load.
2. Low crankcase oil level.
3. Old or improper fuel.
4. Internal wear or damage.
5. Quality of fuel.
6. Incorrect grade of oil.
Engine Loses Power
1. Low crankcase oil level.
2. High crankcase oil level.
3. Dirty air cleaner element.
4. Dirt or water in the fuel system.
5. Excessive engine load.
6. Engine overheated.
7. Faulty spark plug.
8. Low compression.
9. Exhaust restriction.
10. Low baery.
11. Incorrect governor seing.
Engine Uses Excessive Amount of Oil
1. Incorrect oil viscosity/type.
2. Clogged, broken, or inoperative breather.
3. Worn or broken piston rings.
4. Worn cylinder bore.
5. Worn valve stems/valve guides.
6. Crankcase overfilled.
7. Blown head gasket/overheated.
• Check for buildup of dirt and debris on the
crankcase, cooling fins, grass screen and other
external surfaces. Dirt or debris on these areas
can cause overheating.
• Check for obvious 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 the air cleaner cover and base for damage
or indications of improper fit and seal.
• Check the air cleaner element. Look for holes,
tears, cracked or damaged sealing surfaces,
or other damage that could allow unfiltered
air into the engine. Also note if the element is
dirty or clogged. These could indicate improper
maintenance.
• Check the carburetor throat for dirt. Dirt in the
throat is further indication that the air cleaner
was not functioning properly.
• Check if the oil level is within the operating range
on the dipstick. If it is above, sniff for gasoline
odor.
• Check the condition of the oil. Drain the oil into
a container; it should flow 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 the wrong type or weight of oil was
used, the oil was not changed at the recommended
intervals, an over-rich fuel mixture, or weak ignition,
to name a few possible causes.
Oil Leaks from Oil Seals, Gaskets
1. Clogged, broken, or inoperative breather.
2. Worn or broken piston rings.
3. Piston blowby, or leaky valves.
4. Restricted exhaust.
External Engine Inspection
Before cleaning or disassembling the engine, make a
thorough inspection of its external appearance and
condition. This inspection can give clues to what
might be found inside the engine (and the cause)
when it is disassembled.
3.2
NOTE: It is good practice to drain oil at a location
away from the workbench. Be sure to allow
ample time for complete drainage.
Cleaning the Engine
Aer inspecting the external condition of the engine,
clean the engine thoroughly before disassembling
it. Also clean individual components as the 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
the manufacturer’s instructions and safety precautions
carefully.
Section 3
Troubleshooting
Make sure all traces of the cleaner are removed before
the engine is reassembled and placed into operation.
Even small amounts of these cleaners can quickly
break down the lubricating properties of engine oil.
Basic Engine Tests
Crankcase Vacuum Test
A partial vacuum should be present in the
crankcase when the engine is operating. Pressure
in the crankcase (normally caused by a clogged or
improperly-operating breather) can cause oil to be
forced out at oil seals, gaskets, or other available spots.
Crankcase vacuum is best measured with a water
manometer or vacuum/pressure test gauge. See
Section 2. Complete instructions are provided with the
testers.
Test the crankcase vacuum with the manometer as
follows:
1. Insert the rubber stopper into the oil fill hole.
Be sure the pinch clamp is installed on the
hose and use the tapered adapters to connect
the hose between the stopper and one of the
manometer tubes. Leave the other tube open to
the atmosphere. Check that the water level in the
manometer is at the “0” line. Make sure the pinch
clamp is closed.
2. Start the engine and run at no-load high idle
speed (3200 to 3750 RPM).
3. Open the clamp and note the water level in the
tube.
The level in the engine side should be a minimum
of 10.2 cm (4 in.) above the level in the open side.
If the level in the engine side is the same as the
open side (no vacuum), or the level in the engine
side is lower than the level in the open side
(pressure), check for the conditions in the table
below.
4. Close the pinch clamp before stopping the
engine.
To perform the test with the vacuum/pressure gauge:
1. Insert the stopper as in step 1.
2. Insert the barbed gauge fiing into the hole in the
stopper. Be sure the gauge needle is at “0”.
3. Run the engine, as in step 2, and observe the
gauge reading. Needle movement to the le
of “0” is a vacuum, and movement to the right
indicates a pressure. A minimum of 10.2 cm (4 in.)
of vacuum should be present.
3
Incorrect Vacuum in Crankcase
Possible Cause Solution
1. Crankcase breather clogged or inoperative.
2. Seals and/or gaskets leaking. Loose or
improperly torqued fasteners.
3. Piston blowby or leaky valves. Confirm with
cylinder leakdown test.
4. Restricted exhaust.
1. Disassemble breather, clean parts thoroughly,
reassemble, and recheck pressure.
2. Replace all worn or damaged seals and gaskets.
Make sure all fasteners are tightened securely.
Use appropriate torque values and sequences
when necessary.
3. Recondition piston, rings, cylinder bore, valves,
and valve guides.
4. Repair/replace restricted muffler/exhaust
system.
3.3
Section 3
Troubleshooting
Compression Test
These engines are equipped with an automatic
compression release (ACR) mechanism. Because
of the ACR mechanism, it is difficult to obtain an
accurate compression reading. As an alternate, use the
leakdown test described below.
Cylinder Leakdown Test
A cylinder leakdown test can be a valuable alternative
to a compression test. By pressurizing the combustion
chamber from an external air source, you can
determine if the valves or rings are leaking, and how
badly.
The cylinder leakdown tester is a relatively simple,
inexpensive leakdown tester for small engines.
The tester includes a quick disconnect coupling for
aaching the adapter hose and a holding tool.
Leakdown Test Instructions
1. Run the engine for 3-5 minutes to warm it up.
2. Remove the spark plug.
3. Rotate the cranksha until the piston is at top
dead center of the compression stroke. You
will need to hold the engine in this position
while testing. The holding tool supplied with
the tester can be used if the PTO end of the
cranksha is accessible. Slide the holding tool
onto the cranksha, align the slot with one of the
mounting holes on the PTO face, and tighten it
onto the cranksha. Install a 3/8" breaker bar into
the slot of the holding tool, so it is perpendicular
to both the holding tool and cranksha, or insert
a shoulder bolt through the slot and thread it into
the mounting hole. If the flywheel end is more
accessible, you can use a breaker bar and socket
on the flywheel nut/screw to hold it in position.
You may need an assistant to hold the breaker
bar during testing. If the engine is mounted in
a piece of equipment, you may be able to hold
it by clamping or wedging a driven component.
Just be certain that the engine cannot rotate off of
TDC in either direction.
4. Install the adapter into the spark plug hole, but
do not aach it to the tester at this time.
5. Connect an adequate air source (80-100 psi) to the
tester.
6. Turn the regulator knob in the increase
(clockwise) direction until the gauge needle is in
the yellow set area at the low (right) end of the
scale.
7. Connect the tester quick-disconnect to the
adapter. Note the gauge reading and listen for
escaping air at the carburetor inlet, exhaust
outlet, and/or crankcase breather.
8. Check your test results against the table below:
Leakdown Test Results
Air escaping from crankcase breather ................................................Defective rings or worn cylinder walls.
Air escaping from exhaust system ......................................................Defective exhaust valve.
Air escaping from carburetor ...............................................................Defective intake valve.
Gauge reading in low (green) zone .....................................................Piston rings and cylinder in good condition.
Gauge reading in moderate (yellow) zone .........................................Engine is still usable, but there is some wear
present. Customer should start planning for
overhaul or replacement.
Gauge reading in high (red) zone ........................................................Rings and/or cylinder have considerable wear.
Engine should be reconditioned or replaced.
3.4
Air Cleaner and Air Intake System
Section 4
Air Cleaner and Air Intake System
Section 4
Air Cleaner
These engines are equipped with a replaceable, high
density, paper air cleaner element. Some engines also
have an oiled, foam precleaner, located in the outer air
cleaner cover. See Figure 4-1.
Air Cleaner
Base
Optional Foam Precleaner
Intake air is drawn in through the upper opening from
the blower housing, passes through the precleaner
(if so equipped), the paper element and then into
the carburetor. The outer air cleaner cover is secured
by two knobs, and removed by turning the knobs
counterclockwise.
Air Cleaner Element
Air Cleaner Cover
4
Figure 4-1. Air Cleaner Assembly - Exploded View.
Check the air cleaner daily or before starting the
engine. Check for and correct any buildup of dirt and
debris, and loose or damaged components.
NOTE: Operating the engine with loose or
damaged air cleaner components could
allow unfiltered air into the engine causing
premature wear and failure.
Air
Cleaner
Cover
Knobs
Precleaner Service
If so equipped, wash and oil the precleaner annually
or every 25 hours of operation (more oen under
extremely dusty or dirty conditions).
1. Loosen the air cleaner cover knobs and remove
the cover.
2. Remove the precleaner.
4.1
Section 4
Air Cleaner and Air Intake System
3. Wash the precleaner in warm water with
detergent. Rinse the precleaner thoroughly until
all traces of detergent are eliminated. Squeeze out
excess water (do not wring). Allow the precleaner
to air dry.
4. Saturate the precleaner with new engine oil.
Squeeze out all excess oil.
5. Reinstall the precleaner into the outer cover.
6. Install the air cleaner cover and secure with the
two knobs.
7. When precleaner replacement is necessary, order
Kohler Part No. 20 083 03-S.
Paper Element Service
Check the paper element annually or every 25 hours
of operation (more oen under extremely dusty or
dirty conditions). Clean or replace the element as
necessary. Replace the air cleaner element annually or
every 100 hours.
1. Remove the air cleaner cover and the precleaner
(if so equipped), service as required.
2. Remove the air cleaner element with the integral
rubber seal.
8. When element replacement is necessary, order
Kohler Part No. 20 083 02-S.
Inspect Air Cleaner Components
Whenever the air cleaner cover is removed, or the
paper element or precleaner is serviced, check the
following areas/components:
Outer Air Cleaner Cover - Make sure the air cleaner
cover is in good condition, not cracked, damaged, or
missing a retaining knob, which can affect the sealing
ability of the air cleaner element.
Air Cleaner Base - Make sure the base is properly
secured and not cracked or damaged. Since the
air cleaner base and carburetor are secured to the
intake port with common hardware, it is extremely
important that the fasteners securing these
components are tight at all times. The air cleaner
base also provides the mounting points for the air
cleaner cover retaining studs. Make sure the bosses
are not cracked, broken or damaged, and the studs are
properly secured.
Before reinstalling an air cleaner base that has been
removed, make sure the metal bushings in the base
mounting holes are present. See Figure 4-2. The
bushings prevent damage to the base and maintain
the proper mounting torque.
3. Gently tap the pleated side of the paper element
to dislodge dirt. Do not wash the paper element
or use pressurized air, as this will damage the
element. Replace a dirty, bent, or damaged
element with a genuine Kohler element. Handle
new elements carefully; do not use if the rubber
seal is damaged.
4. Clean all air cleaner components of any
accumulated dirt or foreign material. Prevent any
dirt from entering the throat of the carburetor.
5. Install the air cleaner element with the pleated
side out and seat the rubber seal onto the edges
of the air cleaner base.
6. Reinstall the precleaner (if so equipped), into
the upper section of the air cleaner cover. Make
sure the hole in the precleaner is aligned with the
upper mounting knob. See Figure 4-1.
7. Reinstall the air cleaner cover and secure with the
two knobs.
Figure 4-2. Bushings in Air Cleaner Base.
Breather Hose - Make sure the hose is not cracked or
damaged, and aached to both the air cleaner base
and valve cover.
NOTE: Damaged, worn, or loose air cleaner
components can allow unfiltered air into the
engine causing premature wear and failure.
Tighten or replace all loose or damaged
components.
4.2
Figure 4-3. Breather Hose.
Disassembly
The following procedure is for complete disassembly
of all air cleaner components. As the removal of the
air cleaner base also affects carburetor mounting and
governor adjustment, steps 3 and 4 should only be
performed if required. Detailed photos are provided
in Sections 5, 8, and 10 for the various individual
steps.
Section 4
Air Cleaner and Air Intake System
Reassembly
The following procedure is for complete assembly of
all air cleaner components. Steps 1-3 are necessary
only if the air cleaner base and/or the cover mounting
studs were removed in Section 8, Disassembly.
1. Install the mounting studs into the air cleaner
base if removed previously. Tighten the studs
until boomed, or to the end of threads (do not
force).
2. Install the air cleaner base gasket and air cleaner
base, with the two metal spacers, onto the
mounting stud(s) and/or alignment pin. Make
sure the upper mounting tab is located above the
closure plate. Install and finger tighten the hex
flange nut(s). When a long M6 thread forming
mounting screw is used, apply hand pressure
to keep the parts from shiing, then remove the
alignment pin and install the M6 thread forming
screw. DO NOT OIL. Torque the nut(s) to
5.5 N·m (48 in. lb.). Torque the screw to 8.0 N·m
(70 in. lb.) into a new hole, or 5.5 N·m (48 in. lb.)
into a used hole, do not over tighten.
4
1. Loosen the air cleaner cover retaining knobs and
remove the air cleaner cover.
2. Remove the foam precleaner (if so equipped),
and the air cleaner element with formed rubber
seal.
3. Disconnect the breather hose from the valve
cover or air cleaner base.
NOTE: The air cleaner base should be removed
only if necessary.
4. Remove the two hex flange nuts from the
mounting studs. If one stud and one thread
forming screw is used; first remove the thread
forming screw on the right side of the carburetor
inlet, which secures the air cleaner base,
carburetor and gaskets. Insert a 3/16” diameter
rod approximately 4” long, into the hole to serve
as a temporary alignment pin. Be careful not
to force the rod or damage the threads. Then
remove the hex flange nut from the stud on
the le side of the carburetor inlet. Carefully
remove the air cleaner base and gasket. The cover
mounting studs thread into the air cleaner base,
and they should only be removed if necessary.
3. Reconnect the breather hose and perform the
governor adjustment (Section 5, Initial Governor
Adjustment).
4. Install the air cleaner element with the pleated
side out and seat the rubber seal onto the edges
of the air cleaner base.
5. Install the serviced precleaner (if so equipped)
into the air cleaner cover. Make sure the hole
in the precleaner is aligned with the upper
mounting knob.
6. Reinstall the air cleaner cover and secure with the
two knobs.
4.3
Section 4
Air Cleaner and Air Intake System
Air Intake/Cooling System
Clean Air Intake/Cooling Areas
To ensure proper cooling, make sure the grass screen,
cooling fins, and other external surfaces of the engine
are kept clean at all times.
Annually or every 100 hours of operation, (more oen
under extremely dusty, dirty conditions), remove the
blower housing and any other cooling shrouds. Clean
the cooling fins and external surfaces as necessary.
Make sure all parts are reinstalled. Torque the M6
blower housing fasteners to 7.7 N·m (68.3 in. lb.).
NOTE: Operating the engine with a blocked grass
screen, dirty or plugged cooling fins, and/or
cooling shrouds removed, will cause engine
damage due to overheating.
4.4
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