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TP-2527-A Aegis LH630

1. o aa Into Aluminum 1 2 11 1 7 15 2 9 26 4 1 36 5 0 44 2 0 18 2 5 22 3 2 28 5 8 51 8 1 72 9 7 86 4 0 35 4 3 38 5 7 50 9 9 88 14 0 124 16 5 146 6 8 60 10 5 93 13 6 120 24 4 216 33 9 300 40 7 360 17 0 150 Tightening Torque N m ft Ib or 20 Property Class Noncritical Fasteners Into Aluminum 21 7 16 27 1 20 47 5 35 66 4 49 81 4 60 33 9 25 36 6 27 47 5 35 82 7 61 116 6 86 139 7 103 61 0 45 58 3 43 76 4 55 131 5 97 184 4 136 219 7 162 94 9 70 Torque Conversions N m in lb x 0 113 N m ft Ib x 1 356 in lb N m x 8 85 ft lb N m x 0 737 English Fastener Torque Recommendations for Standard Applications Tightening Torque N m in Ib or 20 Bolts Screws Nuts and Fasteners Assembled Into Cast Iron or Steel Q Grade 2 Size 8 32 2 3 20 10 24 3 6 32 10 32 3 6 32 1 4 20 7 9 70 1 4 28 9 6 85 5 16 18 17 0 150 5 16 24 18 7 165 3 8 16 29 4 260 3 8 24 33 9 300 Grade 5 2 8 25 4 5 40 4 5 40 13 0 115 15 8 140 28 3 250 30 5 270 Tightening Torque N m ft Ib or 20 47 5 35 61 0 45 67 8 50 94 9 70 101 7 75 135 6 100 149 2 110 189 8 140 199 3 150 271 2 200 47 5 35 54 2 40 74 6 55 101 7 75 108 5 80 142 4 105 169 5 125 223 7 165 244 1 180 311 9 230 332 2 245 440 7 325 Section 1
2. bech bech bech bech bech bech bh Na Choke Repair Kit Contains aly Choke Plate Screw Choke Spring Choke Lever Choke Shaft Choke Plate Choke Bushing Choke Lever Cap Sealant 2 1 1 1 1 1 1 1 Reassembly Procedure Reassemble the carburetor using the following steps See Figure 5 6 1 Assemble fuel inlet needle to the float tab Install the float float shaft and inlet needle to the carburetor upper body Tighten the screw Check float height using the procedure found previously in the Adjustments subsection 2 Install the slow jet so the stepped end will be toward the bottom of the carburetor Make sure jet is fully seated 3 Install the low idle adjusting needle and spring 4 Assemble the carburetor upper body and carburetor lower body using the four screws Torque screws to 1 7 N m 15 in 1b 5 Install the carburetor on the engine following the procedures in Section 11 Reassembly Governor General The engine is equipped with a centrifugal flyweight mechanical governor It is designed to hold the engine speed constant under changing load conditions The governor gear flyweight mechanism is mounted inside the closure plate and is driven off the gear on the camshaft The governor works as follow e Centrifugal force acting on the rotating governor gear assembly causes the flyweights to move outward as speed increases Governor spring tension moves them inward as speed
3. 5B 26 Fault Codes The ECU continuously monitors engine operation against preset performance limits If the operation is outside the limits the ECU activates the MIL and stores a diagnostic code in its fault memory If the component or system returns to proper function the ECU will eventually self clear the fault code and turn off the MIL If the MIL stays illuminated it warns the customer that dealer service is required Upon receipt the dealer technician can access the fault code s to help determine what portion of the system is malfunctioning The 2 digit blink codes available are listed on page 5B 28 The codes are accessed through the key switch and displayed as blinks or flashes of the MIL Access the codes as follows 1 Start with the key switch off 2 Turn the key switch on off on off on leaving it on in the third sequence The time between sequences must be less than 2 5 seconds 3 Any stored fault codes will then be displayed as a series of MIL blinks from 2 to 6 representing the first digit followed by a pause and another series of blinks from 1 to 6 for the second digit See Figure 5B 35 a It s a good idea to write down the codes as they appear as they may not be in numerical sequence b Code 61 will always be the last code displayed indicating the end of code transmission If code 61 appears immediately no other fault codes are present Section 5B EFI Fuel System Example of Diagn
4. Air Cleaner Section 4 Carburetor amp External Governor Section 5 Ignition Charging amp Electric Starter Section 8 Clean all parts thoroughly Only clean parts can be accurately inspected and gauged for damage or wear There are many commercially available cleaners that will quickly remove grease oil and grime from engine parts When such a cleaner is used follow the manufacturer s instructions and safety precautions carefully Make sure all traces of the cleaner are removed before the engine is reassembled and placed into operation Even small amounts of these cleaners can quickly break down the lubricating properties of engine oil Use an aerosol gasket remover paint stripper or lacquer thinner to remove any old sealant Apply the solvent allow time for it to work and then brush the surface with a brass wire brush After the old sealant is removed clean the surface with isopropyl alcohol lacquer thinner or aerosol electrical contact cleaner Do not scrape the surfaces as any scratches nicks or burrs can result in leaks See Service Bulletin 252 for further information Refer to A Guide to Engine Rebuilding TP 2150 A for additional information Measurement Guide TP 2159 B and Engine Inspection Data Record TP 2435 are also available use these to record inspection results Camshaft and Crankshaft Inspection and Service Inspect the gear teeth of the camshaft and crankshaft If the teeth are badly worn
5. Cylinder Head and Valves Inspection and Service After cleaning check the flatness of the cylinder head and the corresponding top surface of the crankcase using a surface plate or piece of glass and feeler gauge as shown in Figure 10 5 The maximum allowable out of flatness is 0 076 mm 0 003 in 10 4 Figure 10 5 Checking Cylinder Head Flatness Carefully inspect the valve mechanism parts Inspect the valve springs and related hardware for excessive wear or distortion Check the valves and valve seat area or inserts for evidence of deep pitting cracks or distortion Check clearance of the valve stems in guides See Figure 10 6 for valve details and specifications Section 10 Inspection and Reconditioning Intake Valve E Exhaust Valve A Insert Seat Angle Insert O D 36 987 37 013 mm 1 4562 1 4572 in 32 987 33 013 mm 1 2987 1 2997 in Guide Depth 4 mm 0 1575 in 6 5 mm 0 2559 in Guide LD 7 038 7 058 mm 0 2771 0 2779 in 7 038 7 058 mm 0 2771 0 2779 in Valve Head Diameter 33 37 33 63 mm 1 3138 1 3240 in 29 37 29 63 mm 1 1563 1 1665 in Valve Face Angle 45 45 Valve Margin Min 1 5 mm 0 0591 in 1 5 mm 0 0591 in Valve Stem Diameter 6 982 7 000 mm 0 2749 0 2756 in 6 970 6 988 mm 0 2744 0 2751 in Figure 10 6 Valve Details A B C D E F G H 10 5 Section 10 Inspection and Reconditioning Hard starting or loss of power accompanied by high fuel consu
6. position Cable Low Idle 3 Set the low idle speed to 1200 RPM 75 RPM Speed Screw by turning the low idle speed adjusting screw in or out Check the speed using a tachometer NOTE The actual low idle speed depends on the application Refer to the equipment manufacturer s recommendations The low idle speed for basic engines is 1200 RPM Some early models contained an adjusting cable and knob attached to the adjusting screw See Figure 5 3 FY IA Figure 5 3 Carburetor with Adjusting Cable on the Low Idle Speed Adjustment Screw Early Models 5 5 Section 5 Fuel System and Governor Troubleshooting Carburetor Related Causes Possible Cause Probable Remedy 1 Engine starts hard runs roughly Low idle fuel mixture speed improperly adjusted Adjust the low or stalls at idle speed idle speed screw Low idle fuel mixture circuit blocked restricted Clean carburetor as required Engine runs rich indicated by Clogged air cleaner Clean or replace black sooty exhaust smoke Choke partially closed during operation Check the choke lever misfiring loss of speed and power linkage to ensure choke is operating properly governor hunting or excessive Float level too high Separate fuel bowl from carburetor body throttle opening Free if stuck or replace float Dirt under the fuel inlet needle Remove needle clean needle and seat and blow with compressed air Bowl vent or air bleeds p
7. Safety and General Information Grade 2 or 5 Fasteners Into Aluminum 08 Grade 8 18 7 165 22 6 200 39 6 350 40 7 30 67 8 50 81 4 60 108 5 80 142 4 105 155 9 115 223 7 165 237 3 175 311 9 230 352 6 260 447 5 330 474 6 350 637 3 470 Section 2 Tools amp Aids Certain quality tools are designed to help you perform specific disassembly repair and reassembly procedures By using tools designed for the job you can properly service engines easier faster and safer In addition you ll increase your service capabilities and customer satisfaction by decreasing engine downtime Here is the list of tools and their source Separate Tool Suppliers Kohler Tools SE Tools Design Technology Inc Contact your source 415 Howard St 768 Burr Oak Drive of supply Lapeer MI 48446 Westmont IL 60559 Phone 810 664 2981 Phone 630 920 1300 Toll Free 800 664 2981 Fax 810 664 8181 Tools Balance Gear Timing Tool K amp M Series Kohler 25 455 06 S To hold balance gears in timed position when assembling engine Formerly Y 357 Camshaft Endplay Plate For checking camshaft endplay oP er eee Cylinder Leakdown Tester For checking combustion retention and if cylinder piston rings or valves are worn pete eae Oe Electronic Fuel Injection EFI Diagnostic Software Kohler 25 761 23 S Use with Laptop or Desktop PC EFI Service Kit For troubleshooting and setting up an EFI engine K
8. See Figure 9 54 Figure 9 54 Removed Rocker Arms and Pivots 2 Compress the valve springs using a valve spring compressor and remove the valve spring keepers Remove the compressor See Figure 9 55 Figure 9 55 Compressing Valve Springs 3 With the keepers taken out the following items can be removed See Figure 9 56 e valve spring retainers e valve springs e valve spring caps e intake and exhaust valves e valve stem seals intake valve only Figure 9 56 Disassembled Head and Valve Components NOTE These engines use a valve stem seal on the intake and exhaust valves Serial No 3422000010 and lower used a seal on intake side only See Figure 9 57 Always use new seals when the valves are removed from the cylinder head Replace the seals if they are deteriorated or damaged in any way Never reuse an old seal Figure 9 57 Cylinder Head Showing Intake Seal 4 Repeat the above procedure for the other cylinder head Do not interchange parts from one cylinder head with parts from the other cylinder head Section 9 Disassembly Remove Closure Plate 1 Remove the ten hex flange screws securing the closure plate to the crankcase See Figure 9 58 If a thick washer is installed under the screw head in the 10 location and or one silver ground screw is used normally the No 4 or 6 position note these special assembly details for proper reassembly later Figure 9 58 Removing Closure
9. The engine coolant temperature sensor Figure 5B 7 is used by the system to help determine fuel requirements for starting a cold engine needs more fuel than one at or near operating temperature Mounted in the throttle body intake manifold it has a temperature sensitive resistor that extends into the coolant flow The resistance changes with coolant temperature altering the voltage sent to the ECU Using a table stored in its memory the ECU correlates the voltage drop to a specific temperature Using the fuel delivery maps the ECU then knows how much fuel is required for starting at that temperature Service The coolant temperature sensor is a sealed non serviceable assembly A faulty sensor must be replaced If a blink code indicates a problem with the temperature sensor it can be tested as follows 1 Drain coolant from system so level is lower than the coolant temperature sensor approximately 1 1 2 qt then remove the sensor from the throttle body intake manifold assembly 2 Wipe sensor clean and allow it to reach room temperature 20 C 68 F 3 Unplug the main harness connector from the ECU 4 With the sensor connected check the coolant temperature sensor circuit resistance Check between the 6 and 4 pin terminals The resistance value should be 2375 2625 Q See chart on page 5B 24 5 Unplug the sensor connector and check the sensor resistance separately Resistance value should again be 2375 2
10. break down the lubricating properties of engine oil 30 Remove flywheel end oil seals Typical Disassembly Sequence Disconnect Spark Plug Leads The following sequence is suggested for complete 1 Disconnect the leads from the spark plugs See D engine disassembly The sequence can be varied to Figure 9 1 accommodate options or special equipment NOTE Pull on boot only to prevent damage to spark plug lead Disconnect spark plug leads Shut off fuel supply Remove muffler Remove starter and adapter plate Drain coolant from cooling system Drain oil from crankcase and remove oil filter Remove flywheel cover radiator assembly mounting brackets and attached components 8 Remove air cleaner assembly 9 Remove throttle and choke controls 10 Remove external governor controls 11 Remove carburetor and adapter 12 Remove Oil Sentry 13 Remove breather cover 14 Remove valve covers 15 Remove lower drive pulley and fan belt Figure 9 1 Disconnecting Spark Plug Leads 16 Remove fan assembly mounting bracket and fan shaft 17 Remove ignition modules oe oS Ne 9 1 Section 9 Disassembly Shut Off Fuel Supply Drain Coolant from Cooling System 1 Loosen the radiator cap then loosen the radiator Remove Muffler drain plug and allow the system to drain Use 1 Remove the exhaust system muffler and a suitable container to catch the coolant See attaching hardware from the engine Figure 9 4 Remove Starter a
11. 2 FAULT CODES Refer to detailed Code 51 Injector 1 fault code listing before flow chart and servicing Code 52 Injector 2 i J l D D D information for the respective components k Code 55 MIL Diagnostic Light L Code 56 Pump Relay 1 Code 21 Engine Speed Synchronization 2 Code 22 Throttle Position Sensor TPS 2 MIL circuit grounded between light and ECU Pin 3 Code 23 Engine Control Unit ECU circuit 29 4 Code 31 Oxygen Sensor 5 Code 32 Oxygen Sensor 3 ECU 6 Code 33 Fuel System temporary adaptation factor NOTE The MIL diagnostic light used must be a 1 4 7 Code 34 Fuel System permanent adaptation watt incandescent lamp An LED style light factor will stay on continuously dim and should 8 Code 42 Engine Coolant Temperature Sensor not be used 9 Code 43 TPS Auto Learn Initialization Function Below Min Limit Diagnostic Aid 4 SPEED SENSOR MIL does not 10 Code 44 TPS Auto Learn Initialization turn off during cranking Indicates the ECU is not Function Above Max Limit receiving a signal from the speed sensor 11 Code 51 Injector 1 12 Code 52 Injector 2 Possible causes 13 Code 55 MIL Diagnostic Light 1 Speed sensor 14 Code 56 Pump Relay 2 Speed sensor circuit problem Pin circuits 9 and 15 Code 61 End of Fault Blink Code Transmission 10 3 Speed sensor toothed wheel air gap 4 Toothed wheel 5 Flywheel key sheared 6 ECU 5B 35 S
12. EFI engines are equipped with either a 15 or 25 amp charging system to accommodate the combined electrical demands of the ignition system and the specific application Charging system troubleshooting information is provided in Section 8 Fuel Components Fuel Pump External Internal Figure 5B 20 Fuel Pump Styles General An electric fuel pump is used to transfer fuel in the EFI system Depending on the application the pump may be inside the fuel tank or in the fuel line near the tank The pumps are rated for a minimum output of 25 liters per hour at 39 psi The pumps have an internal 60 micron filter In addition the in tank style pumps will have a pre filter attached to the inlet In line pump systems may also have a filter ahead of the pump on the pick up low pressure side The final filter is covered separately on pages 5B 18 and 5B 19 When the key switch is turned on and all safety switch requirements are met the ECU through the relay activates the fuel pump which pressurizes the system for start up If the key switch is not promptly turned to the start position the engine fails to start or the engine is stopped with the key switch on as in the case of an accident the ECU switches off the pump preventing the continued delivery of fuel In this situation the MIL will go on but it will go back off after 4 cranking revolutions if system function is OK Once the engine is running the fuel pump r
13. Fuel Shut off Solenoid Kit 6 x S 14 Idle Speed Adjusting Screw SS 15 Jet Accelerator Pump Carburetor only 8 16 Accelerator Pump Cover 17 Diaphragm D 18 Diaphragm Spring 19 O Ring 20 Rubber Boot 21 Bushing 22 Return Spring Accelerator Pump Parts We Figure 5 6 Carburetor Exploded View 5 9 Section 5 Fuel System and Governor Carburetor Service Repair Kits Always refer to the Parts Manual for the engine being serviced to ensure the correct repair kits and replacement parts are ordered Carburetor Repair Kit Contains Description Carburetor Body Gasket Carburetor Body Screw Idle Needle Spring Slow Jet O Ring Main Jet O Ring Solenoid O Ring Solenoid O Ring Solenoid O Ring Inlet Needle Clip Inlet Fuel Inlet Needle Valve O Ring kA kb k eo ae Float Kit Contains Carburetor Body Gasket Float Screw Float Assembly Float Shaft High Altitude 1500 Meter Kit Contains Carburetor Gasket Carburetor Gasket plastic intake manifold Air Cleaner Base Gasket Main Jet O Ring Solenoid O Ring Solenoid O Ring Solenoid O Ring Main Jet 5 10 Solenoid Kit Contains on Solenoid Screw O Ring O Ring O Ring Solenoid Assembly Solenoid Seat Accelerator Pump Diaphragm Kit Contains Screw Diaphragm Spring O Ring Accelerator Pump Seal amp Bushing Kit Contains op E Clip Retainer Seal Hex Nut Boot Collar Spring Washer Washer Washer Washer
14. Lubrication System General This engine uses a full pressure lubrication system This system delivers oil under pressure to the crankshaft camshaft and connecting rod bearing surfaces In addition to lubricating the bearing surfaces the lubrication system supplies oil to the hydraulic valve lifters A high efficiency gerotor pump is located in the closure plate The oil pump maintains high oil flow and oil pressure even at low speeds and high operating temperatures A pressure relief valve in the closure plate limits the maximum pressure of the system service The closure plate must be removed to service the oil pickup the pressure relief valve and the oil pump Refer to the appropriate procedures in Sections 9 and 10 Oil Recommendations Using the proper type and weight of oil in the crankcase is extremely important so is checking oil daily and changing the oil and filter regularly Use high quality detergent oil of API American Petroleum Institute service class SG SH SJ or higher Select the viscosity based on the air temperature at the time of operation as shown in the following table RECOMMENDED SAE VISCOSITY GRADES 10W 30 a a 5W 20 5W 30 Kohler 10W 30 TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE Use of synthetic oil having 5W 20 or 5W 30 rating is acceptable up to 4 C 40 F Synthetic oils will provide better starting in extreme cold below 23 C 10 F NOTE Using
15. Malfunction Indicator Light MIL Operation The EFI system is designed to provide peak engine performance with optimum fuel efficiency and lowest possible emissions The ignition and injection functions are electronically controlled monitored and continually corrected during operation to maintain the theoretical ideal or stoichiometric air fuel ratio of 14 7 1 The central component of the system is the Motronic Engine Control Unit ECU which manages system operation determining the best combination of fuel mixture and ignition timing for the current operating conditions An electric fuel pump is used to move fuel from the tank through the fuel line and in line fuel filter A fuel pressure regulator maintains a system operating pressure of 39 psi and returns any excess fuel to the tank At the engine fuel is fed through the fuel rail and into the injectors which inject it into the intake ports The ECU controls the amount of fuel by varying the length of time that the injectors are on This can range from 1 5 8 0 milliseconds depending on fuel requirements The controlled injection of the fuel occurs each crankshaft revolution or twice for each 4 stroke cycle One half the total amount of fuel needed for one firing of a cylinder is injected during each injection When the intake valve opens the fuel air mixture is drawn into the combustion chamber ignited and burned Section 5B EFI Fuel System The ECU contr
