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CV17-CV25, CV620-CV730, CV740, CV750 Service Manual

1. ole Sors Nis ad Fosters sone io e e oo cre amas REE OED gt ze 38E zia 2 3262 EE 3662 x E El 79001 E TETTE 505 TSELON 220001 aT 283081 39269 TU Sen a Ea u I4 tm sitom TET Tongue Wa i ane TE EH z EHI EH z 8 ETC est es EI E Tos oy rea ey 1225 36500 Ud 57 EE 0 EE EENE ERUN HE E z ubi faim ET TEC SSS EI z Sez E z 21200 7 ors etis Torque Rasonmen doa for Sandan plos opr Cass Eus Eod MESI CET ETE 0 T un S308 Bea ona ST iis 853 GENA HET i500 407660 Ty TEE EE TE TE T 305 E ee e ITO aee 1468 sisi Trek ig FO S SESTO Nm Nm f ib 1 356 nds inb NmXEES Nm x 0 737 KohlerEngines com 24 690 07 Rev Tools and Aids Certain qualty tools aro designed to help you perform specifi disassembly repair and reassembly procedures By using these tools you can properly service engines easier faster and safei In addition youll Increase your service Capabillies and customer satisfaction by decreasing engine downtime Here list of to
2. 24 69007 Rev B KohlerEnginos com 5 Specifications Engine Dimensions with Commercial Mower Air Cleaner Dimensions in millimeters Inch equivalents shown in KohlerEngines com 24 69007 Rev Specifications Engine Dimensions with Heavy Duty Air Cleaner Dimensions in nvlimetors Inch equivalents shown in 24 69007 Rev B KohlerEngines com 7 Specifications ENGINE IDENTIFICATION NUMBERS Kohler engine identification numbers model specification and serial should be referenced for efficient repair ordering corect parts and engine replacemant Mods CEN Command Engine Verica Shat Numerical Designation Specification CV620 0001 Serial 3973500328 NoacMalacised Code Factory Coda Code Year 30 2006 40 2000 41 2 GENERAL SPECIFICATIONS CV22 CV23 CV25ICV730 CV750 CV670 CV680 CV740 E Timm Imm Bom mm ATI ariny Gosh ism EEG 67 mm 284 n X Tin Dispiacemani Bice p Se THe ires
3. Nm aF Key Sh AG Batey Sete fas Kay Sch Ground AL AMI Busted aN tery Posie AG Banery agains 24 69007 Rev 8 KonlerEngoes com s Electrical System Wiring Diagram 15 20 25 Amp Regulated Battery Charging System with Smart Sparky Kohler ngines 24 690 07 Rev B Electrical System Smart Spark Advance Ignition System SMART SPARK equipped engines an electronic capaGiive discharge lanian system wih spark advance A typical application consists of following components 1 magnet assembly which is permanently affixed to flywheel 2 electronic capacitive discharge ignition modules which mount on engine crankcase 1 Spark advance module which mounts ta engine shrouding 1 12 volt battery which supplies current to spark advance modulo 1 kil switch or key switch whieh grounds spark advance module to stop engine 2 spark plugs Oi Presse Svih B Oi Seni Uum Spam Page 8 a yee Sor ETE Sra meer Wtonuoue RES y LIRE Sman Yel anda Module Spin rown fallow fs Pink on Dic a ME ven EET Racer agua OS Ki p Scena S inar
4. CLEARANCE SPECIFICATIONS Cv22 CV23 CV2SCVTN CV750 even CV620 CV640 Crankcase Governor Cross Sal Bore LD imm Shaft New 6 0256 050 mm 92372102382 n Max Wear Limit oes mm 02367 i 8mm Shaft New 8 025 075 mm 0315803179 Max Wear Limit 3 066 mm 0 3184 Crankshaft End Play Fes THOT WHAT Bore n crankcase New d 40 966141 003 mm 18128 1 643 in Max Wear Limit 41016 mm 16148 n Cranishaf lo Sins Bearing cranicase 830 8 mm 0001200035197 Running Clearance New Bore n ol pan Nau Pan 4059871405974 mm 1 6136 1 6131 in Crankshafl Bore n ai panio Crankshaft Running Clearance New 0 039 0 074 mm 0 001510 0029 in Fiywheel End Main Bearing Journal OD Now 4091340935 mm 1 6107 1 6116 in ODD Max Wear Limit 4084 mm 1 608 in Max Taper 0 022 mm 0 0009 i Ouot Round 0 025 mm 0 0010 in Oi Pan End Main Bearing Journal OD Now 4091340935 mm 1 6107 1 6116 in OD Wear Limit 4084 mm 1608 in Taper 0 022 mm 0 0009 i Ouot Round 0 025 mm 0 0010 in Connecting Rod Journal OD New 35 955135 973 mm 1 4156 1 4163 in ODD Max Wear Limit 3594 mm 1445 in Taper 0018 mm 0 0007 in Ouot Round 0 025 mm 0 0010 in TIR TO End Crank in Engine 0 279 mm 0 0110 in Entre Crank in V Blocks 0 10 mm 0 0039 in Cylinder Bore Cylinder Bor
5. isassembly Inspection and Service Remove Sentry Remove Valve Covers T Disconnect lead rom OW Sentry switch 2 Remove Sentry switch from breather cover Remove Inner Baffles and Breather Cove T Remove screws securing inner bales to crankcase 2 Remove inner valley baffles 3 Remove remaining screws from breather cover 4 Pry under protruding edge of breather cover with a screwdriver to break RTV or gasket seal Do not pry sealing surfaces as it could cause damage resulting in leaks Most engines use a formed gasket rather than RTV sealant 5 Remove breather cover and gasket f used Crankcase Breather System Breather system is designed to control amount of ol in head area and sili maintain necessary vacuum in crankcase A spring steel reed and stop is mounted on each bank of crankcase between lita bores When pistons move downward alr is pushed past reeds into cylinder head cavities On cylinder 2 upper end of head Is completely Sealed by rocker cover So a low positive pressure is Created in head cavity Cylinder 1 rocker cover has hole in i for venting Bottom nipple of oll separator Canister is ted into hole with grommet From top nipple of canister a breather hose goes back to air leaner base Air moving into cyinder 1 head cavity is fered through separator and then is drawn Into air intake Upward travel of pistons closes reeds and creates a ow vacuum in lower cra
6. 24 690 07 Rev B Starter System When engine starts fywhee rotates faster than starter and drive prion This moves drive pinion out f mesh with ing gear and into retracted postion When power is removed rom starter armature Stops roiling fnd vo prion is held in retracted postion by andi sping Starter Dive Service SPA NOTE Do not oversight vise as this can distort drive pinion 1 Remove starter from engine and remove dust cover 2 Hold drive pinion in a vice with jaws when temoving or inslaling stp nut Armatura wil rotate ih nut unl drive pinion stops against intemal Spacers 3 Remove slop nut stop gear spacer antri spring dust cover spacer and dive pinion Clean splines on dive shaft thoroughly with solvent Dry spines thoroughly 5 Apply small amount ot Kohler electric starter drive brant to spines Use of other lubricants may Cause drive pinion lo sick oF bind 6 Apply a small amount of Loctite 271 to stop nut treads Install drive pinion dust cover spacer antri Spring stop gear spacer and slop nu Torque stor N m RETO n iB arit dd FM Rubber dust cover has molded ip on inside that Snaps into a groove in dust cover spacer Tum drive pinion clockwise unt It reaches fully extended position Whe holding iin extended postion grasp ip of dust cover wilh les or vise gap and pull t feo rom spacer 2 Disassemble snap ring removal tool Grasp spring retain
7. RaciferReguatr o Green p gt Assembly o voee n s fices Temaro wwe gar V sr pw Re car pene m Or Sen Pana v Seelen z mare mania Seow aa aie CASEI PT asa Ca AE Warez AG Recess Batey Sume AT Gud AK Key Swen Ground AL AW Busted aN Eater Pose AO Banery Wepaive AB AG Fuse AR Ste Send Sur AS Sols Tara AT Bak Gen 24 690 07 Rev B KohlerEnginos s Electrical System Wiring Diagram 15 20 25 Amp Regulated Battery Charging System with DSAI Ignition and Key Switch e KohlerEngines 24 690 07 Rev B Electrical System DSAI Ignition System This system uses dila microprocessor which i cated m lon modules milan Uming varies depending upon engine speed with this system There are 2 inductive styie ignition modules tnat conto ignition timing based on nine typical DSAI application consists of 1 magnet assembly which is permanently affixed to fywher 2 Inductive 12vol ton modules which mount on engine crankcase 4 volt battery which supplies currant to ignition modules 1 1 di switch or key swich which grounds spark advance module to stop engine geben
8. pan leaving ines attached Remove screws mounting al cooler to bower Tusing Remove cooler Ines and fiter adapter as an assembly Remove Mutfler Remove exhaust system and attaching hardware fram engine On engines equipped with a port liner remove it Remove Air yer Assembly Lowrolile and Commercial Mower Air Cleaners 1 Unhook latches located on either side of air cleaner cover or loosen cover retaining knob and remove 2 Remove wing nut from element cover Remove element cover element and precleaner 4 Remove nuts securing spilback cup baffle or bracket and air cleaner base Additional lower Screws must bo removed if engine contains a lower air cleaner support bracket 5 Disconnect breather lube from nipple on underside or hose from base as equipped 6 Remove base and gasket while carefully pulling rubber breather tube tough base KohlerEngines com Gasoline is exremely lammabla and fs vapors can Sure oniy m approved Containers n well ventlated unoceupied bulkinos away sparks or fames Spiled fal could ignite fit comes in contact wit hot parts or sparks from ignifon Never use gasoline a a cleaning agent 1 Disconnect fuel ines at carburetor and at in line fuel fier Disconnect pulse vacuum hose from crankcase 3 Remove mounting screws from blowar housing and remove fuel pump and lines as an assembly
9. m KohlerEngines com obtained Otherwise heat from en threads may cause compound to SS SP prematurely Studs closest to liters must have an exposed hight 7 mm 2 15716 i Studs furthest fom ters must have an exposed height of 66 mm 2 3 4 m y lt Remove nuts and repeat procedure as required 4 Check that dowel pins are in place and instal a new finder head gasket printing 5 Instali cylinder head Match numbers on cylinder bade crankcase Maka sure head is hat on Gasket and dovel pin 6 Ughty lubricate exposed upper reads of stude wh engine ol Insal a fat washer and nut onto Sach mourning stud Torque hax nuis Y stages fist 16 Nim 150 in b then foal lo 339 N m S00 I folowing sequence shown Install Push Rods and Rocker Arms NOTE Push rods should always be same postion as olore dizatsembiy Nota mark or tag identiving push rod as either intake or exhaust and cylinder 1 or 2 Dip ends of push rads P engine of nd nsa making sure that ach push rod bal seats in ts hydraulic ter socket 2 Applygrease to contact surfaces of rocker arms and rocker arm pivots Instali rocker arms and rocker arm parois on one cylinder nead and str screws Torque screws to 11 3 Nm 100 in Ib Use a spanner wrench or rockar arm liting tool to if rocker arms and poston push rods underneath 5 Repeat above steps for remaining cylinder Do not parte rom cyinder tease 6
10. 7 Poston drive plate over paws with actuating ears own and inside of pawie ii 3 Apply a small amount of Loctite 271 to threads of Center screw Install center screw with washer Tora serew to 7 4 8 Nm 08 75 in lb 9 Remove clamp and pull starter rope out way to Check operation of pawis Install Starter 1 Install retractable starter onto Blower housing leaving crews slightly loose 2 Pull starter handle out until pawls engage in drive cup Hold handie in this position and tighten screws Securely 5 KohlerEngines com 24 690 07 Rev B Disassembly Inspection and Service E warning Accidental Sas can cause sevara Tur Before working on engine or equipment disable engine as fica ia Sar WY Jis 1 Disconnect spark pog leads 2 Disconnect Disconnect and ground spark plug lead s ay cable tor Hoy tare saving External Engine Components P e a X G Ta senum Farm 5 p esempi Suter baa F G merae al ore om 1 wor Fr s 24 69007 Rev B KohlerEngines com isassembly Inspection and Service Spur tae es dee mam ti ener ons ee ee a Zio qum Ee E Disconnect Spark Plug Leads NOTE Pull on boot only fo prevent damage to spark plug lead 4 Disconnect leads from spark plugs 2 Shutoff ue
11. 72984 mm 76985 79979mm 2872 30302 28734 30309 31488 in Max Waar Uma 72839 mm 76840 mm 79 831 mm 82841mm 326140J 28677 30252 31430 Piston Trews Face i Cyimdar Bore Running New 0021 0001 0 045 mm O Smm 0057 mm 0 062mm 0039000180 000091 0 00087 00008 010026 00022 000240 Valves and Valve Liters Hydraulic Valve Lifter to Cranicase Running Clearance mm 0 0008 0 0020 i lake Valve Stunt Valve Gide Running Jearance O038 0 076 mm 0 007870 0030 n Exhaust Valve Siamo Valve Guide Running Clearance 0 0500 088 mm 0 0020 0 0035 n make Valve Guide TD New Max Wear Limit 7 038 1 058 mm B 2771 0 2779 in 7 134 mm 0 2809 in Exhaust Valve Guide TD New T 038 7 058 mm 0 27740 2779 in Wear Limit 7 159 mm 02281910 Valve Guide Reamer Size Standard 1048 mm 02775 n 025 mm O S 7 298 mm 02873 lake Valve Minimum Lit 807 mm 03177 in Exhaust Valve Minimum Lif 807 mm 0 3177 i Nominal Valve Seat Angle 357 Values are in Metric units Values in parentheses are English equivalents Measure 6 mm 0 24 in above bottom of piston skirt at right angles to piston pin 24 69007 Rev B KohlerEngines com Specifications GENERAL TORQUE VALUES English Fastener Torque Recommendations for Standard Applications
12. Flywheel N Washer 0 Support KohlerEngines com 7s Reassembly Install Stator and Backing Plates Install Fan and Debris Screen 1 Apply pipe sealant with Teflon PST 50277 Thread Sealant or equivalent to stator mounting 2 Position stator aligning mounting holes so that leads are at bottom iawards crankcase 3 Install and torque screws to 62 Nm 55 In b 4 Route stator leads in crankcase channel then install packing plates and stator wire bracket f used Secure vith screws Torque screws to 7 3 Nm 65 n lo Install Flywheel NOTE Fosilon locating tabs back of Tan In recesses of yee 1 Instali fan onto flywheel using screws engines with plastic debris sereen 2 Torque screws to 9 9 N m 88 in b 3 engine has plastic debris screen snap screen rto lan Due to posible damage to posie dunna removal instali retainers diferent posts rom Which thay were removed Start relanars by hand Then push thom down with a 13 mm 1 2 socket until hey loc I engine has metal screen I wil be stalled iater Install Supports for Metal Debris Screen cause personal injury 5 Using improper procedures can Tead To broken fragments Broken fragments could be thrown from engine Always observe and use precautions and caution Damaging Crankshaft and Fiywhaal can procedures when Installing fywheol NOTE Before installing fywheel make sure cr
13. acun aicun Gr Capaciy TELL TTS US 4 Hamam Angie of Operation G i ov evel TORQUE SPECIFICATIONS CVOSCVT CV750 C CV740 CV620 CV640 Blower Housing and Sheet Metal VS Fasteners E By io new holes AG Nm 35 n into used holes LI TOT Nm 95 n b ino new holes T Nm 65 nib nto used holes Carburetor and intake Manifold take Manifold Mounting Fastener i Taio TAN BET BY E incromentz finaly to 9 Nr 88 018 Carburetor haunting Nur Connecting Rod Cap Fastener torque B mm sight shank d 227 Nm 200 in lb mm slap don 147 Nm 130 mm straight shank 145 Nm 100 n 2 Values are in Metric units Values in parentheses are Engl Exceeding maximum angle of operation may cause engin Lubricate threads with engine oll prior to assembly lish equivalents e damage from insufficient lubrication Any and horsepower hp references by Kohler are Card Power Ratings and per SAE 11940 amp 41995 hy andar Delais on Cari Power Rats can be fund al Konare ngres com KohlerEngines com 24 690 07 Rev Specifications TORQUE SPECIFICATIONS CViBCV2 CV22CV2N eve C Crankcase Breather C
14. 4 Ifyou get a sign instead of numerical sequence andlor an F at end of test cycle recheck all Connections check condition of tester battery and repeat test l you get or F sign again in retest replace SAM BATTERY CHARGING SYSTEM NOTE Observe following guidelines to avoid damage to etna system and components Make sure battery polaris correct A negative Ground system is use e Disconnect rectiler zegulator plug andlor wein ames pug before doing any else welding on equipment powered by engine Disconnect al other lucite accossones n common ground win enge Prevent stator AC leads from touching or shorting Wle engine running Ths could damage Stator Most engines are equipped witha 15 or 20 amp regulated charging system Some have a 25 amp regulated charging system Some engines utlize a 3 amp unregulated System wth optional 70 watt ighting 24 690 07 Rev B 18 20 25 Amp Regulated Charging System Electrical System Stator Stator is mounted on crankcase behind flywheel Follow procedures in Disassembly and Reassembly if stator replacement necessary Roctifor Rogulator NOTE When installing rectifer regulator take note of terminal markings and install plug s accordingly NOTE Disconnect electrical connections attached to rect regulator Testing may be performed with rectifier regulator mounted or loose Repeat applicable test procedure 2 or 3 times to
15. spet combustion hater fom sources such as glowing carbon deposits tacked cooing ins an impropaty seated valo rong spark Replacement pistons are avaliable in STD bore size and 0 28 mm 0010 n and 150 nm 0 020 nj oversize Replacement peste dude new pato nj and t piston pr Replacement ing sts are also avalablaseparaaly for STD 025 mm 0 010 n and 0 50 mm 0 020 arat pistons Aways usa now pison rings when pistons Never use ol ig Some important points to remember when servicing paien ee 1 Cynder bore must be before service ring Ea 2 leider bore does nol need rebodng and ott Bon is win wear mte and tree of toe or scu cid piston may be reused 3 Remove od ings and clean up grooves Never Batore instaling new ings on piston place top 2 Tinga bach tim n ks emin area o Aden and check erid gap Compare rig Gap o ananas iatea in Speciale 5 Ater instaling new compression and middle Pigs on pistan check tonc i side clearance Compare clearance fo tolerances fsted in sro carae e grenier than a new piston must be used To instal new piston rings proceed as folows 1 Ol conti ring potom groove instali expander and San rata Hold ode oi apandar a net 2 compression ting center groove istat tg a pei Anp loo Make Sure dendhcaon marks up or ye colored simpe r naa le
16. 227 Nm 00n Ib C Emm Svaight Shank T3 Nm 00m NOTE are numbered on crankcase Make Sure to instali piston connecting rod and end int ts appropriate cyinder bore as Previously marked at disassembly De not mix nd caps and connecting rods Proper orientation of pistoniconnecting rod assembles inside engine is extremely imporlant improper orientation can cause extensive wear ar damage Bo certain pistons and connecting ods are assembled exacly as Shown NOTE Align chamfer of connecting rod with chamfer of its mating end cap When installed fat faces of connecting rods should face each other Faces Wi raised rio should be toward outside 1 Stagger piston rings in grooves unti end gaps are T20 apart Ol ring shoud also be staggered 2 Lubricate cinder bore piston nd piston tags with engine oil Compress rings using a piston ng compressor 3 Lubricate crankshaft journals and connecting rod bearing surfaces with engine oll NOTE 24 69007 Rev B T Instal shim removed during disassembly onto camshaft T 2 2 Position camshaft end play checking tool on camshaft 3 Apply pressure on camshaft end play checking tool pushing camshaft toward crankshaft Use feeler Gauge to measure end play between shim Spacer and checking tool Camshaft end play should be 0 076 0 127 mm 0 003 0 005 in I camshaft end play is not within specified rango remove
17. 24 690 07 Rev Remove Throttle Controls Control Panel Components Disassembly Inspection and Service Remove External Governor Controls Loosen nut and remove governor lever fom cross shall Leave lever attached to linkage Remove Carburetor A WARNING Do not fil fuel tank while engine is hot or running Gasoline is extremely Nammable and Ts vapors car explode if ignited Store gasoline onlin approved Containers in weil ventlated unoccupied buildings away from sparks or lames Spilled fuel could ignita i comas in contact with hot parts sparks from ignition Never use gasoline as a cleaning agent Disconnect fuel shut off solenoid lead if equipped 2 Remove carburetor mounting nuts 3 Remove carburetor throtle linkage and governor lover as an assembly 4 Remove carburetor gasket 5 If necessary carburetor throttle linkage and governor lever can be separated Reallach bushings linkage folowing separation to avoid losing them Remove Electric Starter Motor 3 Disconnect leads from starter 2 Remove screws 3 Remove starter assembly and it bracket Some inertia drive starters use a separato stator cover and spacers Remove Outer Batfles and Blower Housing Nur Lock Nur C FatWashar D Convoi Bracket E Carburetor F Ar Cleaner Gasket G GovernarLaver Gavernor Spring 1 Trote Shat 4 Bracket m
18. Backend A Oii Pressure Switch Green Ol c take Mano D Black en nama insta Mania wa Res G Shan Bae H ae ea een 2 opie Sater Wii Recife Fagas m ac oni oaas Roctter Regulator Oi Sey Pus ara gen Pusa Violeta Lead R StrterAssemby S EE T en T Fus V Sarr Soon Tang W Sono Sus X Bus V hr Te Z Yolon AK Rod SRT Power AR We DST KT AG Sorote Grama ake Nani Screw Blok Grundy aw SUSE Pa orsoni Comedie geo Koy Sch Acesuy Batey se an S ENS US an An Buomea a S ETT AS Banery Postive AT SatenNeoawe au Come Suppled ay Relay Sua 24 690 07 Rev B KohlerEnginos Electrical System Wiring Diagram 3 Amp Unregulated Battery Charging System 70 Watt Lighting 0 2 1 ZE EG a seriy Suen 12vBatey sery swen o e EY Shutdown Indical r Light F coun e BEES optonarruse a Red e soa W mI Sar Yt P oe a omae S span Puois T anton Modus Electronic Ignition Systems Tests NOTE lonton tester must be used to Test rion on thasa engines Use any olhar taster can result p findi
19. Be sure sealing surfaces of crankcase and breather cover aro clean of old gasket material or RTV Salant Do not scrape surfaces as this could result n leakage 2 Check to make sure there are no nicks or burrs on Sealing surfaces 3 Position breather gasket and cover on crankcase insta fest screws n locations 3 and 4 as shown Finger tighten at his tme 4 install iner using remaining screws and finger tighten Do not torque screws al tnis Ume the Wil be tighlaned after blower housing and oler Dats are installed Install Blower Housing and Outer Baffles Wires on Starter Side of Engine KohlerEngines com 7 Reassembly NOTE Da nat completa aro instalod to al Tighten screws uni all Tama hing lor hole alignment 1 Pull wire harness and spark plug leads out through appropriate openings in shuding 2 Side blower housing into postion over front edge of inner baffles Start a few of screws lo hold Lin place 3 Posion outer bales and secure using screws wo dong wo short n front maunting holes nto cylnder head including any Ming strap or attached brackets Install wo shori screws in upper mounting holes of outer batles nio backing plates Usa short screw on llt side to mount wire bracket Be sure any leads are routed out rough rope or notches so hoy wil not be pinched Betoun bower housing and bales 4 Tighten all shrouding fasteners Torque blower
20. Is necessary Tor performing each of individual tests Internal damage to solenoid may occur Disconnect leads from solenoid including positive brush lead attached lo lower stud terminal Remove mounting hardware and separate solenoid from starter for testing To test solenoid pullin coliplunger Actuation d Use a 12 volt power supply and 2 test leads 2 Connect 1 lead to flat spade Sistar terminal on solenoid Momentarily connect other lead to lower large post terminal When connection is made solenoid should energize audible cick and plunger retract Repeat test Several umes Continuity 1 Use an ohmmeter set to audible or Rx2K scale and connect 2 ohmmater leads 2 large post terminals 2 Perform solenoid pullin coliplunger actuation test and check for continuity Ohmmeter should indicate Continuity Repeat test several times Condition To test solenoid holdin coi Function 4 Connecta 12 volt test lead to fat spade S start terminal on solenoid and other lead to body or mounting surface of solenoid Manually push plunger IN and check if col holds plunger retracted Do not allow test leads to remain Connected to solenoid for prolonged period of ime Continuity d Use an ohmmeter set to audible or Rx2K scale and connect 2 ohmmeler leads to 2 large post terminals 2 Perform preceding solenoid hold in function test and check for continuity Meter shouid indicate Continuity Repeat test several
21. Nm 49 79 m Ir Muning Screw 35 BT Brush Holder mooning Screw Delco Remy Z533Nm 2229 Ib Stator Mounting Screw I SAN EET Valve Cover Gasket Style Cover Fastener BT Black O ing Style Cover With shoulder screws 58 Nm Sin Ib With lange screws and spacers 88 Nim B8 n lb allow or Brown O ring Style Cover With integral metal spacers 62 Nm 55 n ib CLEARANCE SPECIFICATIONS CVi7 CV22 CV23 CVZSICVT30 CV750 GV22 CV670 CV6Bo CV740 cv620 cv640 Camshaft End Play with shim DO78 0 127 mm 01003070 0080 in Running Clearance 0025 0063 mm 0 0010 0 0025 in Bore LD Now Max Wear Limit 20 00020 895 mm 078740 7884 in 0058 mm OBS Bearing Surface OD New Max Wear Limit 19 906213 975 mm 0 T859 0 7864 in 19 959 mm 0 7858 in Connecting Rod Connecting Running Clearance New Max Wear Limit 0 030 0 055 mm 000120 0022 in 0 070 mm 0 0028 in Connecting Rod to Crankpin Side Clearance 128 063 mm 0 0102 0 0248 mn Connecting Rod to Pislon Pin Running Clearance 6 015 0 028 mm 0 0006 0 011 in Piston Pin End TD Now Max Wear Limit 17 015 17 023 mm 0 6699 0 6702 in 17036 mm 0 6707 in Values are in Metti units Values in parentheses ar Lubricate threads with engine oil prior to assembly 10 KohlerEngines com we English equivalents 24 690 07 Rev B Specifications
22. P pass or F 80 Do nat release taste button uni test cycle completes and display goes of If you get a 9 sign instead of numerical sequence Andjar an F at end of cycle SAM is probably bad Recheck all connections check condition of battory and repeal est I you qe sign dior agai i reest repiace that 3 Disconnect yelow and brown este eads rom long module loads Connect brown tester ead to short brown module lead Connect yelow tester lead 19 short yellow or pink module lead Leave red and green leads connected Repeat stop 2 To test DSAM and ASAM using 25 761 40 S tester NOTE Do not allow aligator cip leads to touch each ober NOTE SAM must be at room temperature when tested Disconnect al SAN loads tt Irom main wing hamess and ignition module s Testing may Be performed with module mound or ese NOTE Some modules contain two black ground leads Win one containing a white stripe Do not Connect to black while lead with bullet connector ora Fal test result wil occur regardless of actual condition Test procedure for twin cylinder SAMs will vary slight depending on whether modules analog ASAM or digital DSAM 1 Chock SAM part number stamped on end of fusing fitis an ASAM 24 584 09 or 24 584 10 Separate short Yellow and brown leads fom long es Each sot wil bo tested separately Connect aster to SAM as follow 4 KohlorEnginos Yalow tester lead to long yellow m
23. Recifier Regulator Testor 240 V 2 Kohler 25 761 41 8 Digital VacuumvPressure Tester Design Technology nc For checking crankcase vacuum DTL21 01 individual componant Design Technology Inc uber Adapter Plug MAREM Electronic Fuel Injection EF Diagnostic Software Kahler 25761 275 For Laptop or Desktop PC EFI Service Kit 76T0T5 Far woubleshooting and seting up an EFI engine Components ot 24761 01 8 P Design Technology nc Fue Pressure Tester DII Nod Light bna 90 Adaptor DTi023 Inine Fin put Coco Plug Rod Wire brio Code Plug Blue Wie put Shrador Vaive Adapter Hose bras Fiywhesi Holding Toot CS SE Tools KR GOT For fywhoo of CS series engines Flywheel Puller SE Toots KR GOS For property removing trom engine Fiywheei Strap Wrench SE Tools KIRA For holding fy i during removal 24 690 07 Rev KohlerEnginos com 15 Tools and Aids TooLs Description Source Part No Hydraulic Valve Lifter Tool For removing and Installing hydraulic ters Kohler 25 761 38 5 Ignition System Tester For testing output on all systems including CD Kater 25455075 Inductive Tachometer Digital For checking operating speed RPM of an engine Design Technology ne reno Offset Wrench K and M Series For removing and reinstaling cyinder barrel retaining nuts Kohler 52455045 Oil Pressure Tes
24. Va rav pido is wom beyond specications t wil not dde a fra sought THe may resa i bum cas or seata doss f compression and excessive qawa To check valve guide to ave stem clearance dea vaiva and vong a s bat Thun Soie morat meme damals clvave san Motte Pire m di efr ee vto aide tage som dlametor to cce Situato dum damale tom daria V Hae 0 680 076 O 01570 030 i ecastaus Gasrance 050 008 mm a diae whether ave et or hide reponse for excessive coran Maximum Lb wear on make ue s 7 194 mm TR m 021 maim loved on exhaust gude Guides ar removable but an be roamed 025 mm oversize Vaives MA eomm veri tme at ho beue I guides are within nis but valve stems are worn Bayona mts nia new valve Valve Sent Inserts Hod aloy intake and exhaust valve sat inert are pros td to cinder head nears we lad qeata Maced er badly warped inde Sout te replace Recondton valve seat insat flowing instucions eater Dau d E be made wi an 9 cuter spacifed Tor Sae teat angle Cuina proper 4 value ace ong weet ond prope aha sel angle 0452 af of T B angle wil acevo costed 6 0 ul ca feria gle sare astro Goat o tilda medi of vao lace and oat 24 69007 Rev B Disassembly Inspection and Service Lapping Valves Mota ar new valves must be lapped in to provide proper ft Use a hand va
25. With engine running in fast seting measure voltage lighting lead 18 ground using an AC vollmeter Condition Vaage is 15 volts or Conclusion Stator is OK Check Tor connections or shorts in wiring hamess Test stator using an ohmmetar Voltage is less than 15 vons 3 With engine stopped measure resistance of stator engine stopped measure resistance from charging Jead to ground using an ohmmeler Note reading Reverse leads and measure resistance again In one direction resistance should be infinity ohms open Wih leads reversed some resistance should be measured about midscale on Rx range Condition Conclusion Resistance is low In boih Dode is shorted Replace recton ede Resistance s high in both Diode or stator winding is directions open Continue testing 4 Cut slaeving on charging lead to expose diode connections Measure resistance from stator side of diode to ground using an ohmmeter Condition Resistance approximately 1 07 ohms Conclusion Stator winding is diode is open Replace diode Stator winding is shorted Replace stator Stator winding of lead is open Replace stator Resistance s 0 ohms Resistance miniy ohms 24 690 07 Rev across stator leads using an AC voltmeter from lighting lead to ground using an ohmmeter Condition Conclusion Condition Conclusion Voltage l
26. atop dead center TDC of compression stroke Hold engin hs posito wie sing Holding ot supple wih tester can be use and cristal accessible Lock holding tool onto crant instal a 3 8 in breaker bar into of holding tool so i Perpendicular to bot holding tool and crankshaft PTO f fiyheel end more accessible use a breaker bar and socket on fywheal nutiscrew ta hold Itin postion An assistant may be needed to hold breaker bar during testing l engine ts mounted in a place of equipment i may possible t hold it by clamping or wedging a driven component Just be certain thal engine cannot rotate of ot TOC in either direction 4 Install adapter into spark plug hole but do not attach it to tester at this time 5 Tum regulator knob completely counterciockwise 8 Connect an al source of at least 50 psi to tester T Tum regulator knob clockwise increase direction until gauge needle is in yellow sat area at low end of scale 8 Connect tester quck connact to adapter hose While frmiy holding engine at gradually open tester valve Noto gauge reading and listen for escaping air at combustion air intake exhaust outlet and crankcase breather Condition Conclusion Ar escaping fom crankcase breather Ring or cylinder wor Air escaping from exhaust system Defective exhaust valvelmproper sealing Air escaping from intake Defective intake valvofmproper saating Gauge reading in low green zona Pist
27. check a be cartam that ol Pressure 20 psi or more s present Run engine at ae for 2 3 minutes then 5 6 minutos more between lie and midrange Adjust carburetor mixture setings necessary as avaiable 2 Adjust idle speed screw and high speed stop as necessary Mako sure maximum engine speed does not exceed 3750 RPM no load 24 69007 Rev B KohlerEngines com Reassembly KohlerEngines 24690 07 Rev 24 690 07 Rev B KohlerEngines a III 1 24 690 07 WWW 2011 by Kohler Co Al rights reserved 50531 99105 KohlorEnginos 24 690 07 Rev B
28. connected including spark plug leads Be cortan all Terminal connections ft snugly Make sure Ignition wich isin run postion KohierEngines com Electrical System Wiring Diagram 15 20 25 Amp Regulated Battery Charging System with Fixed Timing KohlerEnginos 24 690 07 Rev B Fixed Ignition System Electrical System This system uses a capaclive discharge CD col Ignition ting and spark remains constant regardless of engine speed Timing of spark is controlled by location of flywheel magnet group as referenced to engine TOC A typical fixed ignition system consists of 2 spark plugs 1 magnet assembly which is permanently affixed to flywheel 2 blogroniecapactive dlacharge ignition modules which mount on engine crankcase 1 kil site or kay switch which grounds modules to stop engine A Spark 5 GrmesusSsc GE Gm D CE Ties Sr Nani y ROGER s Assembly E kion Medis Ignition Connector 1 meets K voias i Soemd Si Sarar LBER TRT LS Sar Send TST 0 Fus T Ss a KI R wie s Velev u omo v Ra W came x carrear saraa EPP Y Black Ground Z Manifold Screw AA Black AB Light
29. determine condition of part Rectlfer rogulator is mounted on blower housing To replace IL disconnect plug s remove mounting screws and ground wire o metal grounding strap Testing of rectfier regulator may be performed as follows using appropriate Rectifier Regulator Tester To test 4 15 amp rector regulators 1 Connect tester ground lead with spring clamp to of recta regulate Belnd siad nn 2 Connect tester red lead to B terminal ol regulator and 2 black lester leads to 2 AC terminals Plug taster into proper AC outltpower or tester being used Tur on power switch POWER light Should be f uminatad and 1 of 4 situs may be n as wal This does nol represent condita of Part 4 amp Press TEST button unti click is heard and en aleasa Momentary ether HIGH LOW SHORT hgh wit lash 18 amp Press TEST bution unti a cick is heard and thon release Momentariy 1 ol 4 status wil minat indicating condition ol par Condition To ost 20 25 amp rectfler regulalors i 20 amp Connect single lead adapter between B canter terminal ol being tasted Sind squared single end of tandem acaplar lead 25 amp Connect squared single end of tandem lead adapter to B centered lead of ecifrzeguiator Boing tested 2 Connect tester ground lead wih spring clamp to body of rectllor regulalox 3 Connect red lead and 1 black lead to pair of terminais on open end of landem adap
30. er lt Saai nase toon nae crece Genapap or dt EUH USE DEP DEDE fete ed Tesora ae nd m o n o tire Sy sen a tte es ates ora A DNE Eco Sint i eeu a er CHN racer gna aoe cote eh sacs ins farts O toi E pe aton nan nto op dy prato ny race ad Tamaa ees it ere rE 24 690 07 Rev B KohlerEnginos 43 Electrical System To test ASAM only using 25 761 21 8 tester NOTE SAM must be at room temperatura when tested Disconnect al SAM leads oiling t from main wing hamess and ignition module s Testing may performed with module mounied or ese NOTE Do not allow aligator cip leads to touch each ober 1 Connect tester to SAM by attaching Yellow tester lead to long yellow modulo lead b Brown teste lead to long brown module lead Red toster lead to red modulo lead d Green tester lead to green module lead 2 Chock SAM part number stamped on side of housing Very that you have an analog Part No 24584 10 or lower not a ial SAM DSAM Part No 24 584 18 and higher Follow ubapa for iesting an ASAM wih his eso Digital SAM DSAM modules require Tester 25 761 40 5 for proper testing Depress tester button and hold t down Alar approximate four seconds numerical Sequence should be displayed beginning with 1 or 2 and continuing to or 9 followed by a
31. f equipped 6 install lower support control bracket f equipped with a control panel 7 Secure control panel to blower housing with screws f not equipped wih heavy du air leaner Assemble throtle control shaft o control bracket 3 Assemble choke control control bracket 3 Connect governor spring from throttle contro bracket to appropriate hole in governor laver as indicated in applicable chart Note that hole positons are Counted from pivot point of governor lever Governor Lever Hole Position 6 mm A Gewemerlaver B Gavermed idie Hole c D Hole 2 E Hole 3 F Hole 4 Hole 5 H Hole 6 mm Governor Lever and Hole Position RPM Chart onnect Oil Sentry Indicator light wires Attac High idle Governor Lever Governor ovaro spring ta Govern lever Se appropriate RPM Hole No PE TIT 5 Car Install Throttle and Choke Controls 3601 3800 E Throttle and Choke Components 4 Clear Clear 5 Pune 4 Purple 2800 2950 3 Purple 3750 z Car 3150 4 A creier s Tone Gomme Thot Actuator c le Ac D Lecknut E Choke Ratum Spring F 8 0 H Wave Washer 1 Screw 1 Carburetor Models Connect choke linkage to carburetor and choke actuator lever 2 Carburetor Models Install standard throttle c
32. folowing lems Valve spring keepers Valve spring retainers 1 valve springs 2 Valve spring caps intake and exhaust valves mark poston 1 Valve stom seal ake valve 4 Repeat above procedure for other cylinder head Do not interchange parts from 1 cylinder head to other Inspection and Service Valve Deals 1949 e INTAKE INSERT mE df y 77 Esa X Seating Ez E 3 leer OD TTT GET ETE TET ese LITE EXE 5 fede SST mn TOETS mn CATO Va Head Bitar 7868 mm SA i 1372859 SEAS F Vals Fae Angle a ra ae Margin i DELETE Tam GOTT H ate Siom Diemeer 02790 ZIER ETO mm O 27440 IER Aner sig check fatness al oyinder head and Hard staring ar loss af ome accompanied gh poro torpe in eanit LS e S RUN ee possc naat and epoca Hall Acct intestate res ep le lar d pasta ene oe Maymi Se ee EM inspect valve mechanism parts Inspect valve Glean valve heads faces and stems with a power wre Springs and elated hardware fr excessive wear or ua Check valves and valve seat area of Inserts Then carefuly inspect each valve for defects such as or evidence of deep piling cracks or distortion Check warped head excessive conosion or wor atem end Clearance of valve Stema Y guides ez KohlerEngines 24 690 07 Rev B Replace valves found to be in bad condition Valve Guides
33. housing screws to 62 N m 55 in b in a new hole ortos Nm 36 in b ma used Torque Shorter MS side Dalle serewe 10 4 D N m 38 n b Torque MS side patta screws no cylinder pead io S n b n a new hole or lo LON m 35 in Io n a used hole Torque twa lower MG mounting screws t 10 7 Nm 08 i Ib Jin a new hole orto 73 N m 85 n b in a used hole 5 If engine had a plastic debris screen that overaps Bower housing renga t now Torque mounting Screws to 4 0 m 36 Io Fora metal sereen only Locile 242 to screw threads and torque Efe to 9 9 N m 68 in I i 6 Torque four breather cover screws to 7 3 Nm 61n b n sequence shown Install Sentry if equipped 1 Apply pipe sealant with Teflon PST 50277 Thread Sealant or equivalent to Inreads of Oi Sanity switch and install t into breather cover Torque to 4 5 Nem 40 in lb 2 Connect wire lead green to Sentry terminal Install Control Panel equipped 1 Install panel lo blower housing 2 Connect throttle control shaft to throttle control bracket KohlerEngines com 3 Connect choke control cable to throtle control bracket 4 Connect Sentry indicator light wires Reconnect Rectifier Regulator T Install recor regulator in Bower housing T removed previously then connect recifer egulator ground lead with washer and silver screw through Eyelet grounding bracket is used securo
34. on piston is facing towards shoe side o engin Use a hammer wih a rubber and gent tap piston inio ker Be cant ling rale do net spring fee between botom ol ing compressor and top of cylinder 5 Install imer rod cap to connecting rod using screws Three diferent types of connecting rod bot have been used and daen has GOON iorque value mm straight shank bai are use torque in to 22 7 Nm 200 i b mm Sep down bolts aro used torque in increments to 14 7 Nim 30 nl I E mm straight shan bots are tad oue coment ia 113 Nm 00 isroted instructions are povided in seria od package 6 Repeat above procedure for other connecting rod and piston assembly Install Camshaft Connecting Rod Bolt Details T Liberally apply camshaniubricantio sach cam abe Libres cam baring sucer ol crankcase and camshaft wih engine ol 2 Postion timing mark of crankshaft gear at 12 o clock postion 3 Tum govemorcross shaft clockwise unti lower end cot shaft contacts cylinder Make sure cross shaft remains i this postion wie instling camshaft 4 Slide camshaft into bearing surface of crankcase positioning timing mark of camshaft goar at 6 o clock postion sure camshaft gear and crankshaft Sear mosh with both ming marks aligned Determining Camshaft End Play Type A mm Straight Shank B 147 Nm 130 Torque
35. tab thrust washer located under governor gear assembly 3 Carefully inspect governor gear shalt and replace it oriy fit damaged Ahar removing damaged shall press or gh tap replacement shaft ino a pan io apih shown Reassombly T Instat locking tab thrust washer on governor gear shaft wih tab down 2 Position regulating pin within governor gearflyweight assembly and side both onto Governor shal 2469007 Rev B Oil Pump Assembly Disassembly Inspection and Service Remove Governor Cross Shaft Ol pump is mounted inside o pan I service required refer to Disassembly Inspection and Reassembly procedures below Disassembly Te Remove screws 2 Remove ol pump assembly rom pan 3 Remove pump rotor aplastic pickup is used unhook locking and carefully pul fae from oll pump housing M relief valve is ike that shown drive pin to remove al pressure relief val piston and spring Refer to folowing inspection and reassembly procedures it reat valve is a one piece style staked to ol pump housing removal shouid nol be altempted nor i intemal Servicing possible problem wih raat valve is encountered oll pump should be replaced Inspection Inspect ol pump housing gear and rotars for nicks burre wear or any visible damage If any parts ara wom or damaged replace ol pump inspect oil pressure relief valve piston It should be frae Of meka or burrs l Check spring for wear or distortion
36. where her mixing ot ual and air occurs This mixture i then delivered to combustion chamber Carburetor has fud main crc no adjustment is possible Carburetor Adjustments NOTE Carburetor adjustments should ba mado only after engine has warmed up Carburetor is designed to deliver correct fualo air fixture to engine under al operating conditons Main fel et s calbrate at factory and s nol adjustable lale fuel adjusting needles are also set at factory and normaly do no heed adjustment Low idie Speed RPM Adjustment NOTE Actual low idla speed depends on application Refer to equipment mandlacturer e recommandations Low ile Speed for basic engines 1200 RPM Place throne control nto idle or slow position Turn low Ke speed adjusting screw or out to obtain allow ile Speed of 1200 RPM 2 78 RPM Governed idle Speed Adjustment equi fold govern tever stay rom carer so vote ever against ile speed RPM adjustment screw Of carburetor Start engine and allow lo warm ii hen adjust screw to st approximately 1200 Check speed using a acometer Tum agusent Screw nar diockwise i l increase or Counterclockwise to decrease speed 24 690 07 Rev B Fuel System 2 Release governor lever and check that throttle lever is in de positon Tum governed idle adjustment Screw to obtain equipment manufacturer s recommended idle speed 1500 1800 RPM Some engines have a bendable tab that is used to set this s
37. 1 24 69007 Rev B Disassembly Inspection and Service KohlerEngines com n Reassembly Breather Oll Pan OIl ReservoltiPiston Components pn hor PDT porc matt co te Install Flywheel End Oil Seat 1 Make sure seal bore of crankcase s lean and Tree cof any nicks or burrs 2 Apply a light coat of engine oll to outside diameter of ol seal 3 Drive oll seal into crankcase using a seal driver Make sure seal is installed straight and true in bore and tool bottoms against crankcase Install Governor Cross Shatt 1 Lubricate governor cross shall bearing surtaces n crankcase wih engine oi 2 Side smal lower washer onto governor cross shaft and instat cross salt Fom Isida of crankcase 3 8mm governor shaft Install plain washer and then ser Rich pin into smaler Lower hole of governor ross shall 8 mm govemor shaft Instali nylon washer onto governor cross salt then stat push on retaining fng Hold rose shafi up n position place 050 mm 0 020 in j feeler gauge on lop of nylon washer push retaining Tn down shah o secure Remove feeler gauge which wll have established e ar E Retainer m KohlerEngines 24 690 07 Rev Install Connecting Rods with Pistons and Rings Piston and Connecting Rod Details A Ovinderi B Gyinder Reassembly Make sure Fly stamping
38. 2 Intertock suh engaged or fauly 2 Key swich or kil swich in OFF positon Lowi level aly of fu din water stale mixture 1 SMART SPARIC malfuicion 1 Spark plug lead disconnected Engine Starts But Does Not Keep Running Battery is discharged Faulty electric starter or solenoid Faulty key switch or ignition switch Interlock switch is engaged or faulty Loose wires or connections that intermittentiy ground ignition kil circuit Bawis not engaging in drive cup Seized internal engine components Engine Runs But Misses EL EXT Faulty spark plug s pr E e HC eL C em Kr wm tee Engine Will Not idie carburetor 1 Faulty cyinder head gasket 5 Fauly of misacusted ehoks or throttle conto 2 Fuel pump malluncton vacuum hose clogged or akin intake System leak Loose wres or connections that intermitentiy ground ignition kilt circuit Salty of tuel dirt water stale misture 2 Resmaeo ful tank vent Engine Starts Har x Clogged Tuel ine or Tal ir 5 Ente overheated 1 Faulty ACR mechanism 5 Fauly or misaqhusted Choke o throttle controls Faulty spark plas Frye kay sheared Fal pump maifuncton vacuum hose clogged or leaking Interlock swch is engaged o faulty Loose wires or connections that inlemitenty ground onion kil circuit Low compression of fus d water stale mitur 2 Weak spark 18 KohlerEnginos d Hire e
39. 690 07 Rev B KohlerEnginos Electrical System Test Ignition Modules and Connections Smart Ignition Modulo Resistance Table ark only modules may have higher resistance unli they 24 584 11 24 584 36 5 e 1 11 16 in High 2 1 16 in High Meo c E fressen terr to ee ps wera 2 east lasia toni Pri nin pepe ttn yapa edere Ede PRU rete Vot tut flashlight and use a small round wire brush to Ohmmeter meter to check resistance values 16n olei Tee ae table When testing resistance to laminations touch 2 1 16 in H 1175 ohms 136 ohms 9000 ohms Exo D CMM CNN aie pol pct MEMET EISE ER Ren em rar a ep UNE ak ERE Condition Possible Cause 5 Check andor adjust ignition module air An alr gap of 028 0 33 mm 0 011 0 013 in must be maintained under ali three legs of ignition module s Chocking adjusting should be performed with parts at room temperature Conclusion Module was not loosened ar replaced ignition Modulo Air Gap Check that specified alr gap is present under al tee legs If gap is Correct reinstall second mounting screw removed earlier and recheck gap after tightening Module was loosened or replaced ignition Module Adjust ign
40. 7 Rev B A spanner wrench to If rocker arms orum crankshaft may be made out of an ad junk connecting rod 1 Find a used connecting rod from a 10 HP or larger engine Remove and discard rod 2 Remove studs of a Pos Lock rod or grind off Signing steps ol Command rod s0 Join surface is Tar 3 Find a 1 in long capserew with conve thread size to match threads in connecting rad Uso a fat washer with correct LD to slip on capsorew and approximately 1 In O D Assemble apscrow and washer l jolt surfaca of od Kohlerngines Troubleshooting TROUBLESHOOTING GUIDE When troubles occur be sure to check simple causas which at first may seem too obvious to be considered For example a staring problem could be caused by an empty fuel tank Some general common causes of engine troubles are listed below and vary by engine specification Use these to locate causing factors Engine Cranks But Will Not Start Engine Will Not Crank x Batlory connected backwards 2 Blown fuse 1 Carburetor solenoid malfunction 1 Choke not dosing 1 Clogged tuel ine tus tr 2 Diode n wring harness failed in open circuit mode 1 DSAI or DSAM maluncton Pe 2 Empty fuel tank 2 electron control unit Faulty ignition coil s Faulty spark plus 1 Fiel kump nallcion vacuum hose clogged or teak Fuel shut off valve closed lon module s faulty or improperly gapped Boutin vatago io lactate carbo ant
41. Courage Aegis Command Far Servicing wom valve guides SE Tools KUR 82415 AIDS Description Source Part No Camshaft Lubricant Valspar 22613 Kohler 25 357 14 5 Dielectric Grease GE Novaguard GEST Kohler 25357 11 5 Dielectric Grease Loc 81380 Kohler Electric Starter Drive Lubricant inertia Drive Kohler 52 357 015 Kohler Electric Starter Drive Lubricant Solenoid Shif Kohler 52357025 RTV Silicone Sealant Loctitee 5900 Heavy Body in 4 oz aerosol dispenser Only oxime based ai resistant RTV sealants such as those listed are approved far tse Loclte Nos 5900 or 5910 are recommended for best Sealing characiorisics Kohler 25 597 07 5 petite 5910 Loctite Ultra Black Soa Loctite Ultra Blue Sa7 Ultra Copper 5920 Spline Drive Lubricant Kohler 25 357 12 S 16 KohlerEngines com 24 69007 Rev B FLYWHEEL HOLDING TOOL Tools and Aids ROCKER ARM CRANKSHAFT TOOL holding tol can ba made aut of an old junk ng gear and used in placa of a trap wrench 1 Using an abrasive cutoff wheel cut out a six tooth segment of ring gear as shown 2 Grind off any burs or sharp edges 3 Invert segment and place it between ignition bosses crank Ease so tod teeth engage fywheel ing Gear tooth Bosses wil lock tool flywheel IY Postion for loosening tightening or removing with a puler 246900
42. E PATE waur ae ie Hes Ea atat TENE RC IE E EIS sram component dott restricted or leaking 98 e ND M c HS lng au Engin Knocks ai TM Mr Ee iu d DESEE Se 24690 07 Rev B Engine Loses Power Here Her EE a 9 EC E ASP sas Crane Uos Econ Amount OI baatar ris Hoi non ia O Leake ram O1 Sea Gn TS Bp Rata Hee 24 690 07 Rev B Troubleshooting EXTERNAL ENGINE INSPECTION NOTE It is good practice ta drain oil at a location away from workbench Be sure lo allow ample time for completo drainage Belore cleaning or disassembling engine make a horgugh inspection oft appearance and condition Tris inspection can give cies to what might be ound inside engines and cause when tis Chock for buldup of dirt and debris on crankcase fooling is gras screen and other external surfaces Dirt or debris on these andas causa overheating Check for obvious fuel and ol and damaged components Excessive ol leakage can indicate fogged or breather wom or damaged Seals or gaskets or loose fasteners hock aif cleaner cover and base for damage or indcalions of improper ft and seal Check ar cleaner element Look for holes tears acad or damaged sealing sacer ar cer that could allow unlitered air into engine A ey or clogged element could indicate insufficient or impr
43. FF Test several times to verify operation KohlerEngines com 24 690 07 Rev Carburetor Circuits Float Fuel level n bow is maintained by fat and fuel inlet needa Buoyant forca of float stops fual fow when engine at fest When fuel is consumed oat wit drop and fuel Pressure wil push niet needle away rom Seat allowing more fuel 1o enter bovi Wien demand oases buoyant force of loat wil again overcome fuel pressure riang to predetermined seting and stop low Slow and Mid Range speeds engine operates only on slow circuit motored amount of drawn through slow ai bleed fe fuet is drawn through main jet and luher metered through slow jt Air and luel mixed in body o slow el and ex to dia progression transfer chamber From ile progression chamber ar lel madure i metered trough fle passage At low idie fuel mixture i controlled by seting of id fuel adjusting This mixture thon mixed wiih main body of ir and delivered to engine As piate opening increases greater amounts of iua mixture are drawn In through fed and metered cla progression holes As tole plat opens futher vacuum signal becomes real enough at vanturi so main evel begins to work Main high speed At high speadailoads engine operates on main creuit As a motored amount of ari raw through alr jl tel is drawn through main jet Air and ful are mixed in main nozzles then enters main body of
44. Free ler Should te approximately 474 mm 1 in Spring f is distoned or worn Reassembly instal pressure relief valve piston and spring 2 Install ol pickup to ol pump body Lubricate O ing Wi and make sure it remains groove as Pickup is being installed Insta rotor Install ol pump body to pan and secure with screws Torque screws as ows install fastener into screw location 1 and lightly tighten to positon pump b install fastener into screw location 2 and fully torque to recommended value Torque fastener in screw location 1 to recommended value First Time instalation 107 95 in bb AlRemsalalon 6 7 Nm 80 in Ib 5 Alter torquing rotate gear and check for freedom of movement Hake sure thare 18 binding f binding Occurs loosen screws reposition pump rolorque crows and recheck movement of spring lepiace ten Gamat ae Sa rT mue 24 69007 Rev B T Remove hitch pin and plain washer or retainer and nylon washer from governor cross shaft 2 Remove cross shaft through inside of crankcase Governor Cross Shaft Seal 20 mm 00787 Governor Gross Shaft Seal M governor cross shaft seal is damaged andlor leaks replace it using folowing procedure Remove oll seal from crankcase and replace it with a v ona Install new seal to depth shown using seal Installer Remove Connecting Rods with Pis
45. KOHLER Command CV17 CV25 CV620 CV730 CV740 CV750 Service Manual IMPORTANT Read all safety precautions and instructions careful befare operating equipment Refert operating instruction of equipment tat this engine powers Ensure engine is stopped and level before performing any maintenance or service 2 Safety 3 Maintenance 5 Specifications 48 Tools and Aids 18 Troubleshooting 22 Air Cleanerlintake 23 Fuel System 29 Governor System 30 Lubrication System 32 Electical System 48 Startar System 57 Disassemblylnspection and Service 72 Reassembiy 24 69007 Rev B KohlerEngines com Safety SAFETY PRECAUTIONS WARNING CAUTION A hazard that could result in minor personal injury or property damage NOTE is used to notify people important installation operation or maintenance information hazard that could result in death serious Injury or substantial property damage caum on I WARNING lies and severe burns fy Do not tt fuel tank while engine is hot or running Explosive Fuel can cause ignited in conta Gasoline is extremely flammable and ts vapors can explode i Store gasoline oniy in approved containers n wel Vantiatad unoecupied Sway from sparks or fames Spies fue could ignite fit comes ict with hot parts or sparks from lgniton Naver usa gasoline as a cleaning agent WARNING E Accidental Starts can
46. Rotate crankshaft to check or ree operation of Cave bay Chock amanta beteh tae sping ate a ul it Minimum allowable clearance i D25 im 0 010 n Check Assembi Rotate crankshat a minimum of two revolutions to check longhlock assembly and overall proper operation Install Spark Plugs 1 Check gap using wira Tealer gauge Adjust gap to 0 76 mm 0 030 in 2 Install plug into cylinder head 3 Torque plug to 27 Nim 20 ft Ib Install ignition Modules T Rolate fywheol to postion magnet away Tom ignition module bosses 2 On engines equipped wih SMART SPARK both modules are saec simian wi tabs oui On engines not equipped with SMART SPARK modules are netaled with spark plug lead wire rom Modula always away from cyindar On cylinder T Single lab shouldbe awards you On cylnder 2 Single kil tab should be away from you n 24 69007 Rev B 3 Instan each Ignition modulo to crankcase bosses Win screws hex ange or allen head based on modal Side modules up as lar away from fywheel posable and enug screws 1o Pold then at postion Rotate fywheel to postion magnet drectiy under ioniton module 5 Insert a 0 30 mm 0 012 in at feeler gauge teen magnet and n module Screws enough allow magnat to pul module fale gauge Torque screws to 4 0 6 2 Nm 35 85 In I Repeat slaps 4 through 6 for other ignition module Rotate flywheel back and forth checking for Clearance between magne
47. Torque Sequence RTV sealants used as a gasket between pan and crankcase on CV17 23 engines CV25 750 engines Use 559 pan Rote ool and id fr ning approved sealants Aways use rsh sealant Using lad sealant can in leakage 1 sure sealing surfaces have been cleaned and Prepared 2 Check to make sure that there are no nicks or burs on sealing surfaces of l pan or crankcase 3 Apply a 1 5 mm 1 16 in bead of sealant to sealin dol on CV 723 engines C2 750 engines use new gasket Before instaling gasket heck dowel pin on t tor side of crankcase sit se dowel ain contained win a sed seam siyle pin provided wiih new gasket 4 Make sure end of govemor cross shall is lying against bottom of Eyinder 1 inside crankcase 24 690 07 Rev B 5 Install ol pan to crankcase Carefully seat camshaft and crankshaft nto ther mating bearings Rolate Crankshaft sighly o help engage pump and governor gear meshes 6 stall screws securing ll pan to crankcase Torque fasteners to 24 4 Nm 216 folowing a Sequence On some engines one mounting screw is fled ated Screw e ical stad i ie cation 24 69007 Rev B Reassembly FlywheelIgnition Components FwwhesScew B Debris Screen Supporting D Fan E Magnet F Stator G ignition Module H Sud T Screw 3 Key K Manifold L Backing Piate
48. a cleaning agent Nur 8 Lock Nur 1 Instal a new carburetor gasket Make sure all holes C FlatWasher D Control Bracket align and are open E Carburetor F ArCisaner Gasket 2 Install carburetor throttle linkage choke linkage and G Governor Laver Governor Spring governor lever as an assembly li plastic intake manifold is used and or carburetor is equipped wan 1 Trrome Shat Bracket a fuel solenoid reconnect ground and main leads x Bux L Tole M Linkage Spring N Throtie Linkage Carburetor Gasket P Choke Linkage Q Choke Lever Screw S roue Shaft Spring 24 69007 Rev B KohlerEnginos com m Reassembly Install External Governor Controls 1 Install governor lever onto governor cross shall 2 Make sure throtle linkage is connected to governor ever and rola lever On carburetor carburetor models Move control panel ito position on blower housing and connect choke linkage into bushinglavar rom backside ertain that control shaft ofset is back and towards Shinar sida 2 Connect voie inkage and spring 0 governor lever 3 Move governor lever toward carburetor as far as it wi go wide open vote and hold n positon Inserta nail into hole on cross shaft and rotate shaft Dunterclockwes as tar as iwi turn hen loque nut to 68 Nm 80 5 Reconnect lead wire to fuel shut off solenold
49. ace wires in poor condition and with frayed or broken insulation Starlar Swich By pass switch or solenoid wilt a jumper wire TT starter cranks or Solenoid normaly replace faulty components Remove and perform individual solenoid test procedure Starter energizes Bur ms Batay Check specific gravity of battery TF Tow recharge or replace slowly battery as necessary Brushes Chock for excessively dirty or wom brushes and commutator Clean using a coarse clot not emery cioth Replace brushes excessively or unevenly wor Transmission Make sure clutch or transmission is disengaged or placed or neutral This is especially important on equipment wit Engine hydrostatic drive Transmission must be exactly in neutral to prevent resistance which could Keep engine fom starting Check for seized engine components such as bearings connecting rod and piston 48 KohlerEngines com 24 690 07 Rev B INERTIA DRIVE ELECTRIC STARTERS Inertia Drive Starter Components Silo style A AJ Dece Stop Nur C Siep Gear Spacer D Ant Drift Spring E Dust Cover Spacer F Drive Pinion G Retaining Ring H Spring Retainer T Drive Nut Collar Wan power ts applied to Starter armature rotates As Armature rotates Grive pinion moves out on drive shalt Splines and into mesh wih ring gear When Son reaches end of drive ea raids hyo and ranks engine
50. ai piston and connecting rad can Toused after new ings are installed orginal pin can also o roused but new piston pin retainers are required Piston pin is included as par of piston assembly M pin boss in piston or pin are wom or damaged new piston assembly requred KohlerEngines com Ring fallure s usually indicated by excessive consumption and blue exhaust smoke When rings fail ls allowed to enter combustion chamber where it ls Burned along with fuel High consumption can also occur whan piston ring end gap is incorrect because ing cannot properly conform 1 cylinder wall under this Condition control is also lost when ring gaps are not staggered during installation When cylinder temperatures get too high lacquer and varnish Collet on pistons causing rings a stick whieh Tesults 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 Detonation damage occurs when a portion ol fuel charge tes spontanecusy rom heat and pressure shorty rionllon This creates 2 fronts which mae and explode to create extreme hammering pressures on specii area of piston Delonaton generally occurs from using low oclane fuel Preigntkn or inton of uel charge before timed spark Con cause damage simlar 1o detonation regen oan Bore severe an dean damage Prelglon e caused by
51. al with postive brushes and Plastic insulating bushing from end cap 50 KohlerEngines com 4 Instal insulating busting on stud terminal of new postive s bres Inda sud temina ito Eommutstor end cap Secure stud win ber washer and screw Insta brush holder new negative brushes and seil tapping screws ki Ista brush pings and brushes into pockets in rh holder sure charred sides of Brushes away fom Brush springs wan style B end caps have brushes na pase amer housing separat fom end Replacement tos come predetemled I came haut retained tho carton Commutator Service Clean commutator with coarse int Trea cio Do nat use emery cioth If commutator is badly worn or grooved turn It down on a latne or replace starter iner Raney Place thrust washar equipped aver dive shat of 2 Insert amature nto startar Maka sure magnets are coser to dive shaft end of armature Magnets wil hold armature inside fame 3 Install dive ond cap over drive shaft Make sure atch marks on end cap and siarter ame are aligned Silo A commutator end caps Instali brush holder tol to keep brushes in pockets f cammutalor end Alan match marks on commutator end cap and Siarter frame Hold drive ond and commutator end aps ml starter tame Remove brush hoider commutator end caps W brush assembly not being replaced posit
52. alve and fuel ine Correct any observed Jpratiem and reconnect ine Fuss condition Check for a dogged fuel ine Tuer ine is unobstructed chock for overtilad crankcase andlor oil n pulsa line If checks don t reveal cause of problem replace pump 24 690 07 Rev B KohlerEngines com EI Fuel System WARNING Gasoline is extremely flammable and its vapors can y Do not fil fuel tank while engine is hot or running from sparks or lames Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Never use gasoline as clearing agent Keihin Two Barrel Carburetor Components xD Do E KohlerEngines amp Q Cahua e Mese Tc o sew E Ground Lead Washer e Right Side Left Side Slow Jet 3 TUS POM U ietNeede V Right Side w Left Side x Right Side Left Side 24 690 07 Rev B Nikki One Barrel Carburetor Components Fuel System Tala Fuel 24 690 07 Rev ie Speed Seow Aq hey C Carburetor Body D Tie Jet ER E Plug F Man Jet A Carburetor Body B Adjusting Seow pe Sat Sqenos c anita Fist p passage cx sembly Adjusting Spring Cover T Fue J Choke Lever E Cover Gasket F LESS 647 740 e
53. and contact areas are nol excessively worn cracked or broken Brush Replacement X brushes and springs ara serviced as a sel Use a now Kohler brush and spring kt if replacement is necessary 1 Perform steps 1 5 in Starter Disassembly 2 Remove screws securing brush holder assembly to end cap plate Note orientation for reassembly ater Discard oid brush holder assembly Clean component parts as required New brushes and springs come preassembled in rush holder with a protective sleeve that wil also Serve as an instalation toot 5 Perform Steps 10 13 in Starter Reassembly Sequence Installation must be done after armatur drive laver and frame are installed starter has been disassembled 24 690 07 Rev B Starter Reassembly NOTE Aiways use a newretanner Donat res od retainere that have been removed NOTE Correctly installed center pivot section of drive over wil be hush or below machined surface of fusing 1 Apply dive lubricant to armature shaft splines Instal dive pom onto armature shat 2 Install and assemble stop colaretainer assembly Install stop colar down onto armature shaft with counter bore recess up b Install new retainer in larger rear groove of armature shaft Squeeze piers lo compress iin groove lt Side stp collar up and lock tno place so recess surrounds feiner groove i necessary pinion outward on armature spines against retainer to help eat co
54. ankshaft taper and flywheel hub are clean dry and Completely free of any lubricants Presence of ubricants can cause ywheel to be over stressed and damaged when screw is torqued to specifications NOTE Make sure fywheel key is installed properly in Flywheel can become cracked or damaged il key is not propery installed 4 Instali woodruff key into keyway of crankshaft Make sure key is propery seated and parallel with shaft aper 2 instali flywheel onto crankshaft being careful not to shif woodruff key 3 Install screw and washer 4 Use a flywheel strap wrench or holding tool to hold flywheel Torque screw securing flywheel to to 6 4 N m 49 ft b 76 KohlerEngines com 1 Ifa metal debris screen is used wit threaded individual supports installa spacer washer on extemal threads Apply blue Loctite 242 removable to threads Install supports as shown 2 Tighten supports with torque wrench lo 9 9 Nm 88 in Ib Debris screen willbe installed to supports after Blower housing is in place 24 690 07 Rev Cylinder Head Components Reassembly vanes v Sra Pog 8 E ae Siem Sea Vas Sing Rooper 1 vaesm a ETS k L Puntos u mem N Seow S vare Gover ng P Grommet G vate Cove R L Saser Install Hydraulic Liters Valve Stom Seals NOTE Hydrau
55. assembly 2 Secure cooler or adapter to pan with ol iter Torque fiter nipple lo 27 Nm 20 tb 24 690 07 Rev Instali Filter and Fill Crankcase with OI NOTE Make sure hat both al drain plugs are rated and torqued t above speci iatons 1o prevent ad leakage 1 Install ol drain plugs Torque plug s to 136 Nm VT Ion arai valves used make sure valve body is closed and cap on 2 Place new fiter in shallow pan with open end up Fil y now ol untl ol reaches boltom of reads Allow 2minutes foro to be absorbed flr material Apply a thin fim of clean to rubber gasket on oll ter 4 Refer to instructions on fiter for proper instalation 5 Fllerankcase with new Level should be a lop of indicator on dipstick 6 Reinstall ol fi cap dlpstick and tighten securely Connect Spark Plug Leads Connect leads to spark plugs Prepare Engine for Operation Engine i now completely reassembled Before staring or aperaiing engine be sure to do following d Mako sure all hardware is tightened securely 2 Make sure ol drain plugs Sentry pressure Sich and a new ol ile are 3 Adjust carburetor de fuel needle or idle speed adjustng screw as necessary Testing Engine its recommended hal engine be operated a test stand or bench prior lo installation 1n plece of equipment 1 Set engine up on a test stand Install an oll pressure gauge Start engine and
56. blow by or isaky valvas confrm by inspecting components Recondition piston rings cyinder bore valves and valves guides Restricted exhaust Check exhaust screanfapark arrestor IT equipped Clean replace as needed Ropar ar estate ca damagediresinted mutter or exhaust system pars 20 KohlerEngines 24690 07 Rev B Troubleshooting COMPRESSION TEST For Command Twins A compression test is best performed on warm engine Clean any ditor debris away from base of spark plus Before removing ham Be Sure coe s df and irte i Wide open dut test Corpr saon shoud diae 160 Psi and should not vary more than 15 between cylinders All other models These engines re equipped win an automate compression release ACR mechanism cut to obtain an compression reading because of ACR mechanism As use cinder leakdown lest described ion CYLINDER LEAKDOWN TEST A cylinder leakdown test can be a valuable altemative to a compression lest By pressurizing combustion chamber rom an extemal ar source you can determine i valves or nings are leaking and how badly Cylinder leakdown tester is a relatively simple inexpensive laakdown tester for small engines This tester includes a ckcconnect for attaching adaptar hse and a holding lool 1 Run engine for 3 5 minutes to warm it up 2 Remove spark plugs and air fiter from engine 3 Rotate crankshaft unti piston of cylinder being tested is
57. cause severa injury or OR Disconnect and ground spark plug lead s before servicing k Electrical Shock can cause injury Do not touch wires while engine i running Before working engine or equipment disable engine as follows 1 Disconnect spark plug lead s 2 Disconnect negative battery cable from battery M Damaging Cranishall Flywheel can cause personal warnine WARNING in operation Rotating Parts can cause Stay away while engine is Hot Parts can cause severe bums Do not touch engine while operating or just after stopping Using Improper procedures can food o broken fragments Broken fragment Is could be thrown from engine Always observe and use recauilons and procedures when Petaling flywheel clothing parts i Operate Keep hands feet hair and away from all moving prevent injury Never engine with covers shrouds or guards removed Never operate engine wih heat Shields or guards A WARNING ERSTE Avoid inhaling exhaust umes WARNING Cleaning Solvents Use only in well ventisted reas away rom ignition wanuna Unealing Spring can cause severe injury Wear safety goggles protection when servicing retractable starter polsono Carbon inhaled Engine exhaust
58. checking tool and replace shim as acessay Several color coded shims are avaliable White 0 69215 0 72025 mm 0 02725 0 02875 in Blue 0 74295 0 78105 mm 0 02925 0 03075 in Red 079375083185 mm 0 03125 0 03275 in Yellow 0 84455 0 88265 mm 0 03325 0 03475 in Green 0 89535 0 99345 mm 0 03525 0 03675 in Gray 0946151098425 mm 0 03725 0 03875 in 0 99695 1 02505 mm 0 03925 0 04075 in 5 Reinstall end play checking tool and recheck end pay KohlerEngines com n Reassembly Oil Pump Assembly Install Pan Assembly Qi pump is mounted msds pa T senice was required and oll pump was removed refer to Disassernblyinspeci n and Service Governor Gear Assembly Governor gear assembly is located Inside ol pan IT Service was required and governor was removed rafer o Disassembly Inspaction and Service Install Seal in Pan Sealant Pattern Seal Component and Detail A 65mm 0255m CEN T Check to make sure that there are no nicks or burs in bore of oli 2 Apply a light coat of engine oll to outside diameter of ak seal 3 Drive oli seal into oll pan using a seal driver Mako sure oll seal is installed straight and true in bore to epin shown KohlerEngines com Fill groove between Tamminen je points with RTV bead of sealant RIV must ba all round O ring groove
59. cleaner If equipped is clean and air cleaner components are fastened securely 6 Make sure ignition system governor system exhaust system and throtle and choke controls are operating properly Troubleshooting Carburetor Related Caus Condition Possible Cause Conclusion hard rune Ugh Gr Cow ii fue miturerpeed ust Tw la speed tab han sale at lo speed improper adjusted ow il uel needa Engine runs rch dicated by Wack Clogged air ceaner Clean or replace air deanar exhaust smoke misting loss Choke pariany closed TE Check choke leverinkage i5 arsura power operation hoke s operating proper Tap AoW de nece Flat level sar Too Wh Separate Tuai bow rom carburetor body Free I stuck or replace oat lander tue mat mondi Remove needle lean needle and aat and blow with compreeeed a Bow vantar ar bleeds plugged Remove kw ile fue austin pe eed Clean vent and air Bleeds Blow out ai passages win compressed ate Lea cracked or damaged Teal Submerge Toat to check Tr ake Engine rns lean by Low idi uel mixture i improperly Adjust kw ide fuel needle fring ose faced and power hunting orexcossive FiaLier E SaL IBS TOW Separate Toa bowl rom vote opening body Free f stuck or replace oat Ties Aged ir Tur delivery Remove low idi fel adjustin
60. d washer 3 Use a puller to remove flywheel crankshaft 3 Remove woodruff key Inspection Inspect fyvheal for cracks and fywheel keyway for damage Replace ywhee i is cracked Reptace crankshaft and key f yheel key is sheared af keyway la damaged U Inspect ring gear for cracks or damage Kohler does Tol provide ing gears as a serviceable part Replace riae if ring gear is damaged Remove Stator and Backing PI 1 Remove screws securing backing plales and stator wire bracket f equipped Remove backing plates and stator wire bracket 2 Remove screws and stator Note poslton rouling of Slater lead 2469007 Rev B Breather Oil Pan OIl ReservoiriPiston Components B Dpi Tube D Breather Gasket E Breather Cover F Fel Washer Breather Reed H Eovemor Cross Shall 1 olan Gasket J Govemor Gear Tab Thrust K PETS Gear N OFPICUp Tube 0 OrPumpAssemBy P Piston Fin Piston R Piston Ring Ser Piston Ring Retainer Connecting Ros End Red V Cmntsham WI canat 24 69007 Rev B Disassembly Inspection and Service Remove Pan Assembly T Remove screws securing al pan lo crankcase 2 Locate spiiting tabs cast into perimeter of ol pan Insert dive end af a 1 2 breaker bar between piling tab and crankcase and tu
61. e 10 New raoos roo soo 8268883013 mm 73 031 mm 77 025 80 025 mm 32672032682 287421 Goats 3 14987 28752in 30325 31506 n Max Wear Unit 73 070 man 77063 mm 80265 mm WROBTmm 52887 m 2187671 30340 31822 Max 013mm 0 12 mm 0 0047 n 0 0051 in Max Taper OS m 0 0020 5 Cylinder Head Gut ot Flaness 0076 mm GET Values are in Metric units Values parentheses are English equivalents 24 69007 Rev B KohlerEngines com Specifications CLEARANCE SPECIFICATIONS cv17 CViBCV20 CV22ICV23 CV28 CV730 CV750 CV22 CV670 CV680 CV740 CV620 CV640 Governor Governor Gross Shaf to Crankcase Running Clearance Max Wear Limit S mm Shaft 0 013 0 075 mm 0 0005 0 0030 in mm Shaft 0 025 0 126 mm 0000900049 in Cross Shaft OD mm Shalt New 5 975 6 012 mm 0 2352 0 2367 in Max Wear Limit 5 362 mm 0 2347 in 8 mm Shaft New 7 94918 000 mm 0 3129 0 3149 in 7 936 mm 0 3124 in Governor Gear Shaft to Governor Gear Running DOT8 0 140 mm 0 0008 0 0058 i Gear Shall OD Now 5 90006 000 mm 0 2358 0 2362 in Wear Limit 5977 mm 02353 in Ignition Spark Plug Gap 0 76 mm 0 030 in Module Air Gap 02810 33 mm 007170019717 Piston Piston Rings and Piston Pin Piston ie Piston Pin Running Clearance TOET mm 0 9002 0 9007 J Pin Bore LD Ne
62. e carburetors main nozzles can be removed 28 KohlerEngines com trough bottom of maln towers Note orientation recon of nozzles End win 2 raised shoulders Should te ouldown adjacent to main ol Save parts for cleaning and reuse Position of slow jet varies and is removable only on Some yos of carburetors Seo correc Hustralon or corresponding style of carburetor shown location On carburetors slow Jets may be sized lo specific side Mark or tag jets for proper assem Note sma O end on Belom ol ach ot Save parts tor cleaning and reuse unless a jt itis also installed Clean slow jets using Compressed alt Do not use wire or carburetor cleaner Carburetor is now disassembled for appropriate cleaning and instalation of parts in overhaul KI See instructions provided with repair kits for more detailed information High Altitude Operation Engines may require a high alttude carburetor kit to ensure corect engine operation at alludes above 1219 meters 4000 1 obtain high altitude kit information or to find a Kohler authorized dealer visit Kohlarengines com or calI 800 544 2444 US and Canada This engine should be operated in lts original Configuration below 1210 meters 4000 fL as damage may occur I high altitude carburetor Kit is installed and Operated below 1219 meters 40001 24 690 07 Rev B GOVERNOR Engine is equipped with a centrifugal fywaight mechanical govemor Ilis desig
63. er and push it toward starter compressing ani spring and exposing retaining Holding spring retainer in retracted position assemble inner halves of removal tool around armature shaft win retaining nng n inner groove Side colar over iner halves to hols Them in postion 5 Thread center screw into removal tool until you feel resistance Use a wrench 1 1 8 or adjustable ta heid base of removal tool Use anoinar wranch or Socket 112 or 13 mm to tum center screw Clockwise Resistance against center screw wil tell ou when retaining rng has popped o groove in Armature shat 8 Remove drive components from armature shaft paying attention to sequence If spines are if Clean tham with solvent 7 Splines should have a light fim of lubricant ica as necessaty with Kaner ara drive lubricant Reinstall or replace drive components assembling thom in reverse order they were removed KohlerEngines com 49 Starter System Retaining Ring installation T Position retaining ring in groove T one af e halves Assembie other half over lop and side on outer colar 2 Be certain drive components are installed in correct Sequence onto armature shall 3 Sip tool over end of armature shaft so retaining ring inside resting on end af shaft Held ool with one and exering Sight pressure toward starter Tap top ol tool win a Rammer unti you feel retaining ring Snap into groove Disassemble and remove 4 Squeeze retaining ring wit
64. er minule Ata instaling coarse stones in hano proceed as follows 1 Lower hone into bore and after centering adjust so siones are in contact win cylinder wall Use fa ommercil citing coohnj agents recommended 2 Wit lower edge of each stone positioned even with lowest edge ol bore star dil and honing process Mova hore up and dawn whe resizing I prevent formation of outing ridges Check sie frequently 3 When bere is within 0 064 mm 0 0025 in of desired size remove coarse stones and replace them wih bumishing stones Continue wit burnishing stones untl bore is within 0 013 mm 40 0005 in ol desired size and then use finish Stones 220 280 grit and polish bore to its final size erosshatch should be observed If honing is done correctly Crosshatch should intersect at approximately 237 337 off horizontal Too fat an could cause rings to skip and wear excessively and too steep an angie wil resultin high al consumption 4 Alter resizing check bore for roundness taper and Siza Use an inside micrometer telescoping gauge or bore gauge to take measurements These measurements should be taken at 3 locations in Cylinder al top middle and bottom There are 2 measurements that should ba taken perpendicular o each other at all 3 locations glean Cylinder Bore Atter Honing Proper cleaning of cylinder walls following boring and honing is very critical to successful overhaul Machining grit left n cyli
65. ers can qucaly break down iubcating properties of engine ol KohlerEngines 19 Troubleshooting warning Rotating Parts can cause severe injury Stay away while engine is in operation CRANKCASE VACUUM TEST A 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 Konp hands ea hai and away Tram al moving parts to prevent injury Never operate angine w covers shrouds or guards removed on 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 oll to be forced out at seals gaskets or other available spots Crankcase vacuum Is best measured with a water manometer or a vacuum gauge Completa instructions are provided in kits To test crankcase vacuum with manometer 1 Insert rubber stopper Into ol fil hole Be sura pinch amp is installed on hose and use tapered adaplars io connect hose between stopper and one manometer tube Leave other lube open to limaephere Chock nat water level th manometer is at line Make sure pinch camp is closed Start engine and run no load high speed 3 Open clamp and note water level in tube Level in engine sido should be a minimum of 10 2 c
66. from armature 13 Clean parts as required Inspection Drive Pinion Check and inspect following areas Pinion teeth for abnormal wear or damage Surface between pinion and clutch mechanism for nieks of iregulariles which could cause seal damage Check are chin by holding clutch housing and rotating inion Pinion should rotate in direction Brushes and Springs Detail AI Wear Limit Lengih Inspect both springs and brushes for wear Tagus or damage Measure length of each brush Minimum length or each brush is 7 6 mm 0 300 in Replace brushes If thoy are worn undarsze or cond n is questionable KohlerEngines com Armature Components and Details e Tommi OD insulation cea B E Continuity Check Armature Coll 4 Clean and inspect commutator outer surface Mica Insulation must be lower than commutator bars undercut to ensure proper operation of commutator 2 Use an ohmmeler set to Rx scale Touch probes between 2 diferent segments of commutator and hock for continuity Test all segments Continuity must exist between all or armature s bad 3 Chock for continuity between armatura segments and commutator segments There should be no continuity If continuity exists between any 2 armature bad 4 Check armature windings insulation for shorting Shift Fork Check that shift fork is complete and pivot
67. g Kanne Clean main fuel et and all passages blow oul wih compressed Es Fel leaks rom carburetor GELI Separate Tosi bow Tom carburetor body Free f ci or replace at lr andor Tue iat oed Remove needle dean needle and aat and bow wih compressed 2 Bow vents plugged Blow wih compressed alr bow gaskoi lake Replace gasket Fuel Shut Off Solenoid Most carburetors are equipped with Tual shutoff solenoid Solenoid s attached to fuel bowl Solenoid has a Spring Jaded pin that retracts when 12 voli is applied lo lead allowing fuel ow to main je When current is removed pin extends blocking fuel flow Below is a simple test performed with engine of that can determine If solenoid is functioning properly 1 Shut off fuel and remove solenoid carburetor When solenoid is loosened and removed gas wil leak aut of Carburetor Have a container ready to catch fuel 2 Wipe tip of solenoid with a shop towel or blow with compressed air to remove any remaining fuel Take solenoid to a location with good ventilation and no fuel vapors present You wil also need a 12 volt power source that can be Switched on and of 3 Be sure power source is switched OFF Connect positive power source lead to red lead of solenoid Connect negative power source lead to solenoid body 4 Tum power source ON and observe pin in center of solenoid Pin should retract with power ON and return to ts original position with power O
68. g aver and armature be careful losa thrust washer Disconnect lead wire from solenoid 2 Remove nuts securing solenoid and remove steno rom staner assemly 3 Remove two thu bolt 4 Remove commutator end cap 5 Remove insulator and brush springs trom brush Spring holder idis 6 Remove armature rom frame Remove drive lever and armature from drive end 5 Stop collar consists of two similar pieces held in Rate by being snapped over a einer Retainer is ld in lace Dy a groove in armature To remove slop colar to pieces must be pred of 9 When stop collars are removed retainer can be removed rom armature shafi Do hol reuse retainer Brush Replacement Brushes sartor are of starter rame Brush kt coniains four replacement brushes and springs I replacement necessary all our brushes shouid be replaced 1 Remove brushes from brush holder and remove rush holder rom frame 2 Cut brush lead viro at edge af post with a pak of nippers 3 off any burrs on post 4 Replacement brushes have a solid portion which should be crimped on post 5 Solder crimped portion to post 6 Replace brush holder in frame and place brushes in Brush holder Reinstall springs Starter Reassombly NOTE Always use new retainer Tighten retainer in groove to secure Insert rear slop collar on armature shaft 2 Place retainer in groove on armature shaft 3 Fit front stop collar over shaf
69. g when crankshaft ground provides easy access or removing any grinding deposits collected in ol passages Use following procedure to remove and replace plug Procedure to Remove Crankshatt Plug rita 2 96 hole Hough plug in crankshaft Thad ale era pon sn ot a Washer inio hola Flat washer must bo large enough 0 seat against shoulder ol plug bore 3 Tighten self tapping screw unti draws plug out of Ganesha on d Procedure to install New Plug Use single cylinder camshaft pin as a driver and tap plug into lug bore unti seats at bottom of Gore Make Eire plug 1s tapped in eveniy to prevent leakage Remove Flywheel End Seal Remove seal rom crankcase KohlerEngines com e isassembly Inspection and Service Crankcase inspection and Service NOTE Some CV25 engines feature POWER BORE Cylindere special patented nickel siicone plating process for increased power superior Control reduced exhaust emission and vitualy permanent cylinder le POWER BORE Cinders cannot be resized or honed scribed in folowing procedure Ia pated lider bore is damaged of out of specication Vra new minblock or short block repair ngine Use along procedures or crankcases Wi a cast von sleeve Check all gasket surfaces to make sure they are free of gasket fragments Gasket surfaces must also be ree of ep scratches or nicks Check cylinder bore for scoring In severe cases unbumed fuel can cause seuling and
70. gases contain jus carbon monoxide monoxide Is odorless colorless and can cause dealh if Carburetor cleaners and solvents are extremely flammable Follow Cleaner manufacturer s warnings and instructions on its proper and Safe use Nevar use gasoline as a leaning agent contain a reco spring tatis Ender tension Always wear safety goggles when servicing retractable Starters and carefully follow Instructions in Retractable Starter fer relieving spring tension KohlerEngines com 24 69007 Rev Maintenance MAINTENANCE INSTRUCTIONS E WARNING gb ineo NE cn eet aaa ed Disconnect and ground spark pug laa My etre seren Normal maintenance replacement or o amissam control devices and system may ba parlammad by any repair estabilsmen or individua however warrant repairs must be performed by Kehler authorized dealer MAINTENANCE SCHEDULE Wooky Check heavy duty air deaner sement LO Ares Every 25 Hours or Annually e Servicelreblace low profiis precisanar Ar Cleaneriintake Every 100 Hours or Annually f Replace low prolle alr cleaner alamen Ar Cleanerintake f Change Lubrcalion Syster Remove cooling shrouds and clean cooling areas ir Cleanerfintake Check cooler fins clean as necessary f equipped Lubrication System Every 200 Hours f Change ol fito L
71. h a ples to compress t inio groove 5 Assemble inner halves with larger cavity around Spring retainer Side colar over them and thread Gente screw in unti resistance Is fl 6 Hold base of tool with 1 1 8 wrench and tum Center screw clockwise with 1 2 or 13 mm wrench 0 draw spring retainer up around retaining ring I inning when esistance ereases Disassemble and remove tool 7 Reinstall dust cover Starter Disassembly O O 1 Remove dive eomoonantTolowing REGIE Tor Servicing div 2 Locate smal raised on edge of drive end cap win sive comentator ond caps uit algned wii ie on staat kame Frame s not pre marked on starters wih style B ahd Sape Paco a piaca of mashing tane o rare and RE on apa in ine wi alta ine en end ze Remove thru bots 4 Remove commutator end cap wih brushes and ah springe styl AY Sie B amd caps remove Diete Mh bashes and carter email irre amp Remove drive end cap Remove armature and trust washar f equipped Tom nal anar teme Remowebrushicarier assembly rom aye mes Brush Replacement NOTE Use a brush holder tool ta keep brushes in osha A brush holder too can easly bo made rom thin sheet metal Remove brush springs from pockets in brush holder 2 Remove sell tapping screws negative brushes and plastic brush holder 3 Remove nut and fiber washer from stud terminal Remove stud termin
72. h cylinders However If only 1 testor is avalabie 2 individual ests must be performed Side nol being tested must have spark phig lead connected groundad Do not crank engine or perform tests with 1 spark plug lead disconnected and not grounded permanent system damage may occur 4 With engine stopped disconnect 1 spark plug lead Connect spark plug lead to post terminal of spark tester and attach tester io a good engine ground Crank engine over establishing a minimum of 550 600 RPM and observe testers for spark 3 Repeat spark test on opposite cylinder f cylinders are being tested individually Condition Possible Cause Conclusion Both cyindars have good spark bur Spark stall naw spark plugs and retest engine runs poorly or existing plug engine performance ondion is questionatie problem persists check forming Vance SAI and Smart Spark T cylinder has and other ZE Test onion modules and ET nimiam apa connections DSAI and Smart Spark oniy Spark on Both cyindars bul power Timing Advance Check forming advance OSAT and suspect Smart Spark only Test Timing Advance and Smar Make a line near edge of flywheel screen with a marking pen chalk or narrow tape 2 Comma acme at hd oad Spar 3 Run engine at dla and use timing light beam Io locate ine on screen Draw a line on blower housing next to line screen Accelerate to full throtle and watch f
73. haft Wl be necessary Inspect crankshaft bearing sufaces tor scorn grooving ele Measure running clearance between Crankshaft journals and Mer rospectve bearing bores an tide mietomaler er fleseonog gauge 1o measure inside diameter of both bearing bores in vertical honzonlar planes Use an outside micrometer io measure ouside diameter of crankshaf main bearing journals Subtract Joumal diameters from their respeclive bore diameters 0 get running Clearances Check results against tolerances in Specifications i unning clearances are witin speciication and thera s mo evidence of scoring grooving ete no further condoning necessary I beating surfaces are worn or damaged crankcase andr wil need to be replaced Inspect crankshaft keyways If wom or chipped roplacemont o erankshaf wil be necessary pac for score mua or maie pup Sight score marks can be cleaned wih erocus cioth soaked in o f wear imis as stated in Specifications are exceeded 1 wil be necessary either replace or regrind crankpin to 0 25 mm 0 0101 Undersize If reground a 025 mm 0 010 in undersize connecting rod big end must then be used o achieve Proper running clearance Measure crankpin far size Vapor outat round Ganvecing rod journal can be ground 1 size under Vien grinding crankshaft grinding tone deposits Can caught al passages whlch could causa Severe engine damage Removing crankpin plu
74. ight be causing problems To test charging system for no charge to battery 1 Insert an ammeter in B lead from recifer regulalot Win engine running at 3600 RPM and a terminalon reciter regulator o ground using a DC Volmeter M volg 13 8 vots or more place a minimum kad of amps um on lighis i 80 watts or more or acea 2 chm 100 wall resistor across baton terminals on biter to reduce vonage Observe ammeter Condition Conclusion Charge rale increases whan load is applied Charging system is OK and battery was fully Charged Test stator and rectifer Charge rate dogs nor eds regulator steps 2 and 3 increase when load is applied 2 Remove connector from reclifier regulator With engin running at 3600 RPM measure voltage across stator leads using an AC voltmeter Condition Conclusion WalagaisZ8volsor Stator is OK Recitar more regulator is faulty replace Volageisiessian28 Stalor is replace vols Test stator further using an ohmmeter steps and 4 3 With angina stopped measure resistance across stator leads using an ohmmetor Condition Conclusion Resistance 0 102 ohms Srs OK Resistance E O ohms Stators shorted replace Resistance is infin ohms Stators open replace 4 With engine stopped measure resistance from cach stator lead to ground using an ohmmetr Condition Conclusion Resistance Is infinity ohm
75. into angie increasing engin speed Speed reaches governed seting governor spring and force applied by regulating pin vl again fat each other oad a steady engine speed Governor Adjustments O OO O NOTE Do nol tamper gaveror seting Overapoed ie hazardous and could cause personal initial Adjustment Procedure Wake i adjustment whenever governor arm is Ibosened or removed rom crass shaft Adjust as follows 1 Mako sure trol linkage is connected to governor arm and roti lever on carburetor 2 Loosen nut holding governor lever lo cross shaft 3 Move governor lever toward carburetor as far as i Migo wd open voti and nod im ts postion 4 Insert a ong thin rod or tool into hole on cross shaft ard rotate shal clockwise Viewed rom end lar as t wil tum nen torque mitto 6 8 N m 80n o Sensitivity Adjustment Sans adjusted by repositioning ovarno spring in holes of governor ever speed occurs with a chande in engine load governor Sat oo sensive fa big drop in Speed occurs when ormat d is apples governor shoud be set or greater sensibly as fotove 1 To increase sonsiiviy move spring closer to governor lever pivot point 2 To decrease sensitivity move spring away governor lever pot point COMMERCIAL MOWER GOVERNOR RRRANGEMENT Commercial mower governor arrangement is used mari on wide area walk behind mower applications ial adjasiment and sansibviy adjustment E same as or standar gover
76. ipated ambient tamparatures Actual cold cranking egufemeni depends engine size appicab n and Starting temperatures Cranking requirements crease as lamporatires decrease and battery capacity shrinks Reler to equipments operating intuctons for specific battery requirements Battery Size Recommendations Temperatur Above 32 F 0 C Battery Required 200 cca minimum 32 F ATCO 250 cca minimum SF lo OF 21 18 300 cca minimum AOF 2350 or below 3400 cca minimum Toate charge is insufficient 1o Turn over engine recharge bota Battery Maintenance Regular maintenance s necessary ts prolong Battery Test To test battery follow manufacturer s instructions 24 690 07 Rev B There are 3 different types of ignition systems used on hose engines Al systems use an igniton module which energizes sparkplug Difference in systems sin way anion timing is Piggered Al ignition systems are designed to be rouble free for ie of engine Other than penadeally chackng eplacing Spark plugs no maintenance or timing adjustments necessary or posse Mechanical systems Occasionally fall or break down Refer la Troubleshooting determina root of a reported problem Reported ignion problems are most otten due to poor Connections Before begimning tes procedure check Sil extemal wring Be certain al gon related wres
77. it hot parts or sparks from Ignition Never use gasoline as a cleaning agent NOTE E15 E20 and EBS are NOT approved and hou NOT be used effects of oid stale or contaminated fel ae nol warrantable Fuel must meet these requirements 1 len tas urieaded gasoline raina o 87 Rs 2 or higher Research Octane Number RON 0 aane minimum 1 Gason up 10 10 eh leona 80 unloaded s acceptable Teriary Buy Ether MTBE and unleaded ten na 15 volume are Approved ada oi to gasoline 2 Do not over fuel tank 3 Ba not use gasoline oder than 30 days 4 KohlerEngines com STORAGE If engine wil be out of service for 2 months or more follow procedure below 4 Add Kohler PRO Series fuel treatment or equivalent fo fuel tank Run engine 2 3 minutes to gat stabilized fel into fuel system failures due to untreated fuel are not warrantable 2 Change oi while engine is stil warm from operation Remove spark plug s and pour about 1 oz of engine oil into cylinders Replace spark plug s and rank engine slowly to distribute oll 3 Disconnect negative battery cable Store engine in a clean dry place 24 690 07 Rev Specifications Engine Dimensions with Low Profile Air Cleaner Dimensions in millimeters inch equivalents shown in
78. ition modula air gap a Adjust ignition module air gap 1 Turn magnet away from module position 2 Attach module to mounting legs pull it away from flywheel and tighten screws to hold it temporary 3 Rotate flywheel magnet is centered under module 4 Position 0 30 mm 0 012 in feeler gauge between magnat and all three legs of module Ignition module air gap i cr cal to proper system performance Do not attempt to sat with a business card folded microfiche card Use feeler gauge specified 5 Loosen mounting screws allow magnet to pull module down against feeler gauge and retighton mounting 8 Rotate flywheel to remove feeler gauge position magnet back under module and recheck that specified gap minum of 0 28 mm 0 011 n exists under each leg of module When you ara certain gap is correct True module mounting screws to 4 0 N m 45 in lb Repeat these 6 steps t set other ignition module 6 Reallach lead wires to ignition module s noting if resistance ls fell indicating a snug fit between male and female terminais connections do not feel snug disconnect lead lighiiy pinch female terminal with a pliers and recheck fi T When integrity of connections has been verified retest for spark 42 KohlerEngines 24690 07 Rev B Electrical System Condition Possible Cause Conclusion Sang sisady spark is now present Problem should be Gato bo
79. l carbureod fuel system and related components include Fuel tank and valve Fuel ines in ine fue ftr Fuel pump carburetor Fuel from tank is moved through in ine fitar and fuel lines by uel pump Fuel then enters carourtor oat bowl And i draum into Carburetor body and mixed wih air This modure is then bured in engine combustion hamber FUEL RECOMMENDATIONS Refer to Maintenance FUEL LINE Low permeation fuel Ine must bo installed on carturatad Karier Co engines to maintain EPA and CARB regulatory compliance FUEL PUMP Some engines use pulse style fuel pump Pumpin ion e puise sl pumps is created by positive and negative pressures within crankcase Tris Pressure is transmitted to pulse pump through rubber hose connected between Pump and crankcase Pumping action causes diaphragm bn ride ol pump to pull luel in on ts downward siroke and to push tino carbureor nit upward stroke Two check valves prevent uel ram Backward trough pump FUEL SYSTEM TESTS Fuel System Performance Minimum fuel delivery rate must be 7 5 Uhr 2 gal mr yan a pressure at 0 3 pel and a fuel i ol 24 n ALI hr 0 34 gal ihr fuel rato must be maintained at 5 iz Fuel Pump Replacement NOTE Make sure orintallon of new pump is constant with removed pump Internal damage may occur T installed incorrectly Replacement pumps are available through your source Of Supply To replace pulse pump follow fede ste
80. l supply Drain Oll From Crankcase and Remove Oil Filter 1 Remove ol fil capidipstck and 1 drain plug 2 Allow ample time for oil to drain from crankcase and lite 3 Remove mounting screw and detach fil tube 4 Remove and discard fiter Heavy Duty Alr Clean contect breather hose from fiting in adaptar or Remove nuts securing adapter and any attached clips to mounting studs Pull adapter elbow and gasket off mounting studs 3 Remove screws inner valve cover screws on each Side securing ar cleaner main support bracket Do not losa any of mounting hardware Tuo barrel carburetor models only unhook choke retum spring from bottom of air cleaner mounting bracket 4 Remove upper screws securing air cleaner mounting bracket to blower housing and remove air cleaner assembly 1 Disconnect Ol Sentry Indicator Light wies 2 Disconnect choke control cable from throttle control bracket 3 Disconnect throttle control bracket from cylinder head 4 Remove panel rom blower housing Remove Fuel Pump Remove Oil Cooler equipped T Use 57187 Allen wrench to remove ol Tiler Nipple Explosive Fuel can cause tres and severe 2 Forcrankcase mounted cooler Separate cooler bums from ol pan Remove and discard gasket located y Do hot fl fuel tank while engine is hot or between them phot For blower housing mounted cooler Separate fiter adapter from
81. leaner with new engine oil squeeze out excess ol 4 Reinstall precleaner over paper element Paper Element Clean area around element Remove wing nut lament cover and paper element wih precle ner 2 Separate procleaner from element service precleaner and replace paper element 3 Check condition of rubber seal and replace if necessary 4 Install new paper element on base install precleaner over paper element reinstall element cover and Secure with wing nd Reinstall alr cleaner cover and secure with knob Heavy Duty 1 Unhook retaining and remove end cap s 2 Check and clean inlet sereen if equipped 3 Pul air cleaner element out housing and replace Check condition of inner element replace when diy 4 Check all parts for wear cracks or damage and that ejector area is clean 5 Install new elementi 6 Reinstall end caps with dust ejector valvalscraen down secure wih retaining clips BREATHER TUBE Ensure sure both ends of breather tube are properly connected AIR COOLING warning Hot Paris can cause severe burns Set cs ee ad after stopping Naver operate engine with heal shields or guards removed Proper cooling is essential To prevent over healing clean screens cooling fins and other extemal surfaces Gf engine Avoid spraying water at wiring harness or any electrical components Refer to Maintenance Schedule 24 69007 Rev B Typica
82. lic ters should always postion as betore dsassembly Exhaust iter ara located on output shaft ol pan ada af engine ers are located an fan Side l engine numbers aro embossed on top of crankcase and each cyinder head 1 Refer to DisassembiyInspecion and Service for hydraulicibleecing lifer procedures poly camshaft lubricant o bottom suaca ofeach Mr ifere and ifer bores in crankcase wh engine ol 3 Note mark or tag identifying hydraulic Mer as ether iata ar esau and er cyinder 2 Vial trs nto their appropriate locations im crankcase nol use a magne eather reeds and stops were removed trankease rita ten at ins uma and secure with screw Torque screw to 4 0 Nm 35 n o 24 69007 Rev B These engines use valva sem seals on naka valves and occasionally on exhaust valves Use a new seal valve removed orf seal deteriorated or damaged in any way Never reuse an old seal Byori saan rate a orga ih engine paying partir attention lo pc valve som se Slams and vale guides ial in ordor tad below using a valve spring compressor Intake and exhaust valves Vaive spring Hor Valve spring retainers 3 Nalve Shing keepers KohlerEngines com Reassembly Install Cylinder Heads Torque Sequence NOTE Cylinder heads must be attached with original t
83. llar around retainer 3 install ofset thrust sop washer so smaller ost ot Washer taces 4 Apply a small amount of ol to bearing in drive end wh dive on 5 Lubricate fork end and center pivot of drive lever wth drive lubricant Poston fork end ino space captured washer and roar ot 6 Side armature into drive end cap and at same ime saat drive levar into housing 7 instali backup washer olowed by rubber grommet into matching recess of drive end cap Molded ecosses in grommet shouldbe oui mating and ned win those in end cap Insta rame with small notch forward onto armatura and drive end Abg notch wih Corresponding section in pubber grommet Install tube in rear cutou Wk was removed previous 3 Instal fat thrust washer onto commutator end of armature shal 10 Starter System Starter reassembly when replacing bushesibrush holder assembly kuna a Hold starter assem vericaly on end pousing and postion assembled bush holder assembly wih supplied protective tube against end of commmulatr armature Mounting serow foes in metal clips must be Side brush alder assembly down nto place around commutator and install positive brush lead grommet n cuturof frame Proteedve lube may So saved and used for future servicing Starter reassembly when nol replacing bushes brush haider assembly Carefully unhook retaining caps f
84. lve grinder win a suton cup for inai lapping Lightly coat valve face win a no grade of grinding compound rotate Valve on seat with rindar Continue ginding untra smooth surae is on seat and on valve face Thoroughly clean Jinder head in soap and hot water to remove al races riding compound Afer drying cylinder head app Sight coating of SAE 10 to prevent rusting intake Valve Stem Seal These engines uso valve stom seals on intake valves Always use new seal when valves aro removed fom Cylinder head Seals should be replaced If deleniorated or damaged in any way Never reuse an old Seal Hydraulic Liters inspection heck base surface ol hydraulic liters for wear or damage fter need to be replaced apply a liberal eat ol Komer canto ase of each new before tis installed Bleeding Liters To Prevent a possible bent push rod or broken rocker afm is important to bleed any excess oul of Mars before they ara installed 4 Cut a 50 75 mm 2 3 n place trom end of an old push rod and chuck in d dril press 2 Lay a rag or shop towel on table of dril press and place iter open end up on towel 3 Lower chucked push unt it contacts plunger in liter Slowly pump plunger 2 or 3 imes to force ol of feed hole in side ef iter KohlerEngines com Disassembly Inspection and Service Flywheelignition Components A B Deis Screen C Suppor
85. m 4 in above level in open side W level in engine side is less han specified Vacuum or level in engine sida E lower than level in Bpen side pressura check for conditons in table 4 Close pinch clamp before stopping engine Condition To test crankcase vacuum with vacuumipressure gauge 1 Remove dipstick or ol fll plugicap 2 Install adapter into fllldipstick tube opening upside down over end of a small diameter dipstick lube or directiy into engine if a tube is nol used Inset barbed gauge fiting into hole in stopper 3 Run engine and observe gauge reading Analog tester noodio movement to left of 0 is a vacuum and movement to right Indicates a pressure Digital loster dopross test button top of tester Crankcase vacuum should be a minimum of 10 2 em in of water If reading is below specification or f pressure is present check table below for possible Conclusion Grarkcasa breather clogged or inoperative NOTE W 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 fatness reassemble and recheck pressure Seals and or gaskets leaking Loose or mpropery torque fasteners J Replace al wom damaged seals and gaskets Make sure all fasteners are tightened securely Use appropriate valves and sequences when necessary Piston
86. m t to break RTV Pal Do not pry on sealing surfaces as is can Cause leaks Inspection Inspect ot seal in ol pan and remove ti its wom or damaged Refer ta Instali OI Seal in Pan in for new of sea pstallaln Inspect main bearing surface for wear or damage refer Replace di pan assembly fure KohlerEngines com 65 Disassembly Inspection and Service Pump Assembly Oi Pump Oi Pump Y Pickup Tube Original Siye Later Sve Xe PER TA man Piston F Spring Paslic Ol Pickup Torque Sequence One Piece Relief i Valve ssembly mor Shaft Component and Details ED mm 13386 1 SEHD 940 mm 0 7638 i Gear Shaft Li KohlerEngines com Governor gear assembly is located inside ol pan If service is required refer to Inspection Disassembly and Reassombly procedures Inspection Inspect governar gear teeth Replace gear it is wom Chipped or f any teeth sre missing Inspect governor uela They should move freely f governor gear Disassembly NOTE Goyemor gear is held onto stat by smal Molded tabs in gear When gear 8 removed from tha these tab are destroyed and gear must replaced Therefore remove gear only i absolutely necessary Governor gear must be replaced once itis removed from ol pan 1 Remove regulating pin and governor gear assembly 2 Remove locking
87. nar Should governor spring be disconnected from throtli ever and governor lever reconnect t as flows 1 Hook long end of spring through hole in lever from pres 2 Rotate spring 180 unt hooked 3 Hook short end of spring into appropriate hole in governor lever Refer to Reassembly for correct hole Sse or speed involved KohlerEngines com 29 Lubrication System This engine uses a full pressure lubrication system which delivers oi under pressure to crankshall camshaft connecting rod bearing surfaces and hydraulic valve A high efficiency gerotor pump maintains high flow and oll pressure even at low speeds and high operating temperatures A pressure reef valve limits maximum pressure of system must be removed to service Olt pickup pressure relief valve and oll pump Lubrication Components GiFWOpsik OrFmTue C Bakside Ol iter Nipple F O Cooler s Ong Oi Drain Plus 1 Oi Seniny GIL RECOMMENDATIONS Refer to Maintenance CHECK OIL LEVEL NOTE To prevent extensive engine wear or damage never run engine with ol level below or above operating range indicator on dipstick Ensure engine is cool Clean ol fiidipsick areas ofan deb o d 1 Remove dipstick wipe oi of 2 Reinsort dipstick into tube rest cap on tube do not thread cap onto tube 3 Remove dipstick check level Level should bo at top of i
88. nder bore can destroy an engine in less than 1 hour of operation after a rebuild Final cleaning operation should always be a thorough scrubbing with a brush and hot soapy water Use a Strong detergent capable of breaking down machining Q wile maintaining a good level of suds If suds break down during cleaning discard dirty water and start again with more hot water and detergent Following scrubbing inse eylinder with very hot clear water dry i complete and apply alight coating of engine alto prevent rusting Measuring Piston to Bore Clearance Piston Detail Sram 024 n NOTE Do not use a feeler gauge to measure pistoro bore clearance wil yield inaccurate measurements Aways use a micrometer 24 690 07 Rev B Before instaling piston into cylinder bore itis necessary clearance be accurately checkad This step alten overlooked and 1 clearances are not within specifications angine failure wil usualy result Use folowing procedure to accurately measure piston clearance 1 Use a micrometer and measure diameter of piston 6 mm 0 24 im above bottom of piston skin and perpendicular to piston pin 2 Use an inside micrometer telescoping gauge or bore gauge and measure eyinder vore Take measurement approximately 63 5 mm 2 5 in below op of bore and perpendicular to piston pin 3 Piston to bore clearance is diference between bore diameter and piston diameter step 2 minus slep
89. ndicator on dipstick 4 Wo low on indicator add oil up to top of indicator Reinstall dipstick and tighten securely E KohlerEngines CHANGE OIL AND FILTER Change while engine is warm 1 Glean area around ol tit capdpstik drain plug lol a Remove drain plug and ol fil cap dipstick Allow ito drain completely b Open oll drain valve cap if needed attach a length of 1 2 in LD hose to direct into appropriate container twist valve drain body Counterclockwise and pull Remove dipstick Allow ol to drain completely 2 Clean area around fiter Place a container under fiter to catch any of and remove fiter Wipe off mounting surface a Reinstall drain plug Torque to 13 6 Nm Ott b y b Close drain valve body remove hose if used and replace cap 3 Place now itor In shallow pan with open end up Fil with new unti ol reaches bottom af threads Allow 2 minutes for oil to be absorbed by fiter material A Appt fim of clean o to rubber gasket on new 5 Refer to instructions on fiter for proper installation 6 Fil crankcase with new Level should be at top of indicator on dipstick 7 Reinstall oil fll and tighten securely Start engine check for ol leaks Stop engine correct Recheck ol ievel dia 9 Dispose of used oll and fiter in accordance with local ordinances OIL COOLER equipped Blower Housing Mounted Oll Cooler T Clean fin
90. ned to hold engine Speed constant under changing load conditions Governor gearfiywoight mechanism is mounted inside crankcase on oll pan and is driven off gear on camshaft Governor Components Inside Engine Lever B Bracket Choke Linkage D Throttle Linkage E Governor Levee F Governor Spring Locking Tab a n Governor Gear shan T Governor Gear J Regulating Pia Governor works as follows Centrifugal force acting on rotating governor gear assembly causes fyweights to move outward as Speed increases Governor spring tension moves thom inward as speed decreases AS flywaighis move outward they cause regulating pin to move outward Regulating pin contacts tab on cross shaft causing shall to rotate Ona end of cross shaft protrudes through crankcase Rotating action of coss shalt is transmitted to throttle lover of carburetor through external linkage 24 690 07 Rev B Governor System When engine is at rest and is in FAST positon raion of governor spring holds ito plate Span When ena operating gover gear against cross shan tends to close rete plate Giver spring tension and Torce applied regulahng Bin lance sath oer operation to engine speed When load is apple and engine speed and governor par speed decreases governor sor lanson moves Sovenor lever to open pate wider This allows Tere
91. ngines in thls series are equipped wih ether muss aera e we applications uso a fuil shut off solenoid instal Solenoid On placa e fuel bowl retaining screw and also an i pFusBowGaser 3 Foar kt accelerator pump Al carbureiors feature em i BwReawng choke Screw Gaskel cu7sDangnesiniNs sodes are equipped wit a Keihin w y Shutoff Solenoid side draft design with xed man jets A s Screw Assembly Televng choke similar to that used on singla vert Tate Shaver P Tiro Paa cerburelorsis aiso contained in design G chest R Choke Pate Troubleshooting Checklst s Ame r Colar When engine starts hard runs or stals T Spring Y fing ila speed check folowing areas before adjusting or W Choke Lever X Te Spoed Saaw disassembling carburetor Y ise Speed Spig Z Seiscrows 1 Make sure fuel tank is filed with clean fresh gasoline 2 Make sure fue tank cap vent is not blocked and that itis operating properly 3 Mako sure fuel is reaching carburetor This includes checking fuel shutoff valve fuel tank fiter screen inline fuel fiter fuel ines and fuel pump for restrictions or faulty components as necessary 4 Make sure cleaner base and carburetor are securely fastened to engine using gaskets in good condition KohlerEngines com 25 Fuel System 5 Make sure air cleaner element including pre
92. ngs Battery on unit must be fly charged and property connected before performing test a battery that is hooked up or charged backward wil crank engine but won t have spark Be certain dive isi neutral and ai extemal loads ate disconnected Test ignition Systems NOTE engine starts or runs during testing you may need to ground kil lead to shut down Because you have interrupted kl circuit tmay hot stop sing switch Isolate and verify rouble is within engine 1 Locate connectors where wiring hamesses from engine and equipment are joined Separate connectors and remove white kil lead from engine connector Rejoin connectors and position or insulate kil lead terminal so i Cannot touch ground Try to start engine verly whether reported problem Is sl present Condition Possible Cause Conclusion Problem goes away Electrical System Chack Key switch wires connections safety interlocks ate Problem persists TgnionorEledica System Leave kil lead isolated unii al testing Is completed identify while kl lead of engine wiring harness connector Establish a connection to a known good around location Engine should kil Completely If not or only one cylinder is affected test ignition modules and while kil lead connection for affected DSAI module DSAI oniy 40 KohlorEnginos 24 690 07 Rev B Electrical System Test for Spark NOTE 2 testers are avallable testing can be performed simultaneously for bot
93. nkcase A combination of ow pressure above and low vacuum below lorc any accumulated oll out of cinder 2 head area into crankcase On cylinder 1 bank you have atmospheric Pressure above vacuum below again drawing any Gi toward crankcase LI KohlerEngines com Three valve cover designs havo boon used Frat ype Used a gasket and RTV sealant between cover and Sealing surface of eyinder head Second had a black O ring installed In a groove on underside of cover and may have metai spacers m holes Latest des ises a Yalow or brown O ning and hole spacers do molded in place 1 Remove screws securing each valve cover Note Vaive cover diferences for proper location n reassembly 2 Oring type covers should it off without prying If ose spacers aro present save them With gasket ype break seal by Carefully prying under edges of Remove Ignition Modules 1 Disconnect leads from each ignition module 2 Rotate flywheel so magnet is away from modules 3 Remove mounting screws and ignition modules Note position of Ignition modules Remove Spark Plugs Remove spark plug from each cylinder haad 24 690 07 Rev Disassembly Inspection and Service Cylinder Head Components XT sea 9 E F Wa Siem Seat Wa Seng Kaspar 1 vaveseing TS L PusnRod W mee n see va
94. o nd 24 690 07 Rev 3 compression ring top groove Install top rin piston ang expander Make sure O 109 Henttication mar is up or dye colored stripe I ontainad 1s t lelt ol end Connecting Rods Offset slapped connecting rods are used n al these engines Inspection and Service Check bearing area big end for excessive wear score marks running and side clearances refer io Spectcator Replace od and cap f scored or excessively wom Service replacement connecting rods are available in STD crankpin size and 0 25 mm 0 010 in undersize Undersized rods have an identification marking on lower end of rod shank Always refer to appropriate parts information to ensure correct replacements used Remove Crankshaft inspection and Service Crankshaft Components and Detail A SeiTappingScrew B Flat Washer Plus D Grankshaft Filet Must Blend Smoothly with Bearing Journal B Surface F High Point from Filet intersections G 45 Minimum H Filet Area Must Be Completely Smooth 24 69007 Rev B Disassembly Inspection and Service NOTE If crankpin is reground visually check to insure Tl blends smoothly with erankpin surface pull crankshaft from crankcase Inspect gear loath of crankshaft If eeth are badly wor chipped or some are missing replacement of cranks
95. occupied away from sparks or larmes Spied could ignite i domes contact win ho parts or sparks frm ignition Never use gasoline as a cleaning agent Fuel Pump Components AS 1 NOTE Fuel pumps may made of metal or plastic It a new fuel pump is being installed make sure orientation of new pump ls consistant wath removed pump Internal damage may occur i installed incorrect Install fuel pump and lines as an assembly Connect pulse line to crankcase vacuum fiting 2 Install fuel pump using screws Torque screws to 2 3 Nm 20 in lb 3 Connect fuel lines KohlerEngines com Laree sa Conner None RT Cam DEC ener al bea uere ee et RA fue ma Eie ee e rir ETT when applicable to 4 0 N m 35 in Ib ma yen uly 2 Aue man sige gst u hoard vale SOLOS bg E ha sow pe monaci Gore 55 65 in Ib Tamyata pian te sem p peres eee Ere 6 Totana ctor ddr atach chake tenn t des Install Mutt 1 Instat por liners f equipped Install muffler and attaching hardware to muffer bracket Torque Screws io 9 9 Nm 88 in Ib 2 Install hex flange nuts to exhaust studs Torque nuts 1024 4 Nm 216 In b Install Oll Cooler it equipped cooler can now be installed to engine Two diferent Styles ara used 1 Depending on style used reverse removal prozedure om Dis
96. odule lead S Brown tester lead to long brown module lead 2 Red tester lead to red module lead Black tester lead to black or green module lead Remaining tester leads pink and brown with black band are nat used for testing ASAM b If t is a DSAM all except 24 584 09 or 24 584 10 connect tester as follows Yellow tester lead to long yellow module lead Brown tester lead lo ong brown module lead Red tester lead to red module lead Black tester load to green or black module ground lead with eyelet terminal Pink tester leat short yellow or pink module lead Brown tester lead with black band or terminal to Short brown module lead 2 Recheck SAM part number noting last digits Refer to table below on tester faceplate lo determine test number to be used SAM 12 283 12 24 ao os 584 33 24 284 09 584 32 No 24 584 08124 584 31 24 584 34 Tesino 1 2 3 3 SAM Par BEZE 22 584 38 No 2454 2r 24 584 19 24 584 39 Test No S T 8 3 Depress tester button repeatedly unti correct test number appears on display After a Tew seconds est number wil fash ree imes and lest wil begin reverse numareal sequence wil be displayed Starting with a 6 and progressing down to 1 Yalowed by a P pass or F lal ndeatng condo of part isting an ASAM retin step and move yellow and brown tester leads to shor set of module leads thon repeat test
97. ols and their source SEPARATE TOOL SUPPLIERS Kohler Tools SE Tools Design Technology Inc Contact your local Kohler source 415 Howard St 768 Bur Oak Drive supply Lapeer MI 48446 Westmont 60559 Phone 810 664 2981 Phone 636 920 1300 Tal Free 800 664 2984 Fax 6309200011 Fax 810 664 8181 TOOLS Description Source Patt No Alcohol Content Tester Kohler 25 455 1 5 For testing alcohol content in refermulated oxygenated fuels Camshaft Endplay Plate SE Tools IRIE For checking camshaft endplay Camshaft Seal Protector Aegis SE Tools KLR 82417 For protecting seal during camshaft instalation Cylinder Leakdown Test For checking combustion retention and if cylinder piston rings valves are worn 25 761 05S individual component available Design Technology Inc Adapter 12 mm x 14 mm Required for leakdown test on XT 6 engines DT T3 05 Dealer Too Kit Domestic Kahler 25 761 355 Complete kit of Kohler required tools Components of 25 761 39 5 Ignition System Tester Kohler 25 455 01 5 Cylinder Leakdown Tester Kohler 25 761 05 5 Ol Pressure Test Kit Kohler 25 761 08 5 Rectfier Regulator Tester 120 V 2 Kohler 25 761 20 8 Dealer Too international Kohler 25 761 42 5 Complete kit of Kohler required tools Components of 25 761 42 S Ignition System Taster Kohler 25 455 01 5 Cylinder Leakdown Tester Kohler 25 761 05 5 Jol Pressure Test Kit Kahler 25 761 06 8
98. on brushes in their pockets in caer Move hom to retracted positon and instali carton stapes to retain thom Align terminal stud tock with notch in starter tame and broshiearier assembly mo ame Commutator wil push carton staples out as brush assembly e installed Foston ond over Suh esami so holes for thv ot are sioned wih hose in brush carier 5 stall thru bolls and tighten securely 5 Lubricate drive shaft with Kohler starter drive brcant Instal ave components flowing instructions for servicing starter drive 24 69007 Rev B SOLENOID SHIFT ELECTRIC STARTERS Solenoid Shift Starter Components oa o nol x Tus z Washer C Amae D Drive E Siop F Rering Ring Colar H Dive End Cap T Screw J Plunger X Spring L Lever M Piate Pug O Solena P Frame and Fa Buen Holder Nut End Screw s Pits T T Bor When power is applied Io starter electric solenoid moves drive pinion aut nta driva and into mash with fywheel ring gear When pinion reaches end of dive shaft it rotates flywheel and cranks engine When engine starts and start switch is released starter solenoid deactivated drive lever moves back and rive pinion moves out of mesh wih ing gear retracted position 24 690 07 Rev B Starter System Nippondenso Starters Starter Disassembly NOTE When removin
99. on rings and cylinder in good condition Gauge reading in moderate yellow zona Engine is sill usable bul there is some wear present Customer should start planning for overhaul or replacement Gauge reading in high red Zane Rings andlor cylinder have considerable wear Engine should be reconditioned or replaced 24 690 07 Rev B Kohlernginos E Air Cleaner Intake AIR CLEANER These systems are CARBIEPA certiied and components should not be altered or modifed in any way Low Protile and Commercial Mower Air Cleaner Components A J Ar Cleaner Cover B Ar Cleaner Knob C D Element Gover E Rubber Seal Precleaner 6 Paper Element H Ar Cleaner Base T Element Cover Nat J Rubber Seat K Sud Heavy Duty Alr Cleaner Components L Ar Gleaner Housing M Element N EndCap O Dust Ejector Valve P Reanna cip mner Element R Elector area S Inlet Screen T Fier Minder NOTE Operating engine with loose or damaged air seanar components could cause premature wear and falure Replace all bent or damaged components NOTE Paper element cannot be blown out with compressed alr 2 KohlerEngines com Low Prolile Commercial Mower Loosen knob and remove air cleaner cover Preceaner Remove precleaner rem paper element 2 fup riu reden vam ad delergent Rinse and alow to ar dn 3 Saturate prac
100. ontrol bracket and ar cleaner support bracket f used to cylinder heads using screws Torque screws lo 10 7 Nm 95 in Ib ito new holes or 7 3 N m 65 In Ib nto used holes KohlerEngines com 5 Rogulation others 10 8mm Governor Lever and Hole Position RPM Charts A GovemorLever Hole T c Hole 2 D Hole 3 E Hole 4 2469007 Rev Reassembly CV18 Engines V20 740 Engines Without Throttle Limiter tances Engine Mounted Maximum RPM Throttle Contro THe Control ritis Contro 19 Control ae wor ioe ae ee iue ser Wer aio Hote no 3605 Gen 4 Orngs 4 3688 3606 Rei 4 Bus sm sue 4 creon 4 sro sso pumo orange 3 aer orange me 4 3er2 saoo Bak ases 3300 Car 4 orange amo Red formge 2 rod 3 creon seo Pumie 2 cren 2 3100 Pune 2 sito me 2 sue 2 axo mue 2 pupie 2 3000 orange 1 orange 1 ana 2900 orange Be 2 eno cem 2 sack 1 omo mme 1 Groon 1 amo Rea 1 rea 1 20 740 Engines with 02299 0003 in Thick 22 GA Throttle Limiter Intended Standard Enorme Mounted Maximum RPM rnrotile Con
101. oper maintenance Cock carburetor roat for dit Dirt in throat is further Indica that alr cleaner was nol lunctioning pror het of evel stn operating ange on Space it is above snif or gasoline odor Check conan of ol Drain ol inta a container It Should ow freely Check for metal chips and other Foreign paries Sludge natural by product of combustion a small accumulation is normal Excessive sludge formation could indicate over rich fuel settings weak igniton overextended change interval or wrang weight r type of oll was used CLEANING ENGINE warnine 7 Cleaning Solvents can cause severe injury deat Use only in well ventilated areas away from ignition sources Carburetor ceanars and solvents are extremely flammable Follow cleaner manufacturers warnings and instructions on proper and safe use Never use gasoline a cleaning agent After inspecting external condition of engine clean engine thoroughly before disassembly Clean individual Components as engine is disassembled Only clean parts be accurately inspected and gauged for wear Gr damage There aro many commercialy avaiable Cleaners that wil quickly romove grease ol and grime rom engine parts When such a cleaner is Used falow manufacturer s instructions and safely precautions Carey Make sure all traces of cleaner are removed before engine reassembled and placed into operaton Even Small amounts of these clean
102. or movement of ine on screen relativa to line an blower housing I Both cyindors had good spark repeat test on other cylinder Condition Possible Cause Conclusion on screen dd not move aw Tast gon modules and from ina on Blower housing duning b acceleration Les made on Blower housing not So art Test ignition Modules and Connections DSAI Remove blower housing from engine Inspect wing for any damage cuts bad crimps loose terminals or broken wires Check that connections are oriented propery on terminals of modules 2 Disconnect leads from ignition module s and clean all of terminals male and female with aerosol electrical contact cleaner to remove any old dielectric compound dark residue dirt or contamination Disconnect spark plug leads rom spark plugs 3 Using a mult meter check that a propor ground established between ground black lead of DSAI module closest to sparkplug lead and a known good ground location on engine 4 Turn key switch to ON positon and check for 12 volts at centeripower red lead terminal of DSAI module Use same ground locaton for mull metar as in checking for timing advance Condition Possible Cause Conclusion AT Tasis are OK bul modula has no ignition Module Replace affected modue spark or fails to advance Any test ls BAD Module or Connections Determine cause and fx as required ratas 24
103. over Fastener TaN 851916 1 Or Drain Pug 1588 m OT BJ Cynder Head ead Fastener Hex Flange Nut torque in 2 increments festto 16 9 Nm 160 in finaly to 39 N m 00 Fead Bok orgue n 2 Tneremenis Trst to 226 N m CO0 n Ib finaly to 41 8 Nm 370 b Rocker Am Screw TSN m 00m ib Fan Fastener SENTI Fiyshesl Retaining Screw SANM WORD Fuel Pump Fastener Governor Lever Nat EXWSUSUTORI Ignition Spark Pug TETAS Module Fastener 762 Nm 95 55 in 6 Regulator Fastener Ta Nem 128 Mutter BEY Ol Cooler aper TRAE Ol Seny Pressure Sui ZENA WORT QI Pan Fastener 243 Nm 216 mb Solenoid Starter Mounting Hardware Nippondnso Starter 5090Nm 379 b Daico Romy Starter 2060 Nm 689 b Nut Positive Brush Load ippondanao Starr 40 120 Nem 71 106 in Ib Delco Remy Starter 80 10 Nm 71S7 ib Speed Control racket Fastener TN 05 eris no used noies Values aro in Metric units Values in parentheses are English equivalents Lubricate threads with engine o prior to assembly 2460007 Rev B KoblerEngines com a Specifications TORQUE SPECIFICATIONS cviacv2o cV22iCV2N CV750 CV cve70 cVeB0 CV740 CV620 CV640 Starter Assembly Thru Bot Inertia Drive 4 5 5 7 Nm 40 50 in b Nippondenso Solenoid Shit 4575 N m 40 84 in Ib Deleo Remy Solenoid Shit 5590
104. peed A pliers should be used to bend this tab to Achieve recommended speed Governed ila speed RPM is typically 300 REM approximate higher han low ide speed 3 Move throtle lever to wide open ull throttle position and hold in this position Turn high speed screw to obtain intended high speed no load RPM Governed idle speed must be sel before making this adjustment Low idle Fuel Adjustment Optimum Low Idle Fuel Setting Lean Tat Sida c Midpoint D E Right Side NOTE Engines wil have fixed low or limitar caps on ide ual adjusting needles Stop 2 can only be performed within mts allowed by Do not to remove miter caps 1 Place throttle control nto idle or slow position Adjust low le speed ta 1200 RPM Follow Low Ida Speed RPM Adjustment 2 Low idle fuel needles setting place trot inta dia or slow postion Tum 1 low idle fuel adjusting needle out counterciockwise from preliminar uni Engine speed decreases icn Nole postion ol needle Now tum adjusting needle in clockwise Engine speed may increase non wil decrease ume in lean Nota poston of ead Set adjusting needle midway between neh and lean stings b Repeat procedure on other low idle adjustment carburetor on 3 Recheckiadust Low dio Speed RPM to specified seng KohlerEngines com x Fuel System igh Speed RPN Adjustment 1 With engine
105. pem L Teste Conr M UnkageSprng N Throtie Linkage O Carburetor Gasket P Choke Linkage Q Choke Lever Screw s ote Shall Spring Remove screws securing tate control racket and lower air cleaner brackel some models lo cylinder heads Disconnect spring from governor lever note hole locations for feastembiy 3 Remove choke linkage from choke actuator lever carburetor 24 69007 Rev B T Disconnect wire leads rom start switch on Biawar housing f equipped Disconnect from rectifier regulator Use tp of dipstick or a similar small lat bal to bend locking tang then remove terminal fem conor pasion im plug TNs wil alow ower housing to be removed wihout disturbing wing harness 2 Reclferregulalor does not have to be detached rom blower housing If engine is equipped with SMART SPARK remove mounting screws from spark advance nodule SAM Module wil hang as ol wiring harness 3 Remove screws securing outer batlles Note location tary ing sirap and pasion of hori screws one each side on bottom for reassembly 4 Remove outer batles Il tyaheel screen overlaps blower housing remove fasteners and sereen I R was metal cidem wih long also remove remaining hardware and cooing tan 6 Remove remaining screws securing blower hous Note 1 siver pated screw used for rector regular ground sop or lead Remove blower housing KohlerEngines com s9
106. ps Note orientation of pump before removing 1 Disconnect fuel Ines from inlet and outlet 2 Remove screws securing pump and fuel pump 3 Remove pulse lino that connects pump to crankcase Install a new pump using screws Connect pulse line between pump and crankcase Torque screws to 2 3 Nim 20 in b Connect fuel lines to inet and outlet fittings When engine starts hard or tums over but vill not start fuel system might be causing problems Test fuel system by performing following test 1 Check for fuel in combustion chamber Disconnect and ground spark plug leads b Close choke on carburetor Crank engine several times Remove spark plug and check for fuel at tip 2 Cheek for fuel from tank to fuel pump Remove fuel line from inlet fiting of fuel pump b Hold line below bottom of tank Open shutoff valve f equipped and observe flow Condition 3 Check operation of fuel pump a Remove fuel line from inlet fiting of carburetor Crank engine several times and observe flow Conclusion Fus at ip of spark pug Fusr s reaching combustion chamber No fuel at lip o spark plug Check fuel from fuel tank step 27 Fuel flows fuel Ine Check for faulty fuel pump step 3 tut pump working check for faulty carburetor Refer Carburetor a fuel Tow from Toa ina Check fuel tank cap vent Tual pickup screen Trina fier shutoff v
107. rom brush assembles Do lose springs b brushes back in their siots so hey are fush wath LD of brush holder assembly Insert brush installation ool wi extension or use described above rom a prior brush instalation rough brush holder assembly so fles in mata maniing ars uplaul Install brush springs and snap on retainer caps 4 Hold starter assembly vertically on end housing and carefully tool with extension and assembled original brush holder assembiy onto tnd of armature shaft Side brush holder assembly down into place around commutator instal postive brosh lead grommet n cuta cl Trara Install end onto armature and frame alinin Tin raised rb in end cop win corresponding sion grommet of postive brush lead 12 Install thru bolts and brush holder mounting screws Torque bot o 56 90 Nm 49 19 and brush helder mounting screws 2 33 Nim 2229 n b Hook plunger behind upper end of drive lever and png mto solent inco rough holes in dive end cap Use these o hold Solenoid gasket in positon then mount slane b Connect postive brush leadirackat ta solenoid nd secure win nut Torque Nm Pa b Do nor ov r ghtn 24 690 07 Rev KohlerEngines com Starter System Solenoid Tests NOTE DO NOT leave 12 voli teal leads connected ta solenoid Tor any Uma over what
108. running move throttle control to fast 2 inner adjustment screw outward to decrease or inward lo increase RPM speed Courage singles loosening screws on speed contol bracket and siding towards carburelor to lower and away carburetor lo increase speed Carburetor Servicing E 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 figh atitudes are avallable Inspect cobro body for cracls holas nd or tinago oat tbs Check foal hinge and shat for inspect fel iat needle and seat for wear or damage Inset sorg oa choka piq lo mako sira WARNING Accidental Starts can cause severe injury or Disconnect and ground spark plug lead s servicing 1 umts arate 2 haem afc ae fe al See ens a mat F ee wa Se te ee ae 3 Remove float pin some carburetors may have a Screw which requires removal and inel needle Seat for imet needle s nol serviceable and should abe removed 4 Clean carburetor bow and inlet seat areas required 5 Carefully remove main jets from carburetor For wo bartel carburators nate and mark Jets by location far proper reassembly Main jets may be specific A er main jets are removed on Som
109. s Service Clean spark plug recess Remove plug and replace 4 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 Nm 20 ft Ib 2 KohlarEnginas com Awa piq E caused by excess uel or on combustion Chamar Excess cout be caused by a air leaner a carburetor problem or operating engine with Tao muen choke Ol in combustion chamber is usually caused by a resincted air loaner a breather problem orn pista rings or valve guides 24 690 07 Rev B Carbon Fouled Soft sooty Black deposits indicate incomplete combustion caused by restricted air cleaner over rich Electrical System ELECTRONIC IGNITION SYSTEMS Ignition System Components di Ny KII SwIENOT arburetion weak poor compression al Gun pum Overheated Switch 5 Magnet E Spark Pug F ignon Modes Talk while deposits indicate very high combustion temperatures This condito is usualy accompanied excessive gap erosion Lean carburetor settings an Intake ar leak orincoreci spark are narmal ausos lor high Combustion temperatures BATTERY A32 vot battery with 400 cold cranking amps cca is Geraralyrecotrended or staring in ai canalons A Smaller capacty battery is often sufficient Ian application is stared oniy In warmer temperatures Refer Aion table tor minimum copactes based os antic
110. s Stator Is OK not shored no continuity lo ground Resistance or continuly Stator leads are shored To measured ground replace 48 KohlorEnginos To test charging system for battery continuously charging at high rate 4 With engine running at 3600 RPM measure voltage from B lead to ground using a OG voltmeter Condition Conclusion Varageis 147 volts or Charging system is OK less Battery is unable to hold charge service or replace valage mare than 14 7 Faulty recie regulator vals replace 24 690 07 Rev B 3 Amp 70 Watt Lighting Stator NOTE Zero ohmmeleres on each Scale to ensure accurate readings Voltage tests should bo made with engine running at 3000 RPM with no load Battery must be good and fully charged To test charging system for no charge to battery 4 With engine running in fast setting measure voltage across battery terminals using a DC voltmeter Condition Conclusion Vatage is more than 125 Charging system s OK vals Voltage s 125 volts or Stator or diode are loss probably fautty Continue esting stator and diode 2 Remove connector fram rectifier rogulator With engine runing in fast postion measure AC voltage Electrical System To test charging system for no lights 1 Make sure lights ro not burned out Condition Conclusion 2 Disconnect lighting lead from wiring harness
111. s 28 valls or Stator winding is OK OK 2 approximately 0 4 ohms Voltage Is ess than 28 Test stator using an Resistance Ts 0 ohms Statris shorted Replace vals lohmmetae satr Resstanceisily Stator or lighting leadis 3 With charging lead disconnected from battery and Jopen Replace stator KohlerEngines com ar Starter System NOTE Do not crank engine continuously for more than 10 seconds Allow a 60 second cool down period between staring attempts Failure to follow these guidelines can burn out starter motor NOTE I engine develops sufficient speed disengage startar but does not running a false star engine rotation must be allowed to come to a complete stop before attempting Io restart engine f starter is engaged while flywheel is rotating starter pinion and flywheel ring gear may clash and damage starter NOTE If starter does not crank engine shut off starter immediately Do not make further attempts to start engine until condition is contacted NOTE Do not drop starter strike starter frame Doing so can damage starter Engines in this seres use inertia drive solenoid shift or retractable starters Troubleshooting Starting Difficulties Condition Possible Cause Conclusion Starter does nat energize Battery Chack specific graviy of battery If low recharge or replace battery as necessary Wing Clean corroded connections and tighen loose connections Repl
112. s with a brush or compressed al 2 Remove screws securing cooler and tit to clean Back side 3 Reinstall oll cooler Crankcase Mounted Cooler Clean ins wi a brush or compressed ar a aa OIL SENTRY i equipped This switch is designed to prevent engine from starting ina low ail or no o condition Senlty may not shut own running engine before damage ecu In some applications his switch may activate a warning signal Read your equipment manuals for more information Oil Sentry pressure switch is installed in breather cover On engines not equipped with Ol Sentry instalation hole e sealed wil a 1 27 pipe plug 24 690 07 Rev B Installation 1 Apply pipe sealant with Telon Lootte PST BSZW Thread Sealant or equivalent to threads of switch 2 Install switch into tapped hole in breather cover 3 Torque switch to 4 5 N m 40 in l Testing Compressed ar a pressura regulator pressure gauge and continuity tester are required la fest swich 1 Connect continuity tester across blade terminal and metal case of sch Wi Ops pressure applied Sta tester shuld diat swich E 2 Gradually increase pressure to switch As pressure increases through rango of 3 3 teslar should indicate change to continui switch open Simien shold main apen pressure is PE asd 10 00 pai maximum 3 Gradually decrease pressure through range of 3 5 Testr should indica
113. scoring of cylinder Wall washes necessary lubricating ol off piston and wall As raw uel seeps down cylinder wall piston rings make metal Lo metal contact with wall Scoring of cylinder wall can also be caused by localized hot spats resuling rom blocked cooling fins from inadequate or contaminated lubrication cylinder bore is badly scored excessively wor tapered or resizing necessary Use an inside micrometer to determine amount of wear refer to Specifications then select nearest suitable oversize of either 025 mm 0 010 in or 0 50 mm 0 020 in Resizing to 1 of nese oersizos wll alow usage of Available oversize piston and assemblies Fis Tesizo using a boring bar then use following procedures foeteningeyindor Bis Honing Detail 2533 Crosshalch NOTE pistons are custom machine exacting tolerances When oversizing a cylinder i shoul be machined exactly 025 mm 010 or 0 50 mm 0 020 in over new diameter refer to camespondng oversize Kor replacement piston wil then fit Correctiy KohlerEngines While most commercially avalabe cylinder hones can used with ether portable anis or N presses Uae fa low speed del Press is preferred as faciales more accurate algnment ol bore m relation to crankshaft rossbore Honing s bes accomplished aL a drli speed St about 250 RPM and 60 strokes p
114. t ignition modules Make sure magnet doas not sti modules Check with a feeler gauge and readjust if necessary Fai gap 0200030 mm 0 110 013 in Install Intake Manifold Torque Sequence i 9 OTE T wires ware disconnected Trom ignilon modules on engines with SMART SPARK reattach leads and seal base of terminal connectors with GE Novaguard G661 or equivalent dielectric compound Beads should overlap between Terminals to form a sold bridge of compound Do nat put any compound Inside terminals 24 484 15 5 igniton modules have a separator barrier between terminals On these module seal base of terminals but s not necessary to have overlapping beads of sealant between connections 1 Instali intake manifold and new gaskets or O tings laste manifold wih wiring harmase attached la inder heads Sige any wring hamess clips onto propriate baits before installing Make sufe Jaskels ara in proper orientation Using sequence Shown torque Screws in two increments frat to TA Nim 68 in 1b J then to 99 N m 88 in b 2 Connect kil lead to tab terminal on standard ignition modules 24 69007 Rev B Reassembly Install Breather Cover and Inner Battles Breather Cover Torque Sequence D S RIV sealant was used on models between Leather cover and crankcase A gasket wih imprinted sealant beads is now used and recommended install as 74 1
115. t Kit For tasting verifying oil pressure on pressure lubricated engines Koner 25781065 Radiator Tester For pressure testing radiator and cap on Aegis liquid cooled engines Kotler 25455105 Rectifier Regulator Testor 120 volt current Rectifier Regulator Tester 240 volt current For testing rectifier regulators Components of 25 761 20 5 and 25 761 41 8 CS PRO Regulator Tesi Harness Special Regulator Test Hammes with Diode Kohler 25 781 20 5 Kohler 25 781 41 8 Design Technology Inc DILO Spark Advance Module SAM Tester For testing SAM ASAM and DSAM on engines with SMART SPARK Kotler 25781405 Starter Servicing Kit AN Starters For removing and reinstalling dive retaining rings and brushes Individual component available Starter Brush Holcing Tool Solenoid Shit SE Tools KIRAAT Tools KLR 82416 Triad OH Timing Tool Set For holding cam gears and crankshaft in timed position while installing timing belt Kohler 28 781 01 5 Vaive Guide Reamer K and M Series Far properly sizing valve guides after installation Design Technology ine EOM Valve Guide Reamer O S Command Series For reaming worn valve guides to accept replacement oversize valves Can be used n low speed dril press or with handie below for hand reaming Kohler 25 455 12 8 Reamer Handle For hand reaming using Kohler 25 455 12 5 reamer Dasan Technology ine OSTEKO Valve Guide Service Kit
116. t and bring front and Tear sop ealars together over retainer Using tao pairs of pers apply even force to two collars unti thay snap over retainer and nest into one another 4 Reassamble remaining components of starter in reverse order from cicdssembly Delco Remy Starters Starter Disassembly NOTE Do not reuse old retainer NOTE Do not soak armature or use solvent when cleaning Wipe clean using soft cloth or use Compressed air KohlerEngines com E Starter System 4 Remove hex nut and disconnect positive brush ieadibracket solenoid terminal Remove head screws securing solenoid to startar 3 If solenoid was mounted with Philips head screws separate solenoid and plunger spring from drive ahd Cap If solenoid was mounted with external Tors head screws plunger is part of solenoid unhook plunger pin from drive lever Remove gasket from focess in housing 4 Remove thru larger bolts 5 Remove commutator ond plate assembly containing brush holder brushes springs and locking caps Remove thrust washer fom inside commutator end Remove frame from armature and drive end cap 7 Remove drive lever pivot bushing and backing plate from end cap 8 Take out drive lever and pull armature out of drive end cap 9 Remove thrust washer from armature shaft 10 Push slop collar down to expose retaining ring 11 Remove retainer from armature shaft Save slop collar 12 Remove drive pinion assembly
117. te a change to Switch dosed down to D psi Replace switch fit does not operat as specified 24 69007 Rev B KohlerEngines com Lubrication System 3 Electrical System SPARK PLUGS Inspection AME Do not touch wires while engine is running caution Electrical Shock can cause injury Spark Plug Component and Detalls oT 0 Wie Gauge B Spark Pg Ground B Gap NOTE Do not clean spark lug in a machine usin abrasive grit Some grit could remain in spark lig and enter engine causing extensive wear Sind damage Engine misfire or starting problems are oten caused spark plug hat tas proper gap o n por Engine is equipped with following spark plugs inspect each spark plug as 111 removed from cylindor head Deposits on are an indication of general Condition ol piston rings valves and carburetor Normal and fouled plugs are shown in following photos Normal Plug taken from an engine operating under normal conditions wil have light tan or gray colored deposits If center electrode is not wom plug can be set to proper and reused Ona wom plug center electrode will be rounded and gap Wil bo Greater than specified gap Replace a worn Spark plug immediately Wet Fouled Gap 076 mm 033 n Thread Size 14 mm Reach eiman Hex Sze 150 mm 58 n Refer to Maintenance for Repairs Service Part
118. ter lead Connections are not locaton specific 4 Connect remaining black lead from tester to 1 outer AC terminal on reciflaccequator 5 Plug tester into proper AC oulltpower for ester used Turn oh power swich BOWER light Should be llorinaled and 1 c 4 status igts may be n as well This does nol represent condilion of Part 6 Press TEST button unl a cick is heard and then feleaso Momentanly 1 of 4 satus gs wit l minaie ndicatng partal conditon of part Conclusion damp Amp amp 2E amp OK groan or HIGH gh comes on sna Saye end Partis good and may be used Disconnect tester black Tead attached fo TAC terminal and reconnect ito other AC terminal Repeat test If OK green ight comes again partis good and may be used NOTE flashing LOW Iigh can also occur as a result l an inadequate ground lead Connection Make certain connection locaton is clean and clamp is secure Other lights come on Rectifier regutator i faulty and should not be used 24 690 07 Rev B KohlerEngines 45 Electrical System 18 2025 Amp Battery Charging Systems NOTE Always zero ohmmelor on each scala before testing 1o ensure accurata readings Voltage tests should be made with engine running at 3600 RPM with no cad Battery must be good and fully charged When problems occur in keeping battery charged or battery charges at high rate charging system or battery m
119. th sides Test SAM stop 4 Er a spark problem Test SAM Test SAM 1 Trace red power source lead from SAM to harness connection Separate connector and connect red lead of a DC voltmeter to harness terminal Trace ground lead from SAM biack on singles green on twins to grounding screw Connect black voltmeter lead to eyelet terminal of ground lead or ground screwbol Check voltage kay Switch in both START and RUN postions A minimum of 7 25 volts must be present If correct voltage is not measured connect voltmeter lead directly to negative post of battery and test voltage again in both key positions If correct voltage s now indicated check ground cireuit connections I ground serew bolt or any other fasteners in ground circuit are black oxide coated replace them with zinc Plated silver colored fasteners b If corect voltage is stil not indicated check harness connector terminal for a good connection and crimp to Jead Thon trace power source creuit back trough harness Key switch etc looking lor any poor connections or faulty circuits Condition Possible Cause Conclusion Incorrect voltage 1 measured Voltage Connect black volimater lead areal pete see Sere stir eres ete Neate eas Especie Mee TEE F E or EET Sok pon eer ced eta oxide coated replace them with zinc a arta E Reape me ak i oa NG Spe a Reno Si wig eta i ma rue ay vce oti ume dT
120. times Conclusion to activate continui is indicated Plunger ais ta stay retracted Replace solenoid KohlerEngines com 24 690 07 Rev B RETRACTABLE STARTERS Starter System Remove Starter WARNING Wear safety goggles or face protection whan servicing retractable starter s Uncolling Spring can cause severe Injury Retractable starters contain a powerful recol spring thats under tension Always wear say han servicing reractatle starters and carey follow instructions in Retractable Starter fr relieving spring tension Retractable Starter Components segnem o 24 690 07 Rev B T Remove screws securing siarter fo blower housing 2 Remove starter assembly Rope Replacement NOTE Do not alow pulayispnng fo unwind Ente aid ofa helper f nacessary Rope can be replaced without complete starter disassembly 1 Remove starter assembly trom engine 2 Pull rope out approximately 12 In and t a Temporary sip kotin t keep rom retracting ino star 3 Pull inot end out of handie untie knot and side handia of 4 Hold pulley firmly and untie slipknot Allow pulley to ola slowly as spring tension s released 5 When al spring tension on starter pulley is released remove rope fem pullo a double left hand knot n one end of new rope 7 Rotate pulley counterclockwise
121. ting D Fan E Magnet F Stator G ignition Module H Sud T Sew J Woodruff Key L3 Manifold L Backing Piate m Flywheel N Washer e KohlerEngines Remove Intake Manifold 1 Remove screws securing intake manifold To cyinder heads Note which screws hold wiring clamps 2 Remove intake manifold and intake manifold gaskets aluminum intake manifolds or O ring plastic intake 3 Leave wiring harness attached manifold Remove Debris Screen and Fan 1 On engines wih a fat plastic screen small matar relates aro typically attached on 3 of 7 mount post or retention of plasic debra screen Lise a tool next to post ana pul outward io Separate of small metal retainers Thon unsnap from mounting posts 2 Remove screws or studs and washers Remove paste fan from fy Remove Fiywheel NOTE Always use a lywhsasrapwrenchorhaldng bolt hold tywheel when bosenng or ywneel screw Do not use any type bar or wedge hod wheel Use of duch fools could cause lywheel 1o become cracked or damaged NOTE Always use fiywheei puller to remove fom ania Do notte or as these parts could become cracked of damaged Sting puller or crankshaft can Cause crank gear to move affecting crankshaft day 1 Use a fyaheel strap wrench or holding tool to hold yal and looser screw securing wheel io 2 Remove screw an
122. tons and Rings NOTE Wa carbon ridge is present at op of ethor cylinder bore uso ridge reame tool to remove attempting to remove piston NOTE Cylinders are numbered on crankcase Use numbers to mark cach end cap connecting rod and piston for reassembly Do Hot mix end caps and Connecting rods i 1 Remove screws securing closest connecting rod end Remove end 2 Carefully remove connecting rod and piston assembly rom cylinder bore 80 3 Repeat above procedure for other connecting rod and piston assembly KohlerEngines com er isassembly Inspection and Service Piston and Rings Inspection Piston and Rings Components and Details AT snum e enesenn D Peen p __ QS Rina G Ria BE u Dyecobrea sube Inspection NOTE Rings must be installed Ring instalation instructions are usualy included with new ring see Follow netuclons careluly Use piston ring expander to instal ings Install stom ol control ring fest and top compression ring last Scuffig and scoring ol pistons and cylinder walls occurs when tema engine temperatures approach weiding point ot piston Temperatures high enough to do this are read by tichion which is usualy atrtuted to Improper Arator andlor overheating of engine Normally very lite wear takes place in piston boss plon pi area I origin
123. trol Tattle Control de wor mee We calor Hote No 3685 3800 4 Pune 4 areo 4 3672 seo 3 Rea 4 asea 3300 Cear 4 3 3200 Roa Pupe 2 rea 3 3000 mue 2 clear auo 2000 orange 1 Rea 2 aoza 280 1 eee 1 Engines E Tienda Hasimum RPH Wit Governed idis Systems Configuration High dle wor Spring Color Hote No E 3 3780 5500 orange 1 Standard 3672 3400 1 Parent Material asea 5300 Red 1 5200 lear 1 100 lar 1 24 69007 Rev B KohlerEngines com Reassembly Install Electric Starter Motor Install Air Cleaner Assembly 1 Install starter molor using screws Postion WT bracket to also secure dipstick tube Some inertia drive starters have pinion cover and spacers on Starter bolts 2 Torque screws to 15 3 Nm 135 in b 3 On models with a solenoid shift starter connect leads lo solenoid 4 install dipstick tube and align mounting hole with threaded hole in i bracket Secure with MS screw Torque screw to 4 0 Nm 35 In I Install Fuel Pump bums y Do not fil fuel tank while engine is hot or running WARNING Explosive Fuel can cause fires and severe Gasolina extremely amable and fs vapors can Explode ine Ste gasaina m approves containers n well ventlaled un
124. ubwalonSysem e Rapace fuel fito Every 250 Hours e Replace heavy duty cieanar element and check inna TRF eareke Every 500 Hours Replace heavy duty inner air cleaner Temen Air Cieaneriintake Replace spark plugs and set gap Electrical System Every 500 Hours e Have crankshal spine lubricated 1 Perform these procedures more frequently under savere dusty dirty conditions Have Kohler authorized dealer perform this service REPAIRS SERVICE PARTS Kohler genuine service parts can be purchased from Kohler authorized dealers To find a local Kohler authorized dealer visit KohierEngines com or call 1 800 544 2444 U S and Canada 24 69007 Rev B KohlerEngines com 3 Maintenance OIL RECOMMENDATIONS We recommend use of Kohler olls far best performance Other high quality detergent oiis including Synthetic Of API American Petroleum Institute service class SJ r higher are acceptable Select viscosity based on air temperature al ime of operation as shown in table below FUEL RECOMMENDATIONS wanuna Explosive Fuel can causa fres and severa bums 77 Do not fl fuel tank while engine is hot or running Gasolina is extremely llammable and fa vapors can explode f ignited Store gasoline only in approved Containers n well ventlaled unoccupied buildings away from sparks or ames Spied fu could gite Vi comes in contact w
125. va Govar ana a vane Covor R sesar Remove Cylinder Heads and Hydraulic Lifters NOTE Cylinder heads are retained using either screws or nuts and washers on studs Do not Interchange or mix components as cylinder heads may have diferent machining unique to each fastening method 4 Remove screws or nuts and washers securing each cylinder head Discard screws or nuts and washers once removed Do not reuse Studs if present should only be removed if damaged or if cylinder reconditioning is necessary Once removed they must be replaced 2 Mark location of push rods as elther intake or exhaust and cylinder 1 or 2 Push rods should always be reinstalled in same positions 3 Carefully remove push rods cylinder heads and head gaskets Remove liters from litar bores Use a hydraulic liter tool Do not use a magnet to remove liters Mark lifters by location as either intake or exhaust and cylinder 1 or 2 Hydraulic trs should always be reinstalled in samo poston 24 69007 Rev B KohlerEnginos com Disassembly Inspection and Service Disassemble Cylinder Heads NOTE These engines use valva slam seals on jake valved Use anew seal whenever valve Ts removed ori seal is deteriorated or damaged in any way Never reuse an old seal Remove screws rocker arm pivots and rocker ams from cylinder head 2 Compress valve springs using a valve spring compressor 3 Once valve spring is compressed remove
126. vers requiring RTV sealant apply 1 5 mm CR bead ta sealing sacer of oh cyinder heads instala new cover gasket on each non apply a second bead ol on top surface of Jaskals For O ring covers install new Oi groove ofeach caver Bo nol use gasket sealant 4 Position covers on cylinder heads Locate cover with separator hole on cyinder 1 If loose spacers Were usad a spacer in aach screw hole natal screws n each cover and finger tohten 5 Torque valve cover fasteners to proper specication Using sequence Shown unless screw alo attach heavy duty air cleaner main support bracket or other components Installation and lorqung of screws wil performed alie those paris are stalled Torque Specifications Covers GaskaURTV Sanm GOR Ib Black O ring wishoulder screws 5 6 Nm 50 n lb wiscrews and spacers 89 Nim B8 in Ib Yalow or Brown O ring wintegral spacers 62 Nm 55 in 1b Install Carburetor A warning Explosive Fuel can cause fires and severe bums 77 Do not fl fuel tank while engine is hot or running Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved Containers In well ventilated unoccupied buildings away from sparks lames fuel could git if it comes in contact wit hot parts or sparks from Control Panel Components Reassembly ignition Never use gasoline as
127. w 17 00617 012 mm 0 8695 0 6698 in Max Wear Limit 17025 mm 0 6703 in Pin OD New 16 995 17 000 mm 0 6691 0 6693 in Max Wear Limit 16 94 mm 0 6691 in Tep Compression Ringo Groove Side prog PER 00307 0025048 Clearance o 085mm 0080 007mm 000100001910 00016 000167 0 00127 0 003310 00031 0 0030 in Midde CompressionRUnpi Grove Se DO 7 0807 00307 TOTS OST mm Clearance 0 080 0 080mm 0076mm 0 0006 0 0015 in 0001207 000167 0 00127 0031 in 00031 0 0030 in Oi Control Ringto Groove Side Clearance 0 0467 0 0607 p CORB 17 mm o201mm 0202mm 0196mm 000106500705 oooi 000247 00018 0007910 00080 00077 in Top and Middle Compression Ring End Gap New Bore 025 056 mm 043mm O4bmm 0010060224 00098 00071 O01740 00181 Top Ring 04801 0 380 mm 000717 00180 Ring 0430 mm E 0 00717 00173 Values are in Metric units Values in parentheses are English equivalents 12 KohlerEngines com 24 690 07 Rev B Specifica ns CLEARANCE SPECIFICATIONS cv17 CViBCV20 CV22ICVZN CV2SCV730 CV750 CV670 CVE80 CV740 CV620 CV640 Piston Piston Rings and Piston Pin continued Used Bore Max UIImm oam O84 mm OT 030 00315 Top Ring 070 mm E 0028 Middle Ring 090 mm e E 0035 n Trust Face OD New 2966 T6967 7998x 2986 mm 3 2671 in
128. when viewed from pawl side of pulley untl spring is ghi approximately 6 full tums of pullay 3 Continue rotating pulley counterclockwise unt rope fala in pulley aligned with rope guide bushing af Starter housing 3 Insert unknottad end of new rope through rope hole tror lo and rope gud busing e 10 a slipknot approximately 12 in from free end of Topo Hold pulley frmly and allow ttt rotate slowly slipknot teaches guide bushing ol housing 11 Insert starter rope through starter handle and te a double left hand knot al end of starter rope Insert knot nio hole in handle 72 Untie sip knot and pull on starter handle unti starter i fly extended retract starter rope inio Safter assembly f recai spring is propery lansioned siarter rope wil roact ly and starter handle wil stop agains starter housing KohlerEngines com 55 Starter System Pawis dogs Replacement 17 instala clamp to hold pulley T Tare Rousing and prevent f rom rotating 2 Remove center screw washer and eine 3 Note poston of and paw springs before removing Remove pawis springs brake Spring brake washer tom pulley 4 Cleaniwipe out center pocket of pulley to remove any accumulated dirt and ld lubricant 5 Apply small amount of grease to new brake washer and spring instal hor In center pocket 6 instali pawi springs and into pawi slots of pulley Al paris mustba ay
129. with mounting screw and washer against outer side of rector regulator 2 Install B terminalfead into center position of ect reguator plug and connect plug to rect regulator SMART SPARK Module On engines with SMART SPARKC reinstall SAM module to blower housing or cyindor Do not over ighten retaining screws Install Valve Covers Torque Sequence OTE Do not scrape oi RTV sealant i used o sealing surface of cylinder head as is could Cause damage and result leaks Use of gasket fomoversonent paini remover o 2 recommended Three valve cover designs have been used First ype Used a gasket and RTV sealant between cover ani Sealing surface of cyinder head Second had ick ng stall in a groove on underside of cover and may have metal spacers in holes Latest design uses a yellow or brown O ing wih balt hole spacers melded in place Tightening que diers between gasket and O mg style covers Kits are available or onvering to latest ype covers Dierences are pointed n folowing instalation steps 1 using gasket or sealant type cover prepare sea S racis of cyindar head ad cover Teler 10 Tools S and Ais for approved sealants Always use rash Sealant Using outdated sealani could result in With O ring covers make sure Sealing surfaces aro clean 2 Make sure there aro no nicks or burrs on sealing Surfaces 24 690 07 Rev 3 For co
130. ype of mounting hardware using thar screws of mounting studs with nuts and washers Heads are machined differentiy for studs than for Straws so fastening method cannot be altered unless heads are being replaced Do not intarmix components Match numbers embossed on cylinder heads and crankcase NOTE When Installing cylinder heads new screws should always be used Heads Secured With Screws V Check ta make sure thera are no nicks or burrs on sealing surfaces of cylinder head or crankcase 2 Install a new cylinder head gasket with printing 3 Install cylinder head and start four new hex flange 4 Torque screws in two increments first to 22 6 Nm 200 in b thon finally to 41 8 N m 370 in Ib following sequence shown Heads Secured With Mounting Studs Nuts and Check to make sure there are no nicks burrs on sealing surfaces of cylinder head or crankcase 2 fall studs were left Intact go to Step 6 If any studs Were disturbed or removed install naw studs as described in Step 3 Do nol use renstall any loosened or removed studs 3 Install new mounting stud s into crankcase Thread and lock 2 mounting nuts together on smaller diameter treads S 90 b Thread opposite end of stud with preapplied locking compound into crankcase unti specified trom crankcase surface is achieved When threading in studs use a steady tightening motion Wihcutintarupti unti proper height is NOTE

CV17-CV25, CV620-CV730, CV740, CV750 Service Manual

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