16. Scored Piston and Rings Figure 10 8 Common Types of Piston and Ring Damage 10 9 Section 10 Inspection and Reconditioning Replacement pistons are available in STD bore size 0 08 mm 0 003 in 0 25 mm 0 010 in and 0 50 mm 0 20 in oversizes Replacement pistons include new piston ring sets and new piston pins The ring sets are also available separately Always use new piston rings when installing pistons Never reuse old rings Some important points to remember when servicing piston rings 1 The cylinder bore must be deglazed before service ring sets are used 2 If the cylinder bore does not need reboring and if the old piston is within wear limits and free of score or scuff marks the old piston may be reused 3 Remove old rings and clean up grooves Never reuse old rings 4 Before installing the new rings on the piston place the top two rings each in turn in its running area in cylinder bore and check end gap see Figure 10 9 against the specifications listed in Section 1 Figure 10 9 Measuring Piston Ring End Gap 5 After installing the new top and middle compression rings on piston check piston to ring side clearance Compare findings against the specifications listed below If clearance is greater than specified anew piston must be used Refer to Figure 10 10 10 10 Figure 10 10 Measuring Piston Ring Side Clearance Install Piston Rings To install piston ring
17. The minimum allowable clearance is 0 25 mm 0 010 in Install Valve Covers 1 Make sure the sealing surfaces of cylinder heads and valve covers are clean and free of all old gasket material Figure 11 37 Installing Push Rods 11 12 Section 11 Reassembly 2 Install new valve cover gaskets onto the valve covers See Figure 11 39 Figure 11 41 Installing Coolant Drain Plugs Install Water Pump Drive Belt and Figure 11 39 Installing Valve Cover Gaskets Transfer Tube Assembly 1 Remove the seal protector and or protective tape if used from over the keyway and make sure the end of the camshaft is clean and free of any nicks or damage Install and fully seat the key squarely into the keyway Be careful not to contact the camshaft seal Test fit the cam pulley onto the shaft and key it must slide on without force or restriction Remove the pulley See Figures 11 42 and 11 43 3 Install the valve covers with gaskets in their original locations 4 Install the lower two mounting screws in each cover and finger tighten only Upper screws will be installed later See Figure 11 40 NOTE A mark or dot of paint applied to the top of the pulley indicating the keyway location will make installation easier Figure 11 40 Installing Valve Covers Reinstall Coolant Drain Plugs 1 Reinstall the brass coolant drain plugs in the sides of the crankcase and also the cylinder head plugs if re
18. and Reassembly Sections for starter removal and installation procedures Use the exploded view Figure 8 26 for reference during the disassembly and reassembly procedure Possible Fault Batter 1 Check the specific gravity of battery If low recharge or replace H battery as necessary Starter Does Not Energize Starter Switch or Solenoid 1 Clean corroded connections and tighten loose connections Wiring 2 Replace wires in poor condition and with frayed or broken insulation Bypass the switch or solenoid with a jumper wire If starter cranks normally replace the faulty component Solenoid Shift Starters Perform individual solenoid test procedure See pages 8 21 and 8 22 Battery Starter Energizes But Turns Slowly Check the specific gravity of battery If low recharge or replace battery as necessary Battery too small must be at least 400 cold cranking amps Check for excessively dirty or worn brushes and commutator Clean using a coarse cloth not emery cloth Replace brushes if excessively or unevenly worn Make sure the clutch or transmission is disengaged or placed in Transmission or Engine neutral This is especially important on equipment with hydrostatic drive The transmission must be exactly in neutral to prevent resistance which could keep the engine from starting Check for seized engine components such as the bearings connecting rod and piston 8 12 Section 8 Electri
19. and filling the cooling system Checking Coolant Level The coolant level should be checked at the overflow reservoir located behind the radiator on the fan shroud See Figure 7 4 Figure 7 4 Overflow Reservoir Location 1 Check the coolant level within the overflow reservoir Coolant level should be between the FULL and ADD marks on the reservoir See Figure 7 5 Do not operate the engine with the coolant level below the ADD mark Add coolant to the overflow reservoir as required which is a 50 50 mixture of ethylene glycol and water distilled or deionized water is recommended Figure 7 5 Coolant Levels on Reservoir NOTE Do not operate the engine without coolant in the system Do not remove the radiator cap when hot Engine coolant is hot and under pressure and can cause severe burns To prevent engine overheating and damage do not exceed more than 70 antifreeze in the cooling system Draining Cooling System 1 Stop the engine and let the engine cool sufficiently 2 Slowly remove the radiator cap 3 Loosen remove the radiator drain plug in the lower left rear corner or the bottom of the radiator See Figure 7 6 Radiator Drain Plug d a Radiator Drain Plug Figure 7 6 Radiator Drain Plug Figure 7 7 Engine Block Coolant Drain Plug Some Models Figure 7 8 Removing Reservoir Section 7 Cooling System Drain the coolant into a suitable container Then remove the coolant dr
20. belt driven off the flywheel via a lower split pulley and requires very little service or maintenance DO NOT operate the engine without the fan and properly functioning cooling system or engine damage will occur See Figure 7 9 Figure 7 9 Cooling System Front View 1 Inspect the fan for any cracks damaged missing fan blades and secure mounting 2 The bearings in the hub of the pulley should rotate smoothly without roughness binding or play wobble 3 The v groove of each pulley upper and lower should not be bent nicked or damaged Pulley mounting areas and lower pulley shims should be free of any cracks or elongation Section 7 Cooling System 4 The drive belt is designed and constructed for this system Do not use a substitute belt Check the overall condition and replace the belt if cracked damaged or proper tension cannot be established by repositioning of the lower pulley shims Use only Kohler Part No 66 203 02 S belt if replacement is necessary See an authorized Kohler Service Dealer for any necessary service Checking Fan Belt and Tension The fan belt and belt tension should be checked daily or before each use The fan belt should not be cracked damaged or exhibit excessive wear Proper tension is Figure 7 11 Torquing Lower Pulley Mounting 3 8 1 2 12 7 mm belt deflection per side under Screws 10 Ibs applied tension See Figure 7 10 Hoses and Tubes Hoses and tubes are use
21. for tester being used Turn on the power switch See Figure 8 10 The POWER light should be illuminated and one of the four status lights may be on as well This does not represent the condition of the part Ss 0 ee Figure 8 8 Rectifier Regulator Termen LE e lato SS Testing of the rectifier regulator may be performed as Z Som Ae follows using the appropriate Rectifier Regulator Tester see Section 2 To Test NOTE Disconnect all electrical connections attached to the rectifier regulator Testing may be performed with the rectifier regulator Figure 8 10 mounted or loose The figures show the part removed from the engine for clarity Repeat 4 Press the TEST button until a click is heard the applicable test procedure two or three and then release See Figure 8 11 Momentarily times to determine the condition of the part one of the four lights will illuminate indicating the condition of the part 15 Amp Rectifier Regulators 1 Connect the tester ground lead with spring clamp to the body of the rectifier regulator being tested 2 Connect the tester red lead to the B terminal of the rectifier regulator and the two black tester leads to the two AC terminals See Figure 8 9 8 8 Section 8 Electrical System and Components 3 Connect the red lead and one of the black leads to the pair of terminals on the open end of the tandem adapter lead connections are not location specific 4 Co
22. gasoline blends up to a maximum of 15 MTBE by volume are approved as a fuel for Kohler engines Other gasoline ether blends are not approved 5 1 Section 5 Fuel System and Governor Fuel Filter Most engines are equipped with an in line fuel filter Periodically inspect the filter and replace with a genuine Kohler filter every 200 operating hours Fuel System Tests When the engine starts hard or turns over but will not start it is possible that the problem is in the fuel system To find out if the fuel system is causing the problem perform the following tests Troubleshooting Fuel System Related Causes Test Conclusion 1 Check the following a Make sure the fuel tank contains clean fresh proper fuel Make sure the vent in fuel tank cap is open Make sure the fuel valve is open Make sure vacuum and fuel lines to fuel pump are secured and in good condition Check for fuel in the combustion chamber Disconnect and ground the spark plug leads Close the choke on the carburetor Crank the engine several revolutions Remove a spark plug and check for fuel at the tip Check for fuel flow from the tank to the fuel pump a Remove the fuel line from the inlet fitting of fuel pump b Hold the line below the bottom of the tank Open the shut off valve if so equipped and observe flow Check the operation of fuel pump a Remove the fuel line from the inlet fitting of carburetor b Crank the engine sev
23. key off then key on code 56 would be set also 4 ECU related a Circuit controlling injector 1 damaged b Circuit controlling fuel pump relay damaged Code 52 Source Injector 2 circuit open shorted to ground or shorted to battery Explanation Injector 2 is not functioning because the circuit is open shorted to ground or shorted to battery Expected Engine Response Engine will run very poorly with only one cylinder functioning Possible Causes 1 Injector related a Injector coil shorted or opened 2 Engine wiring harness related a b Broken or shorted wire in harness ECU pin 15 to injector pin 2 ECU pin 28 to fuel pump relay pin 86 Note After key off then key on code 56 would be set also Fuel pump relay pin 87 to injector pin 1 Opened main fuse F1 3 Fuel pump relay related a Bad fuel pump relay Primary side functional but pin 30 to pin 87 remains open Primary side pin 85 to pin 86 is open or shorted during engine operation Note After key off then key on code 56 would be set also 4 ECU related a b Circuit controlling injector 2 damaged Circuit controlling fuel pump relay damaged Code 55 Source MIL Diagnostic lamp circuit open shorted to ground or shorted to battery Explanation MIL is not functioning because the circuit is open shorted to ground or shorted to battery Expected Engine Response Engine will run normally if no other errors ar
24. the ECU suppresses the injection signals cutting off the fuel flow This process repeats itself in rapid succession limiting operation to the preset maximum Service Never attempt to disassemble the ECU It is sealed to prevent damage to internal components Warranty is void if the case is opened or tampered with in any Way All operating and control functions within the ECU are preset No internal servicing or readjustment may be performed If a problem is encountered and you determine the ECU to be faulty contact your source of supply Do not replace the ECU without authorization The relationship between the ECU and the throttle position sensor TPS is very critical to proper system operation If the TPS or ECU is changed or the mounting position of the TPS is altered the TPS Initialization Procedure see pages 5B 7 and 5B 8 must be performed to restore the synchronization Engine Speed Sensor General The engine speed sensor is essential to engine operation constantly monitoring the rotational speed RPM of the crankshaft A ferromagnetic 60 tooth ring gear with two consecutive teeth missing is mounted on the flywheel The inductive speed sensor is mounted 1 5 0 25 mm 0 059 0 010 in away from the ring gear During rotation an AC voltage pulse is created within the sensor for each passing tooth The ECU calculates engine speed from the time interval between the consecutive pulses The two tooth gap crea
25. 3 Install the offset thrust stop washer so the smaller offset of the washer faces the retainer 5 Perform Steps 10 13 in the Starter Reassembly collar See Figure 8 33 sequence Installation must be done after the armature drive lever and frame are installed if the starter has been disassembled 8 17 Section 8 Electrical System and Components 7 Install the backup washer followed by the rubber grommet into the matching recess of the drive end cap The molded recesses in the grommet should be out matching and aligned with those in the end cap See Figure 8 35 Figure 8 33 Installing Thrust Washer 4 Apply a small amount of oil to the bearing in the drive end cap and install the armature with the drive pinion 5 Lubricate the fork end and center pivot of the Figure 8 35 Installing Backup Washer and drive lever with drive lubricant see Section 2 Grommet Position the fork end into the space between the captured washer and the rear of the pinion 8 Install the frame with the small notch forward onto the armature and drive end cap Align the 6 Slide the armature into the drive end cap and at notch with the corresponding section in the the same time seat the drive lever into the rubber grommet Install the drain tube in the housing rear cutout if it was removed previously See Figure 8 36 NOTE Correctly installed the center pivot section of the drive lever will be flush or below the
26. CHECK INJECTOR FUEL DELIVERY WET SPARK PLUG Yes INSTALL IN LINE PRESSURE GAUGE AND KEY ON FUEL PRESSURE IN SPECIFICATION No REFER TO DIAGNOSTIC AID 8 FUEL SYSTEM ELECTRICAL No _ REFER TO DIAGNOSTIC AID 9 FUEL SYSTEM REFER TO DIAGNOSTIC AID 10 Yes BASE ENGINE Operate for an appropriate period of time based upon original fault codes Figure 5B 36 5B 34 Section 5B EFI Fuel System Flow Chart Diagnostic Aids Diagnostic Aid 3 RUN ON MIL remains on Diagnostic Aid 1 SYSTEM POWER MIL doesnot While engine is running illuminate when key is turned on Possible causes Possible causes 1 Fault codes which turn on MIL when engine is 1 Battery running 2 Main system fuse a Code 21 Engine Speed Synchronization 3 MIL light bulb burned out b Code 22 Throttle Position Sensor TPS 4 MIL electrical circuit problem Pin circuits 29 c Code 23 Engine Control Unit ECU and 84 d Code 31 Oxygen Sensor shorted 5 Ignition switch e Code 34 Fuel System permanent adaptation 6 Permanent ECU power circuit problem Pin at limit circuit 1 L Code 42 Engine Coolant Temperature 7 Switched ECU power circuit problem Pin circuit Sensor 2 g Code 43 TPS Auto Learn Initialization 8 ECU grounds Function Below Min Limit 9 ECU h Code 44 TPS Auto Learn Initialization Function Above Max Limit Diagnostic Aid
27. Check as follows NOTE Do not apply voltage to the fuel injector s Excessive voltage will burn out the injector s Do not ground the injector s with the ignition on Injector s will open turn on if the relay is energized 1 Disconnect the electrical connector from both injectors Plug a 12 volt noid light part of EFI Service Kit see Section 2 in one connector Figure 5B 16 Volt Noid Light 5B 13 Section 5B EFI Fuel System 2 Make sure all safety switch requirements are met Crank the engine and check for flashing of noid light Repeat test at other connector a If flashing occurs use an ohmmeter Rx1 scale and check the resistance of each injector across the two terminals Proper resistance is 12 20 Q If injector resistance is correct check whether the connector and injector terminals are making a good connection If the resistance is not correct replace the injector following steps 1 8 and 13 16 below b If no flashing occurs reattach connectors to both injectors Disconnect the main harness connector from the ECU and the connector from the relay Set the ohmmeter to the Rx1 scale and check the injector circuit resistance as follows Check the resistance between relay terminal 87 and pin 14 in the main connector Then check the resistance between relay terminal 87 and pin 15 Resistance should be 4 15 Q for each circuit Check all electrical connections connectors and wiring harness l
28. Crankcase Breather System The crankcase breather system is a necessary complement to the lubrication system To help prevent the engine oil from weeping out past shafts seals and gaskets during operation it is desirable to have a low vacuum inside the crankcase A typical crankcase breather system incorporates a simple one way valve to provide the desired vacuum 6 4 Breather Design and Function The breather system on these engines is designed to control and maintain the vacuum in the engine crankcase When the pistons move downward a controlled amount of crankcase air is pushed past the reed which in turn closes when the pistons travel upward The hole for the breather reed is positioned high in the crankcase so that most of the oil mist has already been purged from the air before it enters the breather chamber Remaining oil is separated through a baffle and filter as the air moves through the chamber A hose connects the breather outlet to an adapter on top of the carburetor where the vented breather air is mixed proportionately with the incoming combustion air on its way to the combustion chamber A drain hole at the bottom of the chamber returns the separated oil to the crankcase ther Co Figure 6 7 Brea ver Section 7 Cooling System A WARNING Explosive release of fluids from pressurized cooling system can cause serious burns When it is necessary to open cooling system at radiator cap shut off en
29. Engine Response A limp home operating mode occurs with an overall decrease in operating performance and efficiency Fuel delivery is based upon the oxygen sensor and five mapped values only Rich running black smoke will occur until closed loop operation is initiated A stumble or misfire on hard acceleration and or erratic operation may be exhibited Possible Causes 1 TPS Sensor Related a Sensor connector or wiring b Sensor output affected or disrupted by dirt grease oil wear or breather tube position must be to side opposite the TPS c Sensor loose on throttle body manifold 2 Throttle Body Related a Throttle shaft or bearings worn damaged 3 Engine Wire Harness Related a Pin circuits 4 8 and or 18 damaged wiring connectors b Pin circuits 4 8 and or 18 routed near noisy electrical signal coils alternator c Intermittent 5 volt source from ECU pin circuit 18 4 ECU Harness Related a ECU to harness connection problem 5B 29 Section 5B EFI Fuel System Code 23 Source ECU Explanation ECU is unable to recognize or process signals from its memory Expected Engine Response Engine will not run Possible Causes 1 ECU internal memory problem a Diagnosable only through the elimination of all other system component faults Code 24 will not blink out Source Engine Speed Sensor Explanation No tooth signal from speed sen
30. Fuel System Fuel System A WARNING Fuel System Under Pressure The fuel system operates under high pressure System pressure must be relieved through the test valve in the fuel rail prior to servicing or removing any fuel system components Do not smoke or work near heaters or other fire hazards Have a fire extinguisher handy and work only in a well ventilated area The function of the fuel system is to provide sufficient delivery of fuel at the system operating pressure of 39 psi 3 If an engine starts hard or turns over but will not start it may indicate a problem with the EFI fuel system A quick test will verify if the system is operating 1 Disconnect and ground the spark plug leads 2 Complete all safety interlock requirements and crank the engine for approximately 3 seconds 3 Remove the spark plugs and check for fuel at the tips a If there is fuel at the tips of the spark plugs the fuel pump and injectors are operating b If there is no fuel at the tips of the spark plugs check the following 1 Make sure the fuel tank contains clean fresh proper fuel 2 Make sure that vent in fuel tank is open 3 Make sure fuel tank valve if so equipped is fully opened 4 Make sure battery is supplying proper voltage 5 Check that the fuses are good and that all electrical and fuel line connections are good 6 Test fuel pump and relay operation as described earlier under Fuel Pump Service
31. Internal wear or damage Hydraulic lifter malfunction Quality of fuel Incorrect grade of oil Engine Loses Power 1 E as i i Low crankcase oil level High crankcase oil level Dirty air cleaner element Dirt or water in the fuel system Excessive engine load Engine overheated See Engine Overheats Faulty spark plugs Low compression Exhaust restriction Low battery Incorrect governor setting Engine Uses Excessive Amount Of Oil 1 EU 2 Incorrect oil viscosity type Clogged or improperly assembled breather Breather reed broken Worn or broken piston rings Worn cylinder bore Worn valve stems or valve guides Crankcase overfilled Blow head gasket overtightened Oil Leaks from Oil Seals Gaskets de sl a ses 3 2 Crankcase breather is clogged or inoperative Breather read broken Loose or improperly torqued fasteners Piston blowby or leaky valves Restricted exhaust Engine Loses or Uses Coolant 1 2 o Overheating See Engine Overheats External leakage from a joint connection or a component of the cooling system Internal leakage from a head gasket or cooling system water jacket passage leak External Engine Inspection Before cleaning or disassembling the engine make a thorough inspection of its external appearance and condition This inspection can give clues to what might be found inside the engine and the cause when it is disassembled Check
32. Plate Screws 2 Locate the three splitting tabs which are cast into the perimeter of the closure plate Insert the drive end of a 1 2 breaker bar between the top splitting tab and the crankcase Hold the handle horizontal and pull it toward you to break the RTV seal See Figure 9 59 If necessary pry at the bottom splitting tabs also Do not pry on the sealing surfaces as this could cause leaks Carefully pull the closure plate from the crankcase Figure 9 59 Splitting Closure Plate from Crankcase 9 15 Section 9 Disassembly Governor Assembly NOTE The cylinders are numbered on the The governor assembly is located inside the closure crankcase Use the numbers to mark plate If service is required refer to the service each end cap and connecting rod piston procedures under Governor Assembly in Section 10 assembly for reassembly later Do not mix the end caps and connecting rods Oil Pump Assembly The oil pump is mounted to the inside of the closure plate as well If service is required refer to the service procedures under Oil Pump Assembly in Section 10 2 Carefully remove the connecting rod and piston assembly from the cylinder bore See Figure 9 62 Remove Camshaft 1 Remove the camshaft and shims See Figure 9 60 3 Repeat the above procedure for the other connecting rod and piston assembly Figure 9 60 Removing Camshaft with Shim Remove Crankshaft 1 Carefully pull the crankshaft
33. RC14YC Kohler Part No 66 132 01 S or equivalent spark plugs 2 Set the spark plug gap to 0 76 mm 0 030 in 3 Install the plugs and torque to 24 4 29 8 N m 18 22 ft 1b See Figure 11 75 Figure 11 77 Connecting Starter Leads to Starter 4 To avoid damage or breakage do not over tighten the hex flange nut when attaching the positive battery cable Torque the nut to 6 9 N m 53 79 in Ib Figure 11 75 installing Spark Plug Install Starter Assembly 1 Mount the starter to the adapter plate using the two hex flange screws NOTE The stator leads and rectifier regulator plug must be above the starter 2 Make sure the starter is square to the flywheel and torque the two hex flange screws to 15 3 N m 135 in Ib See Figure 11 76 11 22 Install Carburetor and Adapter 1 If separated install the breather tube to breather cover as shown in Figure 11 78 Figure 11 78 Breather Hose Installed onto Breather Cover 2 Install the carburetor gasket on the intake manifold See Figure 11 79 Figure 11 79 Installing Carburetor Gasket on Intake Manifold 3 Attach the longer ends of the throttle linkage and spring to the carburetor if disconnected previously then install the carburetor onto the intake manifold Install and torque the two mounting screws to 6 2 7 3 N m 55 65 in Ib See Figures 11 80 and 11 81 Section 11 Reassembly Figure 11 80 Torquing Carburetor Mounting Screw
34. a prior brush installation through the brush holder assembly so the holes in the metal mounting clips are up out Install the brush springs and snap on the four retainer caps See Figure 8 40 Figure 8 40 Brush Installation Tool with Extension d Hold the starter assembly vertically on the end housing and carefully place the tool with extension and assembled original brush holder assembly onto the end of the armature shaft Slide the brush holder assembly down into place around the commutator install the positive brush lead grommet in the cutout of the frame See Figure 8 41 8 19 Section 8 Electrical System and Components Figure 8 41 Installing Brush Holder Assembly Using Tool with Extension 11 Install the end cap onto the armature and frame aligning the thin raised rib in the end cap with the corresponding slot in the grommet of the positive brush lead 12 Install the two thru bolts and the two brush holder mounting screws Torque the thru bolts to 5 6 9 0 N m 49 79 in 1b Torque the brush holder mounting screws to 2 5 3 3 N m 22 29 in Ib See Figures 8 42 and 8 43 Figure 8 42 Torquing Thru Bolts 8 20 13 14 Figure 8 43 Torquing Brush Holder Screws Hook the plunger behind the upper end of the drive lever and install the spring into the solenoid Insert the three mounting screws through the holes in the drive end cap Use these to hold the solenoid gask
35. after initial running Always check the level with the dipstick before adding more oil Push dipstick in completely Reinstall the oil fill cap and tighten securely See Figure 11 122 Install Coolant d Use equal parts of ethylene glycol antifreeze and water only Distilled or deionized water is recommended especially in areas where the water contains a high mineral content Propylene glycol based antifreeze is not recommended Section 11 Reassembly 2 Fill the cooling system through the radiator with the coolant mix Allow the coolant to drain into the lower areas Fill the overflow reservoir midway between the FULL and ADD marks then install the radiator and reservoir caps See Figures 11 123 and 11 124 Figure 11 124 Coolant Reservoir with Coolant Reconnect Battery and Spark Plug Leads Connect the leads to the spark plugs Reconnect the positive battery lead first and the negative lead last when connecting the battery 11 33 Section 11 Reassembly Testing the Engine It is recommended that the engine be appropriately secured and operated on a test stand or bench prior to installation in the application 1 Make sure all hardware is tightened and hose clamps are properly secured 2 Set up the engine on a test stand Install an oil pressure gauge Start the engine and check to be certain that oil pressure 20 psi or more is present Run for 5 10 minutes between idle and m
36. coat of engine oil to the outside diameter of the flywheel end oil seal 3 Install the oil seal into the crankcase using a seal driver Make sure the oil seal is installed straight and true in bore until the tool bottoms against the crankcase See Figure 11 1 i Figure 11 1 Installing Crankshaft PTO Using Tool Side Seal 4 Apply a light coat of engine oil to the outside diameter of the camshaft oil seal 5 Install the camshaft oil seal to a depth of 1 0 1 5 mm 0 039 0 059 in below the top of the seal bore See Figure 11 2 Do not bottom the seal in the bore or the oil passage may be obstructed Figure 11 2 Installing Camshaft Seal 11 2 3 Figure 11 4 Setting End Play of Governor Shaft 4 Install Governor Cross Shaft Camshaft Oil Seal 1 Lubricate the governor cross shaft bearing surfaces in the crankcase with engine oil Apply a small amount of grease to the lips of the oil seal Slide the small lower washer onto the governor cross shaft and install the cross shaft from the inside of the crankcase See Figure 11 3 Figure 11 3 Installing Governor Shaft Install the nylon washer onto the governor cross shaft then start the push on retaining ring Hold the governor shaft up in position then place a 0 25 mm 0 010 in feeler gauge on top of the nylon washer and push the retaining ring down the shaft to secure Remove the feeler gauge which will have established the proper end play S
37. from the crankcase Remove Connecting Rods with Pistons See Figure 9 63 Note the thrust washer and and Rings shims if used 1 Remove the two hex flange screws securing the closest connecting rod end cap Remove the end cap See Figure 9 61 Figure 9 63 Removing Crankshaft NOTE Ifa carbon ridge is present at the top of either cylinder bore use a ridge reamer tool to remove it before attempting to remove the piston 9 16 Remove Governor Cross Shaft 1 Remove the retaining ring and nylon washer from the governor cross shaft See Figure 9 64 Nr H Figure 9 64 Removing Governor Shaft Retaining Ring and Washer NOTE Always use a new retaining ring when reassembling Do not reuse the old retaining ring 2 Remove the cross shaft and small washer out through the inside of the crankcase See Figure 9 65 Figure 9 65 Removing Governor Cross Shaft Section 9 Disassembly Remove Flywheel End Oil Seals 1 Remove the flywheel end crankshaft and camshaft oil seals from the crankcase See Figure 9 66 Figure 9 66 Oil Seals Flywheel Side and Camshaft 9 17 Section 10 Inspection and Reconditioning This section covers the operation inspection and repair reconditioning of major internal engine components Also included are water pump cooling system and fan drive belt inspection criteria The following components are not covered in this section They are covered in sections of their own
38. fuel system must be completely emptied or the gasoline must be treated with a stabilizer to prevent deterioration If you choose to use a stabilizer follow the manufacturers recommendations and add the correct amount for the capacity of the fuel system Fill the fuel tank with clean fresh gasoline Run the engine for 2 3 minutes to get stabilized fuel into the carburetor Close fuel shut off valve when unit is being stored or transported To empty the system run the engine until the tank and system are empty Remove the spark plugs Add one tablespoon of engine oil into each spark plug hole Install plugs but do not connect the plug leads Crank the engine two or three revolutions On units with EFI engines disconnect the negative battery cable or use a battery minder trickle charger while the unit is in storage Store the engine in a clean dry place Section 1 Safety and General Information 440 00 17 323 Ge Rain Cap Removal PORWR ARGS OHV UQUE COCLED Fuel 622 54 24 509 Overall without Rain Cap 2X 184 20 7 252 127 90 5 035 Mounting Hole Mounting Hole 458 49 18 051 Overall Flywheel End 2X 297 47 1 711 119 78 4 716 Starter Side lt 4 120 96 4 762 39 00 Coolant 1 535 Overflow Oil Fill Air Intake Optional Orientation Fill Ul ae i j 583 30 O
39. in Ib gen If the vacuum fitting was removed from the crankcase vacuum fuel pump apply pipe sealant with Teflon Loctite 59241 or equivalent to the threads of the fitting and install With the crankcase upright the fitting must point to the 1 30 position See Figure 11 28 11 9 Section 11 Reassembly Valve Stem Seals 4 Figure 11 28 Crankcase Vacuum Fitting Position Figure 11 30 Cylinder Head Showing Intake Seal Install Hydraulic Lifters Assemble Cylinder Heads 1 Lubricate the lifters and lifter bores in the Prior to installation lubricate all components with crankcase with engine oil engine oil paying particular attention to the lip of the valve stem seal valve stems and valve guides Install NOTE Hydraulic lifters should always be the following items in the order listed below using a installed in the same position as before valve spring compressor See Figures 11 31 and 11 32 disassembly e Valve stem seals 2 Install the lifters into their respective lifter bores e Intake and exhaust valves according to location and cylinder number e Valve spring caps marked during assembly See Figure 11 29 e Valve springs e Valve spring retainers ki Valve spring keepers a Figure 11 29 Installing Lifters Figure 11 31 Disassembled Head and Valve Components Valve Stem Seals NOTE These engines use valve stem seals on the intake and exhaust valves Always use a new seal before val
40. involving an engine always give the Model Specification and Serial Numbers including letter suffixes if there are any The engine identification numbers appear on a decal or decals affixed to the engine The primary location is on the side of the flywheel cover See Figure 1 1 Placement may vary due to OEM requirements and specific options involved An explanation of these numbers is shown in Figure 1 2 Identification Decal Figure 1 1 Engine Identification Decal Location A Model No LH685S tauia cooled en Tue Horizontal Crankshaft Version Code Electri r Numerical Designation S Electric Start Spec No LH685 0001 Model Complete Spec Number LH630 0001 LH750 0001 Incorporating Model No LH640 0001 LH755 0001 with Variation No of Basic Spec LH685 0001 LH760 0001 LH690 0001 LH775 0001 C Serial No 31 05810334 Year Manufactured Code Factory Code Year 2001 2002 2003 2004 2005 2006 2007 Figure 1 2 Explanation of Engine Identification Numbers 1 3 Section 1 Safety and General Information Oil Recommendations Using the proper type and weight of oil in the crankcase is extremely important So is checking oil daily and changing oil regularly Failure to use the correct oil or using dirty oil causes premature engine wear and failure Oil Type Use high quality detergent oil of API American Petroleum Institute Service Class SG SH SJ or higher Select the viscosity based on the a
41. is indicated the solenoid should be replaced Repeat test several times to confirm condition 8 22 Plunger Pushed In 12 volt Test Leads Figure 8 48 Testing Hold In Coil Solenoid Contact Continuity Section 9 Disassembly A WARNING Accidental Starts Disabling engine Accidental starting can cause severe injury or death Before working on the engine or equipment disable the engine as follows 1 Disconnect the spark plug lead s 2 Disconnect negative battery cable from battery General 18 Remove flywheel Clean all parts thoroughly as the engine is 19 Remove stator assembly disassembled Only clean parts can be accurately 20 Remove intake manifold thermostat housing inspected and gauged for wear or damage There are by pass hose and wiring harness many commercially available cleaners that will 21 Remove cam pulley and water pump belt quickly remove grease oil and grime from engine 22 Remove water pump and transfer tube parts When such a cleaner is used follow the 23 Remove spark plugs manufacturer s instructions and safety precautions 24 Remove cylinder heads and valve lifters carefully 25 Remove closure plate 26 Remove camshaft Make sure all traces of the cleaner are removed before 27 Remove connecting rods with pistons and rings the engine is reassembled and placed into operation 28 Remove crankshaft Even small amounts of these cleaners can quickly 29 Remove governor cross shaft
42. machined surface of the housing which receives the backup washer See Figure 8 34 Figure 8 36 Installing Frame and Drain Tube 9 Install the flat thrust washer onto the commutator end of the armature shaft See Figure 8 34 Installing Armature and Pivot Lever Figure 8 37 8 18 Figure 8 37 Installing Thrust Washer 10 Starter reassembly when replacing the Brushes Brush Holder Assembly a Hold the starter assembly vertically on the end housing and carefully position the assembled brush holder assembly with the supplied protective tube against the end of the commutator armature The mounting screw holes in the metal clips must be up out Slide the brush holder assembly down into place around the commutator and install the positive brush lead grommet in the cutout of the frame See Figure 8 38 The protective tube may be saved and used for future servicing Figure 8 38 Installing Brush Holder Assembly with Supplied Tube Starter reassembly when not replacing the Brushes Brush Holder Assembly a Carefully unhook the retaining caps from over each of the brush assemblies Do not lose the springs Section 8 Electrical System and Components Figure 8 39 Removing Retaining Clips b Position each of the brushes back in their slots so they are flush with the I D of the brush holder assembly Insert the Brush Installation Tool with extension or use the tube described above from
43. not disconnect or reconnect the wiring harness connector to the control unit or any individual components with the ignition on This can send a damaging voltage spike through the ECU e Do not allow the battery cables to touch opposing terminals When connecting battery cables attach the positive cable to positive battery terminal first followed by negative cable to negative battery terminal e Never start the engine when the cables are loose or poorly connected to the battery terminals e Never disconnect battery while engine is running e Never use a quick battery charger to start the engine e Do not charge battery with key switch on 5B 4 e Always disconnect negative battery cable lead before charging battery and also unplug harness from ECU before performing any welding on equipment Electrical Components Electronic Control Unit ECU Figure 5B 1 32 Pin MSE 1 1 Plastic Cased ECU General A 32 Pin MSE 1 1 plastic cased ECU is used on these engines See Figure 5B 1 The ECU is the brain or central processing computer of the entire EFI fuel ignition management system During operation sensors continuously gather data which is relayed through the wiring harness to input circuits within the ECU Signals to the ECU include ignition on off crankshaft position and speed RPM throttle position coolant temperature exhaust oxygen levels and battery voltage Th
44. rail is fastened to the manifold the injectors are locked into place A small retaining clip provides a secondary lock Incorporated into the fuel rail is a pressure relief test valve for testing operating pressure or relieving Section 5B EFI Fuel System fuel system pressure for servicing The fuel supply line is attached to the barbed end of the fuel rail with an Oetiker hose clamp Service The fuel rail is mounted to the throttle body intake manifold It can be detached by removing the two mounting screws and the injector retaining clips Thoroughly clean the area around all joints prior to any disassembly No specific servicing is required unless operating conditions indicate that it needs internal cleaning or replacement Fuel Line Figure 5B 27 High Pressure Fuel Line General Special low permeation high pressure fuel line with an SAE30 RO rating is required for safe and reliable operation due to the higher operating pressure of the EFI system If hose replacement is necessary order Fuel Line Service Kit Part No 25 111 37 S containing 60 of high pressure hose and 10 Oetiker clamps or use only the type specified Special Oetiker clamps Kohler Part No 24 237 05 S are used on all fuel line connections to prevent tampering and safety hazards with the high fuel pressure The old clamp must be cut to open a connection so replacement is necessary each time Oetiker Clamps Pliers part of EFI Service Kit see Se
45. scale Touch the Inspect both the springs and brushes for wear probes between two different segments of the fatigue ee damage Measure the length of each brush commutator and check for continuity See Figure The minimum length for each brush is 7 6 mm 8 29 Test all the segments Continuity must exist 0 300 in See Figure 8 27 Replace the brushes if between all or the armature is bad they are worn undersize or their condition is questionable Insulation D s Armature Wear limit length Coil 7 6 mm 0 300 in Figure 8 29 Checking Armature Figure 8 27 Checking Brushes 3 Check for continuity between the armature coil segments and the commutator segments See Armature Figure 8 29 There should be no continuity If 1 Clean and inspect the commutator outer continuity exists between any two the armature surface The mica insulation must be lower than is bad the commutator bars undercut to ensure proper operation of the commutator See Figure 4 Check the armature windings insulation for 8 28 shorting Shift Fork Check that the shift fork is complete and the pivot and contact areas are not excessively worn cracked or broken 8 16 Section 8 Electrical System and Components Brush Replacement Starter Service The brushes and springs are serviced as a set 4 Use Clean the drive lever and armature shaft Apply Brush and Spring Kit Kohler Part No 25 221 01 S if Kohler electric starter drive lubrican
46. the bottom of the bore Make sure the plug is tapped in evenly to prevent leakage Crankcase These engines contain a cast iron cylinder liner that may be reconditioned as follows Inspection and Service Check all gasket surfaces to make sure they are free of gasket fragments Gasket surfaces must also be free of deep scratches or nicks Inspect the main bearing if so equipped for wear or damage refer to Section 1 Specifications Tolerances and Special Torque Values Replace the crankcase using a mini block or short block if required Check the cylinder bore for scoring In severe cases unburned fuel can cause scuffing and scoring of the cylinder wall It washes the necessary lubricating oils off the piston and cylinder wall As raw fuel seeps down the cylinder wall the piston rings make metal to metal contact with the wall Scoring of the cylinder wall can also be caused by localized hot spots resulting from a cooling system problem or from inadequate or contaminated lubrication If the cylinder bore is badly scored excessively worn tapered or out of round resizing is necessary Use an inside micrometer to determine amount of wear refer to the Specifications Tolerances and Special Torque Values in Section 1 then select the nearest suitable oversize of either 0 08 mm 0 003 in 0 25 mm 0 010 in or 0 50 mm 0 020 in Resizing to one of these oversizes will allow usage of the available oversize piston
47. the dial during rotation for indication of any momentary short or open circuits Note the resistance at the full throttle position It should be 1800 3000 Q 5 Disconnect the main wiring harness connector from the TPS leaving the TPS assembled to the manifold Refer to the following chart and perform the resistance checks indicated between the terminals in the TPS socket with the throttle in the positions specified Section 5B EFI Fuel System Throttle Between Closed ae 1200 Closed 1800 3000 Full 1800 3000 Full 800 1200 Any 1600 2500 If the resistance values in steps 3 4 and 5 are within specifications go to step 6 If the resistance values are not within specifications or a momentary short or open circuit was detected during rotation step 4 the TPS needs to be replaced go to step 7 the TPS plug and the main harness connector for 5B Check the TPS circuits input ground between continuity damage etc Pin Circuits 8 and 4 See chart on page 5B 24 a Repair or replace as required b Turn the idle speed screw back in to its original setting c Reconnect connector plugs start engine and retest system operation Remove the two mounting screws from the TPS Save the screws for reuse Remove and discard the faulty TPS Install the replacement TPS and secure with the original mounting screws a Reconnect both connector plugs b Perform the TPS Initialization Procedure integrat
48. the engine is extremely important Improper orientation can cause extensive wear or damage 1 Stagger the piston rings in the grooves until the end gaps are 120 apart The oil ring rails should also be staggered Figure 11 7 Installing 1 Piston 5 Guide the lower end of connecting rod and rotate the crankshaft to join the two Install the rod cap to the connecting rod using the two hex flange screws and torque in increments to 11 3 N m 100 in Ib See Figures 11 8 and 11 9 11 3 Section 11 Reassembly Figure 11 10 Installing Camshaft using Seal Protector Figure 11 9 Torquing 1 Rod Cap NOTE Make sure to align the chamfer of the connecting rod with the chamfer of its mating end cap When installed the flat faces of the connecting rods should face each other The faces with the raised rib should be toward the outside 6 Repeat the above procedure for the other connecting rod and piston assembly Install Camshaft 1 Inspect the edges of the camshaft keyway make sure they are not nicked or burred Use a seal protector 11 16 to prevent damaging the seal lips or dislodging inner spring when the camshaft is installed Cellophane tape over the keyway is also recommended See Figure 11 10 d Lubricate the camshaft bearing surfaces of the crankcase and camshaft with engine oil Apply a small amount of grease to the lips of the oil seal Rotate the crankshaft and position the timing mark o
49. to the 85 terminal and touch the negative lead to the 86 terminal When 12 volts is applied the relay should activate and continuity should exist circuit made between the 30 and 87 terminals Repeat the test several times If at any time the relay fails to activate the circuit replace the relay Fuel Injectors Figure 5B 13 Fuel Injector General The fuel injectors mount into the intake manifold and the fuel rail attaches to them at the top end Replaceable O Rings on both ends of the injector prevent external fuel leakage and also insulate it from heat and vibration A special clip connects each injector to the fuel rail retaining it in place When the key switch is on and the relay is closed the fuel rail is pressurized and voltage is present at the injector At the proper instant the ECU completes the ground circuit energizing the injector The valve needle in the injector is opened electromagnetically and the pressure in the fuel rail forces fuel down through the inside The director plate at the tip of the injector see inset contains a series of calibrated openings which directs the fuel into the manifold in a cone shaped spray pattern DECHE Terr T eT It Le F Ban assets 7 Th ih NI K PN H KP Multi Orifice Director Plate With an Calibrated Opening i 4 Valve housing 5 Armature 2 Electrical connection 6 Valve body 3 Solenoid winding 7 Valve needle Fi
50. used to achieve proper running clearance Measure the crankpin for size taper and out of round 10 1 Section 10 Inspection and Reconditioning NOTE Ifthe crankpin is reground visually check to ensure that the fillet blends smoothly with the crankpin surface See Figure 10 1 High Point From Fillet Intersections The Fillet Must Blend Smoothly With The Bearing 45 Journal Surface Minimum This Fillet Area Must Be Completely Smooth Figure 10 1 Crankpin Fillets When grinding a crankshaft grinding stone deposits can get caught in oil passages which could cause severe engine damage Removing the crankpin plug each time the crankshaft is ground provides easy access for cleaning any grinding deposits that may collect in the oil passages Use the following procedure to remove and replace the plug Procedure to Remove Crankshaft Plug 1 Drill a 3 16 hole through the plug in the crankshaft 2 Thread a 3 4 or 1 long self tapping screw with a flat washer into the drilled hole The flat washer must be large enough to seat against the shoulder of the plug bore See Figure 10 2 Self Tapping Screw Crankshaft Figure 10 2 Removing Crankpin Plug 10 2 3 Tighten the self tapping screw until it draws the plug out of the crankshaft Procedure to Install New Plug 1 Use a single cylinder camshaft pin Kohler Part No 47 380 09 S as a driver and tap the plug into the plug bore until it seats at
51. 0071 0 0150 in Naddle Eeer 0 250 0 450 mm 0 0098 0 0177 in Used Bore MIx E 0 77 mm 0 030 in 2 Measure 6 mm 0 236 in above the bottom of the piston skirt at right angles to the piston pin 1 12 Section 1 Safety and General Information Piston Piston Rings and Piston Pin cont Top and Middle Compression Ring End Gap cont LH685 LH690 New Bore MO TNC ET 0 180 0 430 mm 0 0071 0 0169 in tee E E 0 250 0 460 mm 0 0098 0 0181 in Used Eeer 0 80 mm 0 0315 in LH750 LH755 LH760 LH775 EE 0 250 0 56 mm 0 0098 0 022 in RER e 0 94 mm 0 037 in Piston Thrust Face O D LH630 LH640 IT 76 968 76 986 mm 3 0302 3 0309 in Max Wear LIM cess euee sn ectacneee yrnstaoo ccenctirseiesause hocastusadasgeseccect lt tees uadee 76 840 mm 3 0252 in LH685 LH690 I ee 79 963 79 981 mm 3 1481 3 1488 in e EE 79 831 mm 3 1430 in LH750 LH755 LH760 LH775 ET 82 973 82 991 mm 3 2666 3 2673 in Max Wear CIMI E 82 841 mm 3 3136 in Piston Thrust Face to Cylinder Bore Running Clearance EEO O EE EE 0 014 0 057 mm 0 0005 0 0022 in LH OS S EEI U corrr T 0 019 0 062 mm 0 0007 0 0024 in EHZ OLIS E O0 LH EE 0 015 0 058 mm 0 005 0 0022 in Speed Control Speed Control Bracket Assembly Fastener Torque s eeseesecserereeeeereeess 10 7 N m 95 in Ib into new holes 7 3 N m 65 in Ib into used holes Stator Stator POU Iie Ee EE 6 2 N m 55 in Ib Valve Cover Rocker Arms Valve Cover Fastener Ee asncscsssasonniunssso
52. 083 mm 0 0032 in Connecting Rod to Crankpin Side Clearance NENNEN 0 26 0 63 mm 0 0102 0 0248 in Connecting Rod to Piston Pin Running Clearance ceeeeeseeseeseeeeeeeeeeeeeeenes 0 015 0 028 mm 0 0006 0 0011 in Piston Pin End I D PN VAP eege 17 015 17 023 mm 0 6699 0 6702 in er VV as EE eene Ee 17 036 mm 0 6707 in Values are in Metric units Values in parentheses are English equivalents Lubricate threads with engine oil prior to assembly 1 9 Section 1 Safety and General Information Crankcase Governor Cross Shaft Bore I D IT 8 025 8 075 mm 0 3159 0 3179 in NMax Near CE aaen r E 8 088 mm 0 3184 in Breather Cover Fastener TOrgUE serres 10 7 N m 95 in Ib into new hole 7 3 N m 65 in lb into used hole COTE Dart TOT US esscr n 13 6 N m 10 ft lb Closure Plate E EEN Fastener UE 24 4 N m 216 in Ib Crankshaft Ig clea Re E 0 070 0 590 mm 0 0028 0 0230 in Crankshaft Sleeve Bearing I D crankcase TEE 40 974 40 987 mm 1 6131 1 6136 in E Acar E 41 000 mm 1 6141 in Crankshaft Bore in closure plate TS 40 974 41 000 mm 1 6131 1 6141 in KE E EE a atserse ca eisai A E OE AE ATA 41 038 mm 1 6156 in Crankshaft Bore in closure plate to Crankshaft R nnine Clearance NEW eege 0 039 0 087 mm 0 0015 0 0034 in Main Bearing Journals RTE 40 913 40 935 mm 1 6107 1 6116 in 2D Maxs Wear Ee 40 84 mm 1 608 in EE i E E A ee ee eee 0 022 mm 0 0009 in KE E E 0 025 mm 0 0010 in Crankshaft to Slee
53. 1 Failure Completing Autolearn TPS Offset above maximum Y allowable limit P1260 Injector 1 Open Circuit Injector 1 Short Circuit to Battery P P P P Injector 2 Short Circuit to Battery 0 OD Ol O1 Poss High Temperature Warning Lamp Circuit Open P1657 High Temperature Warning Lamp Circuit Shortened to Ground High Temperature Warning Lamp Circuit Shorted to Voltage g OD O1 N P1670 Failure Completing Autolearn TPS Offset below minimum allowable limit P0261 Injector 1 Short Circuit to Ground 0 O gt O1 Injector 2 Short Circuit to Ground u OD CO N es MIL Lamp Short Cirouitto Ground nen MIL Lamp Short Circuito Batley nen Pump Relay Open Cret nes eem 7 35 122 123 01 132 117 i 0262 1263 Injector 2 Open Circuit 0264 265 658 P1653 i P1231 P1232 Pump Relay Short Circuit to Ground P1233 Pump Relay Short Circuit to Battery P1480 Cooling Fan Driver Circuit Open P1481 Cooling Fan Driver Circuit Shorten to Ground P1482 Cooling Fan Driver Circuit Shorten to Voltage Pe End of Code Transmission N NOTE 1 O Sensor Short to Battery diagnostic detection is disabled with SAS fuel cutoff calibrated out 2 System too Lean used to be O Sensor Short to Ground P0131 3 System too Rich used to be O Sensor Control at Lower Limit P0019 4 Will not blink out MIL Lamp is always switched OFF when failure is S
54. 1 m Gy WE Kacugtgtzeetse eger 18 6 kW 25 HP Recommended 15 9 kW 21 3 HP elo errant A re eae eee ere E eee Maximum ss seeeeees 19 4 kW 26 HP Recommended 16 5 kW 22 1 HP Eege Maximum s es 20 1 kW 27 HP Recommended 17 1 kW 22 9 HP ee Maxi M escasa 20 9 kW 28 HP Recommended 17 7 kW 23 8 HP TT OO PRE E E E E seu siche stant A T EA E Maxi apdnateen 21 6 kW 29 HP Recommended 18 4 kW 24 7 HP Eege EIER em uereg 23 1 kW 31 HP Recommended 19 7 kW 26 4 HP Peak Torque LEG O TER o a eae Ea E ER A E AR TAE O A 48 0 N m 35 4 ft Ib RTE EE 51 9 N m 38 3 ft Ib PMG DTV ee 54 3 N m 40 1 ft lb FAT 7 OHO ZA Te eege 58 1 N m 42 9 ft Ib BL ODDO Eeer 61 0 N m 45 ft Ib eebe 61 5 N m 45 4 ft lb MT EE EEE AAA A E A EEN 61 7 N m 45 5 ft Ib MTZ Fy ODA Te Aeren 64 6 N m 47 7 ft lb Bore EE eegene 77 mm 3 03 in Hale NIN FON N ce A A yeaa voces nat ea ys cu A A E E eas T T 80 mm 3 15 in LR O OO NTO EE 83 mm 3 3 in Stroke LE GON E TO S LR E 67 mm 2 64 in Lr CERA TEE Ke E 69 mm 2 7 in Displacement CE UER en E T A E E TE TTNA A 624 cc 38 1 cu in LHC S EE 674 cc 41 1 cu in EFEO KT RE Kar E 747 cc 45 6 cu in Values are in Metric units Values in parentheses are English equivalents Lubricate threads with engine oil prior to assembly NOTE All listed dimensions and tolerances are measured at 20 C 68 F 1 8 Section 1 Safety and Ge
55. 2 Disconnect one spark plug lead and connect it to the post terminal of the tester Connect the clip to a good eround not to the spark plug Crank the engine and observe the tester spark gap Repeat the procedure on the other cylinder Remember to reconnect the first spark plug lead a If one side is not firing check all wiring connections and terminations on that side If wiring is okay replace ignition module and retest for spark 8 6 b If the tester shows spark but the engine misses or won t run on that cylinder try a new spark plug c Ifneither side is firing recheck position of ignition switch and check for shorted kill lead Battery Charging System General These engines are equipped with either a 15 20 or 25 amp regulated charging system See Figure 8 6 for the 15 20 25 amp system diagram NOTE Observe the following guidelines to avoid damage to the electrical system and components e Make sure the battery polarity is correct A negative ground system is used e Disconnect the plug from the rectifier regulator and the battery cables before doing electric welding on the equipment powered by the engine e Prevent the stator AC leads from touching or shorting while the engine is running This could damage the stator Wiring Color Codes Black Blue Red Yellow White Purple Orange Blue Red B L R Y W P O Ce Section 8 Electrical System and Components CONNECTOR LAYOU
56. 4 Section 11 Reassembly 6 Slide the smaller diameter clamp onto the 8 Carefully push the water pump down from the extruded end of the formed metal tube and insert raised position thereby rotating the tube 90 this end of the tube into the hose section Position within the end connections Guide the pump into the tube so its formed offset leads down and position over the O Ring aligning the two away from outlet perpendicular to the pump mounting pins and five screw hole locations See Install the clamp onto the hose and position the Figure 11 49 Start all of the screws with the tangs of the clamp parallel to those of the first longer screw nearest the pump outlet Torque the clamp See Figure 11 48 screws to 9 9 N m 88 in Ib in the sequence shown in Figure 11 51 Figure 11 48 Transfer Tube Hose and Water Pump as Assembly 7 Holding the pump assembly elevated assemble the transfer tube to the 90 fitting in the crankcase as follows a For new first time tube installation 1 Place a new ferrule compression ring in the 90 fitting of the crankcase and loosely install the hex cap onto the threads of the fitting 2 Insert the plain end of the transfer tube through the hex and compression ring b For reinstallation of an existing tube Figure 11 50 Torquing Water Pump Bolts 1 Insert the end of transfer tube with the compression ring into the 90 fitting of the crankcase 2 Start the hex cap on
57. 5 in Figure 11 15 Oil Seal Depth in Closure Plate Install Closure Plate Assembly RTV silicone sealant is used as a gasket between the closure plate and the crankcase Refer to Section 2 of this manual for a listing of approved sealants Always use fresh sealant Using outdated sealant can result in leakage 1 Be sure the sealing surfaces have been cleaned and prepared as described at the beginning of Section 10 or in Service Bulletin 252 2 Check to make sure that there are no nicks or burrs on the sealing surfaces of the closure plate or crankcase 3 Apply a 1 16 bead of sealant to the sealing surface of the closure plate See Figure 11 16 for sealant pattern Figure 11 16 Closure Plate Sealant Pattern 4 Figure 11 17 Installing Locating Pins 6 Make sure end of governor cross shaft is lying against the bottom of cylinder 1 inside of the crankcase See Figure 11 17 If alignment pins were removed previously install them in their respective locations in the crankcase See Figure 11 17 Install the closure plate on the crankcase Carefully seat the camshaft and crankshaft into their mating bearings Rotate the crankshaft to help engage the oil pump and governor gear meshes See Figure 11 18 Section 11 Reassembly Figure 11 18 Rotating Crankshaft to Seat Closure Plate 7 Install the ten hex flange screws securing the closure plate to the crankcase If a thick flat washer was used on
58. 625 Q a If the resistance is out of specifications replace the temperature sensor and refill the cooling system b Ifit is within specifications proceed to Step 6 6 Check the temperature sensor circuits input eround from the main harness connector to the corresponding terminal in the sensor plug for continuity damage etc Pin circuits 6 and 4 Section 5B EFI Fuel System Oxygen Sensor Figure 5B 8 Oxygen Sensor General The oxygen sensor functions like a small battery generating a voltage signal to the ECU based upon the difference in oxygen content between the exhaust gas and the ambient air The tip of the sensor protruding into the exhaust gas is hollow see cutaway Figure 5B 9 The outer portion of the tip is surrounded by the exhaust gas with the inner portion exposed to the ambient air When the oxygen concentration on one side of the tip is different than that of the other side a voltage signal typically cycling between 0 2 and 1 0 volt is generated between the electrodes and sent to the ECU The voltage signal tells the ECU if the engine is straying from the ideal 14 7 1 fuel mixture and the ECU then adjusts the injector pulse accordingly et a Feo Ki SSS KELSIN phien OG 5 Contact Element 6 Sensor Housing 7 Active Ceramic Sensor 8 Protective Tube 1 Connection Cable 2 Disc Spring 3 Ceramic Support Tube 4 Protective Sleeve Figure 5B 9 Cutaway of Oxygen S
59. A wledi Si gt SSES 2 ink hl Ji 4 0 opp ER cl opal 712 o 123 Bio 0 124 CES EE cue Loo o 26 J1 12 j Mea AAEE AMA A e aA KIK 0 7 8 ie clu e A a A A Alo o ell TT Se MALFUNCTION Talo ob 1 i a wi S S z lt a Bla ri a a9 dr A8 m mi a Oz T T x N 5 SIl a a 20 Di 2 1 FA O H z a 2 T 5 z T a 4 IZ 10A o 6 Motor Throttle d INJECTOR 1 INJECTOR 2 Temperature Position e Sensor Sensor 2 1 12 a E i GROUNDING NOTES A Battery B Lambda Sensor C Fuel Pump D Shield 2 1 1253 SEE Attached to engine block near starter GROUNDING The sensor return is via the engine muffler NOTE B If a slip joint is used a grounding strap is required If a2 leaded sensor is used pin 4 or pin 21 can be used for the is the return Attached to the chassis Attached to the engine block close to the coils CONNECTOR DIAGNOSTIC SEE GROUND NOTE C 50 Tr Ty 87 RELAY MAIN POWER ch oo 11 12 SWITCH IGNITION N O BATTERY GROUND L SEE GROUNDING NOTE A A g BATTERY GENERAL SYSTEM INSTALLATION NOTES The ignition switch must maintain a constant voltage to circuits 84 85 and J1 2 as the keyis swept from the start to the run position to prevent ECU reset during starting The voltage on circuits 84 85 J1 2 and J1 1 must remain within 0 2 V of each other regardless of system current draw to prevent differences between a
60. Engine Will Not Crank i tO pe a Sy PTO drive is engaged Battery is discharged Safety interlock switch is engaged Loose or faulty wires or connections Faulty key switch or ignition switch Faulty electric starter or solenoid Seized internal engine components Engine Runs But Misses 1 Zi 3 SS Sen ZS E Dirt or water in the fuel system Spark plug lead disconnected Loose wires or connections that intermittently short the kill circuit of ignition system to ground Engine overheated cooling system problem Faulty ignition module Faulty spark plugs Carburetor adjusted incorrectly Faulty interlock switch Engine Will Not Idle 1 eS ee Restricted fuel tank cap vent Dirt or water in the fuel system Faulty spark plugs Idle speed RPM adjusting screw improperly set Low compression Stale fuel and or gum in carburetor Fuel supply inadequate Engine overheated cooling system problem 3 1 Section 3 Troubleshooting Engine Overheats 1 T a a Je m Radiator and or cooling system components clogged restricted or leaking Excessive engine load Low crankcase oil level Low cooling system fluid level High crankcase oil level Lean fuel mixture Fan belt failed off Cooling fan broken Water pump belt failed broken Water pump malfunction Faulty carburetor Engine Knocks 1 PE Eh T Excessive engine load Low crankcase oil level Old or improper fuel
61. Fan Assembly Rear View Make sure one flat washer is placed between the two bearings in the hub The other washer is located under the front hex flange nut Torque the four fan pulley hub mounting screws to 6 8 N m 60 in Ib 6 If the fan shaft was removed from the upper mounting bracket apply Loctite No 242 to the rear threads Install and torque the rear hex nut to 15 8 N m 140 in Ib Install the fan and pulley assembly onto the fan shaft and upper mounting bracket 7 Apply Loctite No 242 to the front threads of the fan shaft Install the flat washer and the hex flange nut to secure Torque hex flange nut to 15 8 N m 140 in Ib See Figure 11 97 Figure 11 99 Belt Deflection Tension Checking 11 27 Section 11 Reassembly If the belt tension is low remove the belt and Install Air Cleaner Assem bly relocate a shim from between the pulley halves 1 Install a new elbow adapter gasket onto the to the outside front Reinstall the belt and recheck the tension Repeat the procedure until the correct tension is reached if the shims have all been moved to the outside and the belt is still too loose replace the belt carburetor adapter See Figure 11 102 NOTE Do not assemble the lower pulley with the belt between the pulley halves as pinching of the belt or damage to the pulley can occur When proper tension is obtained individually remove each capscrew apply Loctite No 242 to the threads of
62. Figure 8 23 Figure 8 20 Removing Commutator End Plate Assembly Figure 8 23 Armature and Lever Removed 6 Remove the frame from the armature and drive end cap See Figure 8 21 10 Push the stop collar down to expose the retaining ring See Figure 8 24 Figure 8 21 Starter Frame Removed 8 14 Section 8 Electrical System and Components Figure 8 24 Retaining Ring Detail Figure 8 25 Removing Retaining Ring 11 Remove the retainer from the armature shaft 12 Remove the drive pinion assembly from the Save the stop collar armature NOTE Do not reuse the old retainer 13 Clean the parts as required NOTE Do not soak the armature or use solvent when cleaning Wipe clean using a soft cloth or use compressed air Plunger Armature Frame amp Field Washer en Brush Holder p Nut CE Frame Screw Bolt Figure 8 26 Delco Remy Starter 8 15 Section 8 Electrical System and Components Inspection Commutator O D Drive Pinion Check and inspect the following areas a The pinion teeth for abnormal wear or damage b The surface between the pinion and the clutch mechanism for nicks or irregularities which could cause seal damage c Check the drive clutch by holding the clutch Mica Insulation housing and rotating the pinion The pinion should rotate in one direction only Figure 8 28 Commutator Mica Inspection Brushes and Springs 2 Use an ohmmeter set to the Rx1
63. Fuel System and Governor Mechanical Fuel Pump 3 Remove the vacuum line that connects the pump The mechanical fuel pump is built into the 2 valve to the crankcase cover The actuating arm of the pump extends down inside the cover and contacts one of the rocker arms 4 Install anew pump using the hex flange screws Downward movement of the rocker arm allows the pump diaphragm to flex down drawing in fuel As NOTE Make sure the orientation of the new the rocker arm comes up the fuel is forced out toward pump is consistent with the removed the carburetor pump Internal damage may occur if installed incorrectly 5 Connect vacuum line between the pump and crankcase 6 Tighten the hex flange screws to 2 3 N m 20 in Ib 7 Connect the fuel lines to the inlet and outlet fittings Mechanical Fuel Pump 1 Disconnect the fuel lines from the inlet and outlet fittings 2 Clean the area and remove the four screws securing the valve cover pump assembly to the cylinder head Loosen but do not remove the four valve cover screws on the opposite side 3 Lift the air cleaner mounting bracket up slightly and remove the valve cover pump assembly Remove and discard the old gasket 4 Rotate the engine by hand while observing the actuating rocker arm Stop rotating when end of aon Li k eg the rocker arm is at the lowest point spring is at Mechanical Fuel Pump i maximum compression and valve is open Figure 5 1 Fuel
64. PORADIC P0132 O cuit P0134 O Sensor Circuit No Activity Detected 2 21 22 22 23 24 31 31 32 33 33 34 34 42 42 43 44 51 51 51 52 52 52 54 54 54 55 99 5D 56 56 56 58 58 58 61 5B 28 Diagnostic Code Summary Code 21 Source Engine Speed Sensor Explanation ECU receiving inconsistent tooth count signals from speed sensor Expected Engine Response Possible misfire as ECU attempts to resynchronize during which time fuel and spark calculations are not made Possible Causes 1 Engine Speed Sensor Related a Sensor connector or wiring b Sensor loose or incorrect air gap c Flywheel key sheared 2 Speed Sensor Ring Gear Related a Damaged teeth b Varying gap gear loose out of alignment 3 Engine Wire Harness Related a Pin circuits 9 and or 10 wiring or connectors b Shielding for pin circuits 9 and or 10 damaged or not properly grounded c Poor or improper grounds in system battery ECU oxygen sensor shielding fuel pump ignition output d Pin circuits 9 and or 10 routed near noisy electrical signals coils spark plug lead plug connector 4 ECU Harness Related a ECU to harness connection problem 5 Ignition System Related a Non resistor spark plug s used Section 5B EFI Fuel System Code 22 Source Throttle Position Sensor TPS Explanation Unrecognizable signal is being sent from sensor too high too low inconsistent Expected
65. Pump Styles 5 Position the new gasket onto the new cover fuel Replacing The Fuel Pump pump assembly and install onto cylinder head Replacement pumps are available through your source Align the air cleaner mounting bracket holes with of supply To replace the pulse pump follow these the upper two valve cover screw holes steps Note the orientation of pump before removing 6 Install the longer screws in the upper holes Pulse Fuel Pump and the shorter screws in the lower holes 1 Disconnect the fuel lines from the inlet and outlet Finger tighten all eight valve cover mounting fittings screws four each side then torque the screws to 6 2 N m 55 in 1b in the sequence shown in 2 Remove the hex flange screws mounting fuel Figure 5 2 pump to support 5 3 Section 5 Fuel System and Governor Figure 5 2 Valve Cover Torque Sequence Carburetor General Engines in this series are equipped with emission compliant fixed main jet carburetors manufactured by Keihin All have self relieving chokes for efficient operation Depending on the specifications and application involved most will also contain a fuel shut off solenoid and an accelerator pump An exploded view of the carburetor is shown in Figure 5 6 with the accelerator pump components shown in the inset Float Circuit Fuel level in the bowl is maintained by the float and fuel inlet needle The buoyant force of the float stops fuel flow when the engine is at
66. R 22 965 101 60 E 4 000 F Option 490 74 112 92 19 320 a 4 446 Center of Air Intake 155 58 6 125 E 38 00 1 496 Oil Drain Plug Engine Mounting Surface sooo 3 504 Mounting Holes 4 00 Pilot 157 238 61 9 394 Mounting Hole A Mounting Surface 431 61 16 992 Figure 1 4 Typical Engine Dimensions 26 524 50 99 2 007 Oil Filter Side Optional Oil Fill ele Ze D oi 673 70 N Overall H l Lei Gei ole Oil Drain 38 00 1 496 143 25 175 41 5 640 6 906 Mounting Hole A PTO Side 142 88 Bolt Circle 5 625 0 618 Bolt Circle 197 00 7 756 4x 7 16 14 UNC 2B Inch 4X 3 8 16 UNC 2B Inch 299 00 Oil Filter 11 77 235 19 9 259 Mounting Hole A 177 80 Pilot 7 000 1 4 Inch Square Key 5 8 18 UNF Thread 7 16 20 Thread Option 36 50 1 437 28 575 Option 1 125 Top View Dimensions in millimeters Inch equivalents shown in 1 7 Section 1 Safety and General Information General Specifications Power 3600 RPM exceeds Society of Automotive Engineers Small Engine Test Code J1940 TOO EE Maximum 16 4 kW 22 HP Recommended 13 9 kW 18 7 HP eege Mac egigeges 17 9 kW 24 HP Recommended 15 2 kW 20 4 HP
67. SERVICE MANUAL KOHLER AEGIS LH630 775 Liquipb COOLED HORIZONTAL CRANKSHAFT KOHLER ENGINES Contents Section 1 Safety and General Information cccceseeeeeeeeeneeeeeneeceneecenseseasesenseseeneseneesens Geelen TOONS amp e TEE SECON 3 IROUDICSIIOQUING tee Section 4 Air Cleaner System aaciascrcrctre aire cas se cise see epee tive ree nenwee er teniedenceceecereecteseeesen ee nme Section 5 Fuel System and Governor Section 5B Electronic Fuel Injection EFI Fuel System Section 6 Lubrication System Section 7 Cooling System Section 8 Electrical System and Components Section 9 Disassembly Section 10 Inspection and Reconditioning Section 11 Reassembly ccccscceeeeeeeneeeeneeeenseeeseeeaseecensecensecoasesoaseseaseesoasesonseneanesoesesonseeses Section 1 Safety and General Information Safety Precautions To ensure safe operations please read the following statements and understand their meaning Also refer to your equipment manufacturer s manual for other important safety information This manual contains safety precautions which are explained below Please read carefully A WARNING Warning is used to indicate the presence of a hazard that can cause severe personal injury death or substantial property damage if the warning is ignored A CAUTION Caution is used to indicate the presence of a hazard that will or can cause minor personal injur
68. T Starter L R Battery R Key Switch SSES Oil Pressure Ground B Switch Ignition Kill W Accessory Y Coolant 33 Temp Over gen e E heat Alarm Coolant Temp Switch Intake Manifold Carburetor Screw Assembly Blower Housing Safety Switch Carburetor a Solenoid Enr S Flywheel Ignition Starter Ignition Kill Stator L Solenoid ee DN Assembly g VW w 3 Accessory nl DH Terminal Regulator A Y Rectifier Manifold y Screw 15 Amp Regulator i Rectifier 25 Amp Starter Solenoid Spark Plug 2 Cylinder Regulator Connector Starter Assembly Battery P 8 Spark Plug 7 yO a 1 Cylinder Rectifier Regulator Connector 15 Amp Stator Figure 8 7 15 20 25 Amp Stator and Rectifier Regulator 8 7 Section 8 Electrical System and Components Stator The stator is mounted on the crankcase behind the flywheel If the stator needs to be replaced follow the procedures in Section 9 Disassembly Rectifier Regulator The rectifier regulator is mounted on the bracket below the overflow reservoir See Figure 8 8 To replace it disconnect the connector plug and remove the two screws Take off the rectifier regulator NOTE When installing the rectifier regulator make sure the cooling fins are in towards the fan Figure 8 9 3 Plug the tester into the proper AC outlet power
69. TPS Set Auto Learn Initialization Terminal Throttle Position Sensor TPS and Temperature Sensor Ground Not Used Oil Temperature Sensor Input Not Used Throttle Position Sensor TPS Input Speed Sensor Input Speed Sensor Ground Not Used High Temperature Warning Output Not Used Injector 1 Output Injector 2 Output Not Used Diagnostic Line Throttle Position Temperature Sensor Supply Voltage Battery Ground Oxygen Sensor Input Battery Ground Secondary Not Used Not Used Not Used Safety Switch Input Not Used Not Used Main Relay Output Malfunction Indicator Light MIL Ignition Coil 1 Output Ignition Coil 2 Output Fan Control Output LO CON DOF WN kA 3 2 3 4 5 6 T7 8 9 OD OO 00 0900000000000 00 00 000000000000 On LH775 Kohler liquid cooled engines the ECU and corresponding wiring harness provide two additional circuits Pin circuit 32 provides ability to control an optional OEM electric cooling fan switching it on and off at the appropriate coolant temperatures using a relay Pin circuit 12 switches on when the coolant temperature is too high to operate an optional engine temperature warning light 5B 24 SEE GENERAL NOTE NO 9 SAFETY SWITCH J1 25 N O GROUND J1 10 J1 9 SENSOR ENGINE SPEED A 2 1 PI W eg da Rea E e urey KE vn Cylinder 1 H 8 Shela Grove 2 5 se ogee ZS i R 2 Tel EN oO s e wie cing Nowe
70. aft 4 Verify that the governor has been set correctly With the linkage still retained in the Full Throttle position Step 2 unsnap the bushing clip separate the linkage from the bushing and remove the bushing from the lever Follow Steps 3 and 4 in Checking the Initial Adjustment 5 Reconnect the dampening spring into its governor lever hole from the bottom Reinstall the bushing and reattach the throttle linkage See Figure 5B 30 Reattach the governor spring in the marked hole 6 Start the engine and allow it to fully warm up and establish closed loop operation approximately 5 10 min Check the speed settings and adjust as necessary first the low idle speed and then the high speed setting Troubleshooting General When troubleshooting a problem on an engine with EFI basic engine operating problems must be eliminated first before faulting the EFI system components What appears to be an EFI problem could be something as simple as a fuel tank with debris in the bottom or a plugged vent Be sure the engine is in good mechanical operating condition and all other systems are functional before attempting to troubleshoot the EFI system 5B 22 Troubleshooting Guide Engine starts hard or fails to start when cold 1 Fuel pump not running Engine temp sensor faulty Incorrect fuel pressure TPS faulty TPS offset incorrect Old stale fuel Low system voltage Speed sensor loose or faulty Faulty injec
71. ain plugs if equipped from the sides of the block and allow the remaining coolant to drain See Figure 7 7 On the starter side it may be preferable to first remove the starter or use a piece of cardboard formed in a V to drain the coolant out over the starter After the coolant has drained apply pipe D sealant with Teflon Loctite 59241 or equivalent to the threads of the plugs and reinstall the plugs Torque the plugs to 13 5 N m 120 in Ib Always use brass plugs when service is performed Unhook inboard catch and remove the overflow reservoir from its mounting location See Figure 7 8 Remove the cap and pour out the contents of the reservoir Wash or clean as required Dispose of all the old coolant properly according to local regulations 7 3 Section 7 Cooling System 5 Reinstall the reservoir into the mounting bracket and install the cap Do not kink pinch the hose 6 Flush the cooling system Flushing Cooling System NOTE To prevent engine damage do not pour water into a hot engine Do not operate engine without coolant With system properly drained 1 Fill the cooling system with clean water and a cooling system cleaner recommended for aluminum engines Follow the directions on the container 2 Reinstall and tighten the radiator cap 3 Start and run the engine five minutes or until it reaches operating temperature 4 Drain the cooling system immediately before contamin
72. alling Lower Radiator Hose Clamp 6 Check for adequate clearance between fan and shroud Adjust the lower radiator supports as required then torque the four mounting screws to 9 9 N m 88 in Ib See Figures 11 115 and 11 116 8 If the two flange nuts securing the upper brackets to the top radiator mounts were loosened torque to 9 9 N m 88 in Ib See Figure DI 11 118 Figure 11 115 Fan Clearance Checking 11 31 Section 11 Reassembly 3 Align the lower flywheel cover with the 1 starter side lower radiator support bracket holes Position the rectifier regulator mounting plate behind the cover and install the remaining two screws or nuts and flat washers Torque the four fasteners to 9 9 N m 88 in Ib See Figure 11 120 If screws and Timmerman nuts clips are used torque to 2 2 2 8 N m 20 25 in Ib Figure 11 118 Torquing Top Nuts on Upper Brackets 9 Ifa pulse style fuel pump is used install it to the tapped holes in the 2 side upper radiator support bracket and torque the two screws to 6 8 7 3 N m 60 65 in Ib Connect the outlet line between the pump and carburetor and the vacuum line to the crankcase fitting Secure with the clamps See Figure 11 119 Figure 11 120 Torquing Lower Rectifier Regulator Mounting Screws and 4 If removed mount the rectifier regulator to the plate with the two screws and attach the connector plug See Figure 11 120 Install Muffler 1 Insta
73. an and hub assembly when mounted to the 3 Check the v belt for excessive wear cracking or damage If proper belt tension cannot be obtained or the condition of the belt is suspect replace it with Kohler Part No 66 203 02 S Do not use a substitute belt 10 14 Section 11 Reassembly 3 4 ef 6 G 8 2D General NOTE Make sure the engine is assembled using all specified torque values tightening sequences and clearances Failure to observe specifications could cause severe engine wear or damage Always use new gaskets Apply a small amount of oil to the threads of critical fasteners before assembly unless a Sealant or Loctite is specified or preapplied Make sure all traces of any cleaner are removed before the engine is assembled and placed into operation Even small amounts of these cleaners can quickly break down the lubricating properties of engine oil Check the closure plate crankcase cylinder heads and valve covers to be certain that all old sealing material has been removed Use gasket remover lacquer thinner or paint remover to remove any remaining traces Clean the surfaces with isopropyl alcohol acetone lacquer thinner or electrical contact cleaner Typical Reassembly Sequence The following sequence is suggested for complete engine reassembly This procedure assumes that all components are new or have been reconditioned and all component subassembly work has been completed The sequ
74. and ring assemblies Initially resize using a boring bar then use the following procedures for honing the cylinder NOTE If the bore is beyond the wear limit a new miniblock or short block will be required Honing While most commercially available cylinder hones can be used with either portable drills or drill presses the use of a low speed drill press is preferred as it facilitates more accurate alignment of the bore in relation to the crankshaft crossbore Honing is best accomplished at a drill speed of about 250 RPM and 60 strokes per minute After installing coarse stones in hone proceed as follows 1 Lower hone into bore and after centering adjust so that the stones are in contact with the cylinder wall Use of a commercial cutting cooling agent is recommended 2 With the lower edge of each stone positioned even with the lowest edge of the bore start drill and honing process Move the hone up and down while resizing to prevent the formation of cutting ridges Check the size frequently 3 When the bore is within 0 064 mm 0 0025 in of desired size remove the coarse stones and replace with burnishing stones Continue with the burnishing stones until within 0 013 mm 0 0005 in of desired size and then use finish stones 220 280 grit and polish to final size A crosshatch should be observed if honing is done correctly The crosshatch should intersect at approximately 23 33 off the horizontal Too flat an angle co
75. ants settle refer to Draining Cooling System 5 Fill the cooling system Filling Cooling System NOTE To prevent engine damage do not use antifreeze mixture greater than 70 ethylene glycol in the cooling system Do not use antifreeze with stop leak additive s or mix add other additives to the cooling system Use only ethylene glycol antifreeze Cooling system capacity is approximately 2 liters 2 18 qt 1 Check the condition of cooling system hoses clamps and associated components Replace as required 2 Mix 50 ethylene glycol with 50 distilled or deionized water See Coolant Recommendation For extremely cold temperature applications or protection outside the limits listed in the Coolant Recommendation Section refer to the antifreeze manufacturer s instructions on the container ZA 3 Fill the cooling system through the radiator neck Allow coolant to drain into the lower areas Fill the overflow reservoir midway between the ADD and FULL marks then install the radiator and reservoir caps 4 Start engine run for five minutes and let cool 5 Check coolant level in reservoir Coolant level should be between the FULL and ADD marks See Figure 7 5 Add coolant if required Inspection Cooling Fan Assembly Belt and Drive Pulleys The cooling fan assembly used to draw the air through the radiator is attached to a hub and pulley assembly with sealed ball bearings This assembly is
76. ating Lever Governor Spring Speed Control Bracket Governor Lever Holes for Sensitivity Adjustment 1 IA E 4 cb 6 G 8 9 Figure 5 8 Governor Controls and Linkage External Air Cleaner Removed for Clarity Adjustments General The governed speed setting is determined by the position of the throttle control It can be variable or constant depending on the engine application Initial Adjustment NOTE The LH760 and LH775 EFI engines require a special initial adjustment procedure which is covered in subsection 5B Refer to pages 5B 21 5B 22 Make this adjustment whenever the governor lever is loosened or removed from the cross shaft See Figure 5 8 and adjust as follows 1 Make sure the throttle linkage is connected to the governor lever and the throttle lever on the carburetor 2 Loosen the hex nut holding the governor lever to the cross shaft 3 Move the governor lever towards the carburetor as far as it will move wide open throttle and hold in position 4 Insert a nail into the hole on the cross shaft and rotate the shaft counterclockwise as far as it will turn then torque hex nut to 6 8 N m 60 in Ib 5 12 Sensitivity Adjustment Governor sensitivity is adjusted by repositioning the governor spring in the holes on the governor lever If speed surging occurs with a change in engine load the governor is set too sensitive If a big drop in speed occurs when normal load is applie
77. ature sensor limit is 123 8 C 255 F E Audible Alarm Figure 7 13 Warning Devices If the warning device activates or the engine kills indicating an excessive operating temperature check the following 1 Make sure fan belt is in good condition and properly tensioned 2 Make sure cooling fan is properly secured not broken damaged or missing blades 3 Make sure all air intake and cooling surfaces are clean and free of debris accumulation 4 After the engine has sufficiently cooled check the coolant level in the system to make sure it is not low or improperly mixed 5 Check cooling system for leaks 6 Check the thermostat and pressure test the radiator cap 7 Make sure the water pump and the drive belt are operational 8 Check and inspect the wiring from the sensor for shorting or damage If none of those are found to be the cause do the following 1 Drain coolant from the system so the level is lower than the installed position of the temperature sensor 2 Remove and replace the temperature sensor Use pipe sealant with Teflon on the threads Cooling System Leakage Test A pressure test of the cooling system can be performed as a relatively simple means of determining whether the cooling system may contain a leak A pump pressure type cooling system tester with the appropriate 45 mm adapter may be used to check the cooling system and the radiator cap A typical tester and adapter is sh
78. ause fires and severe burns Do not fill the fuel tank while the engine is hot or running Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent AA WARNING Cleaning Solvents can cause severe injury or death Use only in well ventilated areas away from ignition sources Flammable Solvents Carburetor cleaners and solvents are extremely flammable Keep sparks flames and other sources of ignition away from the area Follow the cleaner manufacturer s warnings and instructions on its proper and safe use Never use gasoline as a cleaning agent 1 2 A WARNING Carbon Monoxide can cause severe nausea fainting or death Avoid inhaling exhaust fumes and never run the engine in a closed building or confined area Lethal Exhaust Gases Engine exhaust gases contain poisonous carbon monoxide Carbon monoxide 1s odorless colorless and can cause death if inhaled Avoid inhaling exhaust fumes and never run the engine in a closed building or confined area A WARNING A burns Do not loosen radiator cap while engine is
79. cal System and Components Delco Remy Starters 3 If the solenoid was mounted with Phillips head screws separate the solenoid and plunger spring from the drive end cap If the solenoid was mounted with external Torx head screws the plunger is part of the solenoid unhook the plunger pin from the drive lever Remove the gasket from the recess in the housing See Figures 8 17 and 8 18 NOTE Test procedure for checking starter solenoid on pages 8 21 and 8 22 Figure 8 15 Completed Delco Remy Starter Starter Disassembly 1 Remove the hex nut and disconnect the positive brush lead bracket from the solenoid terminal 2 Remove the three screws securing the solenoid to the starter See Figure 8 16 Phillips Head Screws Torx Head Screws bh Sw Lh olenoid Screws Figure 8 16 Removing S Figure 8 18 Removing Plunger 8 13 Section 8 Electrical System and Components 4 Remove the two thru larger bolts See Figure 7 Remove the drive lever pivot bushing and 8 19 backing plate from the end cap See Figure 8 22 Figure 8 19 Removing Thru Bolts Figure 8 22 5 Remove the commutator end plate assembly containing the brush holder brushes springs 8 Take out the drive lever and pull the armature and locking caps Remove the thrust washer out of the drive end cap See Figure 8 23 from inside the commutator end See Figure 8 20 9 Remove the thrust washer from the armature shaft See
80. chipped or some are missing replacement will be necessary If there is tooth damage on either the camshaft gear or crankshaft gear both the camshaft and crankshaft must be replaced Inspect the bearing surfaces for scoring grooving etc Measure the running clearance between the bearing journals and their respective bores Use an inside micrometer or telescoping gauge to measure the inside diameter of both bearing bores in the vertical and horizontal planes Use an outside micrometer to measure the outside diameter of the bearing journals Subtract the journal diameters from their respective bore diameters to get the running clearances Check the results against the specifications in Section 1 If the running clearances are within specification and there is no evidence of scoring grooving etc no further reconditioning is necessary If the bearing surfaces are worn or damaged the crankcase and or closure plate will need to be replaced 10 Inspect the crankshaft keyways If worn or chipped replacement of the crankshaft will be necessary Inspect the crankpin for score marks or metallic pick up Slight score marks can be cleaned with crocus cloth soaked in oil If wear limits as stated in Specifications and Tolerances are exceeded it will be necessary to either replace the crankshaft or regrind the crankpin to 0 25 mm 0 010 in undersize If reground 0 25 mm 0 010 in undersize connecting rods big end must then be
81. ck Angle of Operation This engine will operate continuously at angles up to 20 Check oil level to assure crankcase oil level is at the F mark on the dipstick Refer to the operating instructions of the equipment this engine powers Because of equipment design or application there may be more stringent restrictions regarding the angle of operation NOTE Do not operate this engine continuously at angles exceeding 20 in any direction Engine damage could result from insufficient lubrication Section 6 Lubrication System Oil Sentry Some engines are equipped with an optional Oil Sentry oil pressure monitor If the oil pressure decreases below an acceptable level the Oil Sentry will either shut off the engine or activate a warning signal depending on the application Operation The pressure switch is designed to break contact as the oil pressure increases and make contact as the oil pressure decreases At oil pressure above approximately 3 0 5 0 psi the switch contacts open Below this pressure the switch contacts close On stationary or unattended applications pumps generators etc the pressure switch can be used to ground the ignition module to stop the engine On vehicular applications lawn tractors mowers etc the pressure switch can only be used to activate a warning light or signal NOTE Make sure the oil level is checked BEFORE EACH USE and is maintained up to t
82. ck the equipment manufacturer s recommendation For starting and warm up the ECU will adjust the fuel and ignition timing based upon ambient temperature engine temperature and loads present In cold conditions the idle speed will probably be higher than normal for a few moments Under other conditions the idle speed may actually start lower than normal but gradually increase to the established setting as operation continues Do not attempt to circumvent this warm up period or readjust the idle speed during this time The engine must be completely warmed up for accurate idle speed adjustment 5B 20 Adjustment Procedure 1 Make sure there are no fault codes present in the ECU memory 2 Start the engine and allow it to fully warm up and establish closed looped operation approximately 5 10 min 3 Place the throttle control in the idle slow position and check the idle speed with a tachometer Turn the idle speed screw in or out as required to obtain 1500 RPM or the idle speed specified by the equipment manufacturer 4 The low idle speed adjustment can affect the high speed setting Move the throttle control to the full throttle position and check the high speed Adjust as necessary to 3750 RPM no load or the speed specified by the equipment manufacturer Figure 5B 29 Idle Speed Screw Details Initial Governor Adjustment The initial governor adjustment is especially critical on EFI engines becaus
83. ct Leaking fuel injector O Rings 7 Bad spark plug s or coil s Engine idles too fast after full warm up 1 Ss J 4 oF 6 f Throttle linkage binding or not returning to idle position Idle speed adjustment incorrect Vacuum intake air leak Leaking fuel injector O Rings injector to manifold Engine Coolant Temperature sensor faulty TPS faulty or TPS Initialization Procedure incorrect Base ignition timing incorrect Engine misses hesitates or stalls under load Code 22 31 34 43 44 51 52 1 oie p EA SS Fuel injector s fuel filter fuel line or fuel pick up dirty restricted Dirty air cleaner Insufficient fuel pressure or fuel delivery Vacuum intake air leak Improper governor setting adjustment or operation Speed sensor malfunction TPS faulty mounting problem or TPS Initialization Procedure incorrect Bad coil s spark plug s or wires Base ignition timing incorrect Section 5B EFI Fuel System Low Power 51 52 Throttle plates in throttle body intake manifold not fully opening to WOT stop if so equipped 1 i E e dg Insufficient fuel delivery Dirty air filter Faulty malfunctioning ignition system TPS faulty or mounting problem Basic engine problem exists Improper governor adjustment Plugged restricted exhaust One injector not working One spark plug coil or wire not working 5B 37 Section 6
84. ction 2 is used to crimp the replacement clamps A CAUTION Fuel lines between the fuel pump and fuel rail must be made from SAE 30 R9 fuel line Standard fuel line SAE 30 R7 may only be used between the fuel tank and pump 5 16 ID and for the return line from the pressure regulator to the tank 1 4 ID All high pressure fuel line connections must be secured with Oetiker clamps Kohler Part No 24 237 05 S installed crimped with the corresponding pliers 5B 19 Section 5B EFI Fuel System Throttle Body Intake Manifold Assembly Figure 5B 28 Upper Intake Manifold General The EFI engines have no carburetor so the throttle function regulate incoming combustion airflow is incorporated in the intake manifold assembly The manifold consists of a one piece aluminum casting which also provides mounting for the fuel injectors throttle position sensor fuel rail air baffle idle speed screw and air cleaner assembly Service The throttle body intake manifold is serviced as an assembly with the throttle shaft throttle plate and idle speed adjusting screw installed The throttle shaft rotates on needle bearings non serviceable capped with rubber seals to prevent air leaks Idle Speed Adjustment RPM General The idle speed is the only adjustment that may be performed on the EFI system The standard idle speed setting for EFI engines is 1500 RPM but certain applications might require a different setting Che
85. ctuator voltages circuits 65 66 45 and 87 and system voltage J1 1 Ifthe ignition switch controls a powered circuit i e lights horn it is recommended that a relay be used to control the power To prevent signal errors load circuits i e horn lights shall not be powered from EFI engine or chassis wire harness A resistive spark plug with either a resistive spark plug wire or boot must be used to prevent electrical system noise lt is recommended that the ECU housing is mounted with the wire harness down to facilitate proper drainage away from the electrical connector When not in operation the battery must maintain a minimum system voltage of 7Y with a current draw of 2 mA to maintain the adaptive memory During starting the system voltage must be 7V minimum for the ECU operation during cranking Unless otherwise specified all wires are 18AWG Speed sensor wires pins 9 and 10 are to be a twisted pair with 1 twist inch minimum Malfunction indicator lamp MIL can be a 12V 0 25A incandescent lamp Optionally a 20 mA LED can be used This requires a resistor of approximately 600 ohms wired in parallel Normal operating voltage is to 16V dc 9Vdc with a cold cranking voltage of 7V The throttle position sensor TPS connection shown is for CCW rotation of the TPS from idle to wide open throttle as viewed from the throttle shaft side of the TPS CW rotation requires switching the wires to TPS pins 1 and 3 Section 5B EFI
86. d the governor should be set for greater sensitivity See Figure 5 8 and adjust as follows 1 To increase the sensitivity move the spring closer to the governor cross shaft 2 To decrease the sensitivity move the spring away from the governor cross shaft High Speed RPM Adjustment See Figure 5 9 1 With the engine running move the throttle control to fast Use a tachometer to check the RPM speed 2 Loosen the lock nut on the high speed adjusting screw Turn screw outward to decrease or inward to increase RPM speed Check RPM with a tachometer 3 When the desired RPM speed is obtained retighten the lock nut NOTE When the throttle and choke control cables are routed side by side especially under a single clamp there must be a small gap between the cables to prevent internal binding After the high speed setting has been complete check that there is gap of at least 0 5 mm 0 020 in between the control cables Left Side Pull Choke Control Lever 1 Choke Control Cable Kill Switch Throttle Control Cable 3 S Il gt Wi We e E EE Kill Switch Adjusting Screw Dual Control High Speed Lever Stop Screw Do Not Remove High Speed Adjusting Sc Figure 5 9 Governor Control Connections Section 5 Fuel System and Governor Throttle Control Lever 2 Choke Linkage Z Bend 3 Throttle Control Cable gt PN rew Right Side Pull 5 13 Section 5B Electronic Fuel In
87. d external surfaces of the engine are kept clean and in good condition at all times Check the coolant level and clean away any debris accumulation daily or before each use At the same time inspect the hoses and all system connections for signs of leakage Make sure the cooling fan is not cracked or missing any blades Check that the fan belt and the two drive pulleys are in good condition and the proper belt tension is present See Figure 7 2 Figure 7 2 Checking Belt Tension Servicing Every 100 hours of operation more often under extremely dusty dirty conditions clean the removable screen cooling fins of the radiator all shrouding and external surfaces of the engine as necessary Check the condition of fan assembly and v belt tension Do not operate the engine without all shrouds and protective guards installed Lift the screen vertically to remove for cleaning servicing Clean the screen and cooling fins of the radiator with a soft brush or blow out using clean compressed air See Figure 7 3 To avoid damage to the screen and cooling fins do not use a high pressure washer to clean 7 2 Figure 7 3 Cleaning Radiator and Screen Engine coolant should be changed every two years or 1000 hours whichever comes first When changing the engine coolant the system should also be flushed to remove any contaminants left behind during draining Following are general recommended procedures for checking draining flushing
88. d oil filter more frequently under severe conditions Section 6 e Check spark plug condition and gap Section 5 e Change fuel filter carbureted models Section 8 Every 250 Hours e Replace air cleaner element and check inner element Sane ae Aaf e Replace spark plugs Every 2 Years or l Every 1000 Hours Change engine coolant Every 1500 Hours Replace fuel filter EFI engines Perform these maintenance procedures more frequently under extremely dusty dirty conditions Daily or Before Starting Engine Annually or Every 200 Hours 1 5 Section 1 Safety and General Information Storage If the engine will be out of service for two months or more use the following storage procedure 1 1 6 Clean the exterior surfaces of the radiator and engine On EFI engines avoid spraying water at the wiring harness or any of the electrical components Change the oil and filter while the engine is still warm from operation See Change Oil and Filter in Section 6 The coolant anti freeze mixture should be in good condition and tested to guard against freezing in cold temperatures The recommended 50 50 mixture will normally provide protection down to temperatures of 37 C 34 F If storage temperatures will fall below this the cooling system should be drained completely A note should then be attached to the equipment and or engine as a reminder to refill the cooling system before starting The
89. d to connect the components within the cooling system To guard against coolant loss and hose failure the hoses tubes and their connections should be checked regularly for leaks or damage Loss of coolant can result in serious engine damage Over time engine vibration can affect hose joint connections and the hoses themselves can be affected by heat and the coolant Swelling hardening and or deterioration can occur depending on the operating environment Deterioration usually takes place more rapidly from the inside making outside inspections incomplete and not always dependable Regular outside inspection and careful inside inspection whenever connections are opened can minimize a possible in service problem Figure 7 10 Checking Belt Tension If the belt is cracked damaged or is worn to the extent that relocation of pulley shims cannot establish proper belt tension the belt should be replaced Use only Kohler Part No 66 203 02 S belt DO NOT use a substitute belt Use new clamps whenever a hose is replaced or a joint connection is opened When making hose connections a light coating of rubber lubricant will make assembly easier Thermostat Testing and Servicing The thermostat is mounted in the intake manifold beneath the thermostat housing See Figure 7 12 It controls the rapid warm up and operating temperature of the engine If a problem is encountered which is thought to be the fault of the thermosta
90. de out of an old junk flywheel ring gear as shown in Figure 2 1 and 3 Find a 1 in long capscrew with the correct used in place of a strap wrench thread size to match the threads in the connecting rod 1 Using an abrasive cut off wheel cut out a six tooth segment of the ring gear as shown 4 Use a flat washer with the correct I D to slip on the capscrew and approximately 1 O D Kohler 2 Grind off any burrs or sharp edges Part No 12 468 05 S Assemble the capscrew and washer to the joint surface of the rod as 3 Invert the segment and place it between the shown in Figure 2 2 ignition bosses on the crankcase so that the tool teeth engage the flywheel ring gear teeth The bosses will lock the tool and flywheel in position for loosening tightening or removing with a puller Figure 2 2 Rocker Arm Crankshaft Tool Figure 2 1 Flywheel Holding Tool Rocker Arm Crankshaft Tool A spanner wrench to lift the rocker arms or turn the crankshaft may be made out of an old junk connecting rod 1 Find a used connecting rod from a 10 HP or larger engine Remove and discard the rod cap 2 4 Section 3 Troubleshooting Troubleshooting Guide When troubles occur be sure to check the simple causes which at first may seem too obvious to be considered For example a starting problem could be caused by an empty fuel tank Some common causes of engine troubles are listed below Use these to locate the causing factor
91. decreases Figure 5 7 Governor Linkage Section 5 Fuel System and Governor As the flyweights move outward they cause the regulating pin to move outward The regulating pin contacts the tab on the cross shaft causing the shaft to rotate One end of the cross shaft protrudes through the crankcase The rotating action of the cross shaft is transmitted to the throttle lever of the carburetor through the external linkage See Figure 5 7 When the engine is at rest and the throttle is in the fast position the tension of the governor spring holds the throttle plate open When the engine is operating the governor gear assembly is rotating The force applied by the regulating pin against the cross shaft tends to close the throttle plate The governor spring tension and the force applied by the regulating pin balance each other during operation to maintain engine speed When load is applied and the engine speed and governor gear speed decreases the governor spring tension moves the governor arm to open the throttle plate wider This allows more fuel into the engine increasing engine speed As speed reaches the governed setting the governor spring tension and the force applied by the regulating pin will again offset each other to hold a steady engine speed 5 11 Section 5 Fuel System and Governor Governor Lever Hex Nut Governor Cross Shaft Governor Lever Throttle Lever Linkage Choke Linkage Choke Actu
92. ding tool and crankshaft PTO If the flywheel end is more accessible you can use a breaker bar and socket on the flywheel nut screw to hold it in position You may need an assistant to hold the breaker bar during testing If the engine is mounted in a piece of equipment you may be able to hold it by clamping or wedging a driven component Just be certain that the engine cannot rotate off of TDC in either direction Install the adapter hose into the spark plug hole but do not attach it to the tester at this time Connect an adequate air source to the tester Turn the regulator knob in the increase clockwise direction until the gauge needle is in the yellow set area at the low end of the scale Connect tester quick disconnect to the adapter Note the gauge reading and listen for escaping air at the carburetor intake exhaust outlet and oil fill dipstick tube Check your test results against the table below Leakdown Test Results Ait SSCA pier UE E Air escaping from exhaust outlet situs ccatinsesaccidusnsonsarseavecssavnnss Air escaping from carburetor inlet A Gauge reading in low green Zone seeeeeereesrererereresrees Gauge reading in moderate yellow zone Gauge reading in high red ZONE ssssssssisissssssssssrssssssssisesssss Cooling Leakage Test A pressure test can be performed as a simple means of determining whether the cooling system may have a problem The test procedure possible re
93. e e Inspect the fuel inlet needle and seat for wear or damage 5 7 Section 5 Fuel System and Governor 6 5 8 NOTE The fuel inlet needle tip is spring loaded Make sure float assembly rests against the fuel inlet needle without depressing the tip The correct float height adjustment is 22 mm 0 86 in measured from the float bottom to the air horn casting Adjust the float height by carefully bending the tab NOTE Be sure to measure from the casting surface not the rubber gasket surface If proper float height adjustment cannot be achieved check to see if the fuel inlet needle is dirty obstructed or worn Remove the brass screw and float assembly to remove the fuel inlet needle Figure 5 5 Carburetor Float Adjustment 8 10 Once proper float height is obtained carefully lower the carburetor upper body onto the carburetor lower body connecting the choke linkage Install the four screws Torque screws to 1 7 N m 15 in Ib See Figure 5 4 Connect the fuel line Install the breather hose and air cleaner assembly following the steps in Section 11 Reassembly Section 5 Fuel System and Governor Carburetor Upper Body Choke Self Relieving Choke Body Gasket Formed Rubber Slow Speed Jet Inlet Needle Valve Clip Float Pin Float Assembly Kit 9 Carburetor Lower Body Throttle 10 Idle Fuel Adjusting Needle Ya a ee 4 S 11 Main Jet 5 y A 15 12 Solenoid Seat 13
94. e Replace components covered in this section are the plug if necessary e Spark Plugs NOTE Do not clean spark plug in a machine e Battery and Charging System using abrasive grit Some grit could e Electronic CD Ignition System remain in the spark plug and enter the e Electric Starter engine causing extensive wear and damage Spark Plugs Engine misfire or starting problems are often caused 3 Check the gap using a wire feeler gauge Adjust by a spark plug that has improper gap or is in poor the gap to 0 76 mm 0 030 in by carefully condition bending the ground electrode See Figure 8 1 The engine is equipped with the following spark Wire Gauge plugs Type The standard spark plug is a Champion Spark Plug RC14YC Kohler Part No 66 132 01 S Equivalent alternate brand plugs can also be used Gap 0 76 mm 0 030 in Thread Size 14mm Reach 19 1 mm 3 4 in Hex Size 16 mm 5 8 in Spark Plug Service Annually or every 200 hours of operation whichever comes first remove the spark plugs check condition and reset the gap or replace with new spark plugs as necessary Every 500 hours of operation replace the spark plugs To service the spark plugs perform the Electrode 0 030 in Gap following steps Figure 8 1 Servicing Spark Plug 1 Before removing each spark plug clean the area around the base of the plug to keep dirt and debris out of the engine 4 Reinstall the spark plug
95. e 9 28 Removin Assembly Parts Remove Valve Covers 1 Remove the hex flange screws from the two lower valve cover mounting locations on each side See Figure 9 29 Figure 9 31 Removing Lower Pulley Four Screws Ki SH Figure 9 29 Removing Two Lower Valve Cover Screws 2 Remove the valve covers and valve cover gaskets Note on which side the oil fill or fuel pump is located for correct reassembly later See Figure 9 30 9 8 Section 9 Disassembly 2 Remove the pulley halves with the spacer shims NOTE Further disassembly of the fan hub and from the adapter and take the fan belt off the pulley assembly is not necessary unless upper pulley fan assembly Note the number of a problem exists see Inspection shims between pulley halves and on the front Cooling Fan Assembly Belt and Drive side of pulley especially if the same belt will be Pulleys Section 7 If disassembly is reinstalled See Figure 9 32 performed note the assembly order and position of parts See Figure 9 34 Figure 9 32 Disassembled Lower Pulley Assembly Figure 9 34 Disassembled Fan Assembly Remove Fan Assembly Mounting Bracket Component and Fan Shaft 2 Remove the two hex flange screws and take off 1 Remove the front hex flange nut and washer the mounting bracket with the fan shaft securing the fan assembly to the fan shaft attached See Figure 9 35 Remove the fan and pulley assembly from the upper mounting bracket See F
96. e ECU compares the input signals to the programmed maps in its memory to determine the appropriate fuel and spark requirements for the immediate operating conditions The ECU then sends output signals to set the injector duration and ignition timing The ECU continually performs a diagnostic check of itself each of the sensors and the system performance If a fault is detected the ECU turns on the Malfunction Indicator Light MIL on the equipment control panel stores the fault code in its fault memory and goes into a default operating mode Depending on the significance or severity of the fault normal operation may continue or limp home operation slowed speed richer running may be initiated A technician can access the stored fault code using a blink code diagnosis flashed out through the MIL An optional computer software diagnostic program is also available see Section 2 The ECU requires a minimum of 7 0 volts to operate The adaptive memory in the ECU is operational the moment the battery cables are connected however the adapted values are lost if the battery becomes disconnected for any reason The ECU will relearn the adapted values if the engine is operated for 10 15 minutes at varying speeds and loads after the coolant temperature exceeds 55 C 130 F To prevent engine over speed and possible failure a rev limiting feature is programmed into the ECU If the maximum RPM limit 4500 is exceeded
97. e battery is unable to hold a charge Service battery or replace as necessary If voltage is more than 14 7 volts the rectifier regulator is faulty Replace rectifier regulator 8 11 Section 8 Electrical System and Components Electric Starting Motors These engines utilize solenoid shift style starter motors for dependable operation Operation service and troubleshooting of the starter and starter system follow in this section Starting Motor Precautions NOTE Do not crank the engine continuously for more than 10 seconds at a time If the engine does not start allow a 60 second cool down period between starting attempts Failure to follow these guidelines can burn out the starter motor NOTE If the engine develops sufficient speed to disengage the starter pinion but does not keep running a false start the engine rotation must be allowed to come to a complete stop before attempting to restart the engine If the starter is engaged while the flywheel is rotating the starter pinion and flywheel ring gear may clash resulting in damage to the starter Troubleshooting Guide Starting Difficulties NOTE If the starter does not crank the engine shut off the starter immediately Do not make further attempts to start the engine until the condition is corrected NOTE Do not drop the starter or strike the starter frame Doing so can damage the starter Starter Removal and Installation Refer to the Disassembly
98. e between the terminals indicated A reading of 750 1000 Q should again be obtained 5B 5 Section 5B EFI Fuel System Dual Aligning Rails gt Corresponds To EA 9 In Main Corresponds F RW Connector 10 In Main Connector Test Terminals Figure 5B 3 Speed Sensor Connector 7 a If the resistance is incorrect remove the screw securing the sensor to the mounting bracket and replace the sensor b If the resistance in step 2 was incorrect but the resistance of the sensor alone was correct test the main harness circuits between the sensor connector terminals and the corresponding pin terminals in the main connector Correct any observed problem reconnect the sensor and perform step 5 again Throttle Position Sensor TPS General The throttle position sensor TPS is used to indicate throttle plate angle to the ECU Since the throttle by way of the governor reacts to engine load the angle of the throttle plate is directly proportional to the load on the engine 5B 6 1 Throttle Valve Shaft 2 Resistor Track 3 Wiper Arm w Wiper 4 Electrical Connection Figure 5B 4 Throttle Position Sensor Details Figure 5B 5 TPS Location Mounted on the throttle body intake manifold and operated directly off the end of the throttle shaft the TPS works like a rheostat varying the voltage signal to the ECU in direct correlation to the angle of the throttle plate This signal along with the o
99. e fit Use a hand valve grinder with suction cup for final lapping Lightly coat valve face with fine grade of grinding compound then rotate valve on seat with grinder Continue grinding until smooth surface is obtained on seat and on valve face Thoroughly clean cylinder head in soap and hot water to remove all traces of grinding compound After drying cylinder head apply a light coating of engine oil to the seats to prevent rusting Intake Valve Stem Seal These engines use valve stem seals on the intake valves Always use a new seal when valves are removed from cylinder head The seals should also be replaced if deteriorated or damaged in any way Never reuse an old seal Pistons and Rings Inspection Scuffing and scoring of pistons and cylinder walls occurs when internal temperatures approach the welding point of the piston Temperatures high enough to do this are created by friction which is usually attributed to improper lubrication and or overheating of the engine Normally very little wear takes place in the piston boss piston pin area If the original piston and connecting rod can be reused after new rings are installed the original pin can also be reused but new piston pin retainers are required The piston pin is included as part of the piston assembly If the pin bosses or pin are worn or damaged a new piston assembly is required Ring failure is usually indicated by excessive oil consumption and blue exhaust
100. e of the accuracy and sensitivity of the electronic control system Incorrect adjustment can result in overspeed loss of power lack of response or inadequate load compensation If you encounter any of these symptoms and suspect them to be related to the governor setting the following should be used to check and or adjust the governor and throttle linkage If the governor throttle components are all intact but you think there may be a problem with the adjustment follow Procedure A to check the setting If the governor lever was loosened or removed go immediately to Procedure B to perform the initial adjustment A Checking the Initial Adjustment 1 Unsnap the plastic linkage bushing attaching the throttle linkage to the governor lever See Figure 5B 30 Unhook the damper spring from the lever separate the linkage from the bushing and remove the bushing from the lever Mark the hole position and unhook the governor spring from the governor lever Throttle Section 5B EFI Fuel System Rotate the governor lever and shaft counterclockwise until it stops Use only enough pressure to hold it in that position Check how the end of the throttle linkage aligns with the bushing hole in the governor lever See Figure 5B 32 It should fall in the center of the hole If it doesn t perform the adjustment procedure as follows Figure 5B 32 Throttle Link in Center of Hole B Setting The Initial Adjustment 1 Check the split whe
101. e of the oil drain plugs and the dipstick Be sure to allow ample time for complete drainage 3 Before removing the oil filter clean the surrounding area to keep dirt and debris out of the engine Remove the old filter and wipe clean the surface where the filter mounts 4 Reinstall the drain plug Make sure it is tightened to 13 6 N m 10 ft Ib 5 Place a new oil filter in a shallow pan with the open end up Pour new oil of the proper type in through the threaded center hole Stop pouring when the oil reaches the bottom of the threads Allow a minute or two for the oil to be absorbed by the filter material 6 Apply a thin film of oil to the rubber gasket on the new filter 7 Install the new oil filter to the filter adapter Turn the oil filter clockwise until the rubber gasket contacts the surface then tighten the filter an additional 3 4 1 turn 8 Remove the oil fill cap from the valve cover Fill the crankcase with new oil of the proper type to the F mark on the dipstick Refer to Oil Type and Check Oil Level on pages 6 1 and 6 2 Always check the level with the dipstick before adding more oil Push dipstick in completely 9 Reinstall the oil fill cap and tighten securely by turning to the right NOTE To prevent extensive engine wear or damage always maintain the proper oil level in the crankcase Never operate the engine with the oil level below the L mark or above the F mark on the dipsti
102. e present Possible Causes 1 MIL diagnostic lamp related a MIL element opened or element shorted to ground b Lamp missing 2 Engine wiring harness related a Broken or shorted wire in harness ECU pin 29 to lamp open or shorted 3 Vehicle wiring harness related a Broken or shorted wire in harness Power lead to MIL open or shorted 4 ECU related a Circuit controlling lamp damaged Section 5B EFI Fuel System Code 56 Source Fuel pump relay circuit open shorted to ground or shorted to battery Explanation Fuel pump ignition coils and fuel injectors will not function because the fuel pump relay circuit is either open shorted to ground or may be on continuously if shorted to battery Expected Engine Response Engine will not run or fuel pump will continue to run when switch is off Possible Causes 1 Fuel pump relay related a Bad fuel pump relay Primary side open or shorted 5B 2 Fuel pump related a Fuel pump open or shorted internally 3 Engine wiring harness related a Fuel pump fuse F1 open b Broken or shorted wire in harness ECU pin 28 to fuel pump relay pin 86 Ignition switch to fuel pump relay pin 85 4 ECU related a Circuit controlling fuel pump relay damaged Code 61 Source Explanation Denotes the end of fault codes If signaled first no other fault codes are present Troubleshooting Flow Chart The following flow chart provides an alternative met
103. e same voltage reading exists go on to step 3 b If the voltage output is no longer correct a bad ground path exists between the sensor and the engine ground Touch the black lead at various points backtracking from the engine ground back toward the sensor watching for a voltage change at each location If the correct voltage reading reappears at some point check for a problem rust corrosion loose joint or connection between that point and the previous checkpoint For example if the reading is too low at points on the crankcase but correct voltage is indicated when the black lead is touched to the skin of the muffler the flange joints at the exhaust ports become suspect With sensor still hot minimum of 400 C 752 F switch meter to the Rx1K or Rx2K scale and check the resistance between the sensor lead and sensor case It should be less than 2 0 KQ a If the resistance is less than 2 0 KQ go to step 4 b If the resistance is greater than 2 0 KQ the oxygen sensor is bad replace it Allow the sensor to cool less than 60 C 140 F and retest the resistance with the meter set on the Rx1M scale With the sensor cool the resistance should be greater than 1 0 MQ a If the resistance is greater than 1 0 MQ go to step 5 b If the resistance is less than 1 0 MQ the sensor is bad replace it 5 With the oxygen sensor disconnected and engine not running disconnect the main harness connector from the ECU a
104. ead and the black lead to the sensor shell Check for a cycling voltage reading between 0 2 and 1 0 volt a If voltage is in the specified range go to step 2 b Ifthe voltage is not in the specified range reconnect the oxygen sensor lead With the lead connected probe or connect the sensor connection with the red VOA meter lead Attach the black VOA meter lead to a known good ground location Start and run the engine at 3 4 throttle and note the voltage output The reading should cycle between 0 2 and 1 0 volt which indicates the oxygen sensor is functioning normally and also the fuel delivery controlled by the ECU is within prescribed parameters If the voltage readings show a steady decline bump the governor lever to make the engine accelerate very 5B 10 quickly and check the reading again If voltage momentarily increases and then again declines without cycling engine may be running lean due to incorrect TPS initialization Shut off the engine perform TPS initialization and then repeat the test If TPS initialization cannot be achieved perform step c c Replace the oxygen sensor see next page Run the engine long enough to bring the new sensor up to temperature and repeat the output test from step 1 The cycling voltage from 0 2 to 1 0 volt should be indicated Move the black voltmeter lead to the engine eround location and repeat the output test The same voltage 0 2 v 1 0 v should be indicated a Ifth
105. eads if resistance is incorrect Injector leakage is very unlikely but in those rare instances it can be internal past the tip of the valve needle or external weeping around the injector body See Figure 5B 17 The loss of system pressure from the leakage can cause hot restart problems and longer cranking times To check for leakage it will be necessary to remove the blower housing which may involve removing the engine from the unit Check For Leaks Figure 5B 17 Injector Inspection Points 5B 14 10 11 12 Engine must be cool Depressurize fuel system through the test valve in fuel rail Disconnect the spark plug leads from spark plugs Remove the air cleaner outer cover inner wing nut element cover and air cleaner element precleaner Service the air cleaner components as required Remove the two screws securing the air cleaner base to throttle body manifold Remove the air cleaner base to permit access to the injectors Check condition of air cleaner base gasket replace if necessary Remove the flywheel screen if it overlaps the blower housing If the engine has a radiator type oil cooler mounted to the blower housing remove the two oil cooler mounting screws Remove the blower housing mounting screws Note the location of the plated silver screw attaching the rectifier regulator ground lead Remove the blower housing Thoroughly clean the area around and including the throttle body manif
106. eals gaskets or other available spots Crankcase vacuum is best measured with either a water manometer or a vacuum gauge see Section 2 Complete instructions are provided in the kits Test the crankcase vacuum with the manometer as follows 1 Insert the stopper hose into the oil fill hole Leave the other tube of manometer open to atmosphere Make sure the shut off clamp is closed 2 Start the engine and run at no load full throttle speed 3200 to 3750 RPM 3 Open the clamp and note the water level in the tube The level in the engine side should be a minimum of 10 2 cm 4 in above the level in the open side If the level in the engine side is less than specified low no vacuum or the level in the engine side is lower than the level in the open side pressure check for the conditions in the table below 4 Close the shut off clamp before stopping the engine No Crankcase Vacuum Pressure in Crankcase Possible Cause Een 1 Crankcase breather clogged or inoperative 2 Seals and or gaskets leaking Loose or improperly torqued fasteners Piston blowby or leaky valves Confirm by inspecting components Restricted exhaust Replace breather assembly valve cover Replace all worn or damaged seals and gaskets Make sure all fasteners are tightened securely Use appropriate torque values and sequences when necessary Recondition piston rings cylinder bore valves and valve guides Repair r
107. ection 5B EFI Fuel System Diagnostic Aid 5 FUEL PUMP fuel pump not turning on Possible causes 1 Fuel pump fuse 2 Fuel pump circuit problem Circuits 30 87 and relay 3 Fuel pump Diagnostic Aid 6 RELAY relay not operating Possible causes 1 Safety switches circuit s problem Circuit 25 2 Relay circuit s problem Circuits 28 85 30 and 37 3 Relay 4 ECU grounds 5 ECU Diagnostic Aid 7 IGNITION SYSTEM no spark Possible causes 1 Spark plug 2 Plug wire 3 Coil 4 Coil circuit s Circuits 30 31 65 66 relay and relay circuit 30 5 ECU grounds 6 ECU Diagnostic Aid 8 FUEL SYSTEM ELECTRICAL no fuel delivery Possible causes 1 No fuel Air in fuel rail Fuel valve shut off Fuel filter line plugged Injector circuit s Circuits 14 15 45 and 4A Injector ECU grounds ECU tO le Ss ie Diagnostic Aid 9 FUEL SYSTEM fuel pressure Possible causes for low fuel system pressure 1 Low fuel Fuel filter plugged Fuel supply line plugged Pressure regulator Fuel pump GE wl E Possible causes for high fuel system pressure 1 Pressure regulator 2 Fuel return line plugged or restricted 5B 36 Diagnostic Aid 10 BASIC ENGINE cranks but will not run Possible causes 1 Refer to basic engine troubleshooting charts within service manual sections 3 5 and 8 Common Complaints Problems Following are some of the most common complain
108. ed to 1500 RPM using a tachometer The lamp should continue to blink rapidly for another 30 seconds before switching over to a slow blink 8 When the MIL blinks slowly do not do anything but wait until the MIL shuts off This indicates that this procedure has been completed successfully 9 Shut off the engine 5B 8 If the learn procedure was successfully completed the external loads removed disconnected in Step 2 may be reconnected If the procedure was unsuccessful see Steps a and b following a If during this procedure the MIL goes back into blinking 4 consecutive blinks every 2 seconds the engine and Oxygen sensor have cooled down and out of closed loop operation prohibiting the learning from occurring Repeat Steps 5 8 If during the procedure with the engine running the MIL stays On continuously for more than 15 seconds turn off the ignition Then initiate the fault code sequence by doing three consecutive key on key off cycles leaving the key on in the last sequence each key on key off sequence must be less than 2 5 seconds long The fault detected must be corrected before the auto learn function of the ECU can be re initiated The PC based diagnostic tool and software may be used to read out the fault code and assist with the troubleshooting and repair Engine Coolant Temperature Sensor Figure 5B 7 Engine Coolant Temperature Sensor General
109. ee Figure 11 4 k 7 OH Pivot the governor cross shaft so the bottom end faces the 1 side cylinder Section 11 Reassembly Install Crankshaft 1 Lightly lubricate the lips of crankshaft seal with grease NOTE Apply cellophane tape over the crankshaft keyway to prevent cutting the oil seal during installation 2 Carefully slide the flywheel end of the crankshaft into the crankcase through the oil seal See Figure 11 5 Figure 11 6 Piston Connecting Rod and End Cap Detail 2 Lubricate the cylinder bore piston and piston rings with engine oil Compress the rings of the 1 piston using a piston ring compressor 3 Lubricate the crankshaft journals and connecting rod bearing surfaces with engine oil 4 Make sure the FLY stamping on the pistons is facing towards the flywheel side of the engine Figure 11 5 Installing Crankshaft Use a hammer with rubber grip and gently tap the piston down into cylinder as shown in Install Connecting Rods with Pistons and Figure 11 7 Be careful that oil ring rails do not Rings spring free between the bottom of the ring compressor and the top of the cylinder NOTE The cylinders are numbered on the crankcase Make sure to install the piston connecting rod and end cap into its appropriate cylinder bore as previously marked at time of disassembly Do not mix the end caps and connecting rods NOTE Proper orientation of the piston connecting rod assemblies inside
110. emains on Service The fuel pumps are non serviceable and must be replaced if determined to be faulty If a fuel delivery problem is suspected make certain the pump is being activated through the relay all electrical connections are properly secured the fuses are good and a minimum of 7 0 volts is being supplied If during cranking voltage drops below 7 0 volts a reduction of fuel pressure may occur resulting in a lean starting condition If required testing of the fuel pump and relay may be conducted 1 Connect the black hose of Pressure tester part of EFI Service Kit see Section 2 to the test valve in the fuel rail Route the clear hose into a portable gasoline container or the equipment fuel tank 2 Turn on the key switch to activate the pump and check the system pressure on the gauge If a system pressure of 39 psi 3 is observed the relay fuel pump and regulator are working properly Turn the key switch off and depress the valve button on the tester to relieve the system pressure a Ifthe pressure is too high and the regulator is outside the tank just down line from the pump check that the return line from the regulator to the tank is not kinked or blocked If the return line is good replace the regulator see Regulator Service on page 5B 18 b Ifthe pressure is too low install in line T between the pump and regulator and retest the pressure at that point If it is too low there also replace
111. ence may vary to accommodate options or special equipment Detailed procedures follow 1 Install flywheel end oil seal and camshaft seal 2 Install governor cross shaft 26 Zhe 28 29 30 31 OZ Install crankshaft Install connecting rods with pistons and rings Install camshaft Check camshaft end play Install closure plate assembly Install cylinder studs Install reed and breather cover assembly Install hydraulic lifters Assemble and install cylinder heads Install push rods and rocker arms Install valve covers Install coolant drain plugs Install water pump drive belt and transfer tube assembly Install intake manifold assembly Install stator assembly Install starter adapter Install flywheel Install ignition modules Install spark plugs Install starter assembly Install carburetor and adapter Install external governor controls and main control bracket Install lower crankshaft pulley pulley adapter and cooling fan assembly Install air cleaner assembly Install radiator assembly Install flywheel cover rectifier regulator and mounting plate Install muffler Install oil filter and fill crankcase with oil Install coolant Connect battery cables and spark plug leads Section 11 Reassembly Install Flywheel End Oil Seal and 1 Check to make sure that there are no nicks or burrs in the crankshaft and camshaft seal bores of the crankcase 2 Apply a light
112. ensor 5B 9 Section 5B EFI Fuel System The oxygen sensor can function only after being heated by exhaust temperatures to a minimum of 375 C 709 F A cold oxygen sensor will require approximately 1 2 minutes at moderate engine load to warm sufficiently to generate a voltage signal Proper grounding is also critical The oxygen sensor erounds through the metal shell so a good solid unbroken ground path back through the exhaust system components engine and wiring harness is required Any disruption or break in the ground circuit can affect the output signal and trigger misleading fault codes Keep that in mind when doing any troubleshooting associated with the oxygen sensor The oxygen sensor can also be contaminated by leaded fuel certain RTV and or other silicone compounds carburetor cleaners etc Use only those products indicated as O Sensor Safe Service Like the other sensors already discussed the oxygen sensor is a non serviceable component Complete replacement is required if it is faulty The sensor and wiring harness can be checked as follows NOTE All tests should be conducted with a good quality high impedance digital VOA meter for accurate results 1 Oxygen sensor must be hot minimum of 400 C 725 F Run engine for about 5 minutes With the engine running disconnect the oxygen sensor lead from the wiring harness Set VOA meter for DC volts and connect the red lead to the disconnected sensor l
113. entilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent The EFI fuel system remains under high pressure even when the engine is stopped Before attempting to service any part of the fuel system the pressure must be relieved Pressure tester part of EFI Service Kit see Section 2 has an integral relief valve Connect the black tester hose to the test valve in the fuel rail Route the clear hose into a portable gasoline container Depress the button on the tester relief valve Initial Starting Priming Procedure Important The EFI fuel system must be purged of air primed prior to the initial start up and or any time the system has been disassembled or the fuel tank run dry 1 Turn the key switch to the on run position You will hear the fuel pump cycle on and off When the fuel pump stops cycling approximately one minute the system is primed start the engine 5B 2 Fuel Recommendations General Recommendations Purchase gasoline in small quantities and store in clean approved containers An approved container with a capacity of 2 gallons or less with a pouring spout is recommended Such a container is easier to handle and helps prevent spillage during refueling e Do not use ga
114. eplace restricted muffler exhaust system 3 3 Section 3 Troubleshooting Compression Test A compression test is best performed on a warm engine Clean any dirt or debris away from the base of the spark plugs before removing them Be sure the choke is off and the throttle is wide open during the test Compression should be at least 160 psi and should not vary more than 15 between cylinders Cylinder Leakdown Test A cylinder leakdown test can be a valuable alternative to a compression test By pressurizing the combustion chamber from an external air source you can determine if the valves or rings are leaking and how badly Cylinder Leakdown Tester see Section 2 is a relatively simple inexpensive leakdown tester for small engines The tester includes a quick disconnect for attaching the adapter hose and a holding tool Leakdown Test Instructions 1 Run engine 3 5 minutes to warm it up 2 Remove spark plugs dipstick and air filter from engine 3 Rotate crankshaft until piston of cylinder being tested is at top dead center TDC of compression stroke You will need to hold the engine in this position while testing The holding tool supplied with the tester can be used if the PTO end of the crankshaft is accessible Slide the holding tool onto the crankshaft and adjust the set screw to fit in the key slot Install a 3 8 breaker bar into the square hole of the holding tool so it is perpendicular to both the hol
115. er spark is wasted Section 5B EFI Fuel System Service Except for removing the spark plug lead by unscrewing it from the secondary tower see Figure 5B 18 no coil servicing is possible If a coil is determined to be faulty replacement is necessary An ohmmeter may be used to test the wiring and coil windings Figure 5B 18 Ignition Coil NOTE Do not ground the coils with the ignition on as they may overheat or spark 1 Disconnect the main harness connector from ECU Locate pins 30 and 31 in the 32 pin connector See page 5B 24 2 Disconnect the connector from the relay and locate terminal 87 in connector 3 Using an ohmmeter set on the Rx1 scale check the resistance in circuits as follows Check between terminal 87 and pin 30 for coil 1 Repeat the test between terminal 87 and pin 31 for coil 2 A reading of 1 8 4 0 Q in each test indicates that the wiring and coil primary circuits are OK a If the reading s are not within specified range check and clean connections and retest b If the reading s are still not within the specified range test the coils separately from the main harness as follows 1 Disconnect the red and black primary leads from the coil terminals 2 Connect an ohmmeter set on the Rx1 scale to the primary terminals Primary resistance should be 1 8 2 5 Q 5B 15 Section 5B EFI Fuel System 3 Disconnect the secondary lead from the spark plug Connect a
116. eral times and observe flow Fuel Pump General These engines are equipped with either a mechanical or pulse style fuel pump See Figure 5 1 5 2 If there is fuel at the tip of the spark plug fuel is reaching the combustion chamber If there is no fuel at the tip of the spark plug check for fuel flow from the fuel tank Test 3 If fuel does flow from the line check for faulty fuel pump Test 4 If fuel does not flow from the line check the fuel tank vent fuel pickup screen in line filter shut off valve and fuel line Correct any observed problem and reconnect the line If fuel does flow from the line check for faulty carburetor Refer to the Carburetor portions of this section If fuel does not flow from the line check for a clogged fuel line If the fuel line is unobstructed check for overfilled crankcase and or oil in pulse line If none of the checks reveal the cause of the problem replace the pump Operation Pulse Fuel Pump Operation and pumping action is created by alternating positive and negative pressures within the crankcase This pressure is transmitted to the pulse pump through a rubber hose connected between the pump and the crankcase The pumping action causes the diaphragm on the inside of the pump to pull fuel in on its own downward stroke and to push it into the carburetor on its upward stroke Two check valves prevent fuel from going backward through the pump Section 5
117. ermanently affixed to the flywheel e Two electronic capacitive discharge ignition modules which mount on the engine crankcase e A kill switch or key switch which grounds the modules to stop the engine e Two spark plugs Figure 8 2 Battery Voltage Test The timing of the spark is controlled directly by the location of the flywheel magnet group as referenced to engine top dead center Kill Switch or Off Position of Key Switch Ignition Modules Spark PS vn Magnet 0 008 0 012 in 0 20 0 30 mm Air Gap N Figure 8 3 Capacitive Discharge Ignition System Flywheel 8 4 Eyelet Terminal for Ignition g Key Switch or Starter Post Diodes Ignition Module Input Red B and Carburetor Solenoid Input Oil Pressure Safety Input d E Section 8 Electrical System and Components Carburetor Solenoid Oil Pressure WW vi Safety 7 Modules F Spark Plugs Violet Flywheel Stator Rectifier Regulator Figure 8 4 Electronic CD Ignition System For Customer Connected Tractor Applications Figure 8 5 Capacitive Discharge Ignition Module Operation As the flywheel rotates the magnet grouping passes the input coil L1 The corresponding magnetic field induces energy into the input coil L1 The resultant pulse is rectified by D1 and charges capacitor C1 As the magnet assembly completes its pass it activates the triggering device L2 which causes the semiconduc
118. ernor lever mounting screw See Figure 9 21 Leave the throttle linkage and spring connected to the lever Lift the governor lever off of the governor shaft and lay the assembly on top of the crankcase to be removed with the carburetor 9 6 Figure 9 21 Loosening Governor Lever Mounting Nut Remove Carburetor and Adapter A WARNING Explosive Fuel Gasoline is extremely flammable and tts vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent 1 Disconnect the lead to the fuel shut off solenoid if equipped If a mechanical fuel pump is used disconnect the fuel line from the carburetor inlet 2 Disconnect the breather hose from the adapter fitting on the carburetor 3 Remove the two carburetor mounting screws See Figure 9 22 If a flexible tube and knob idle speed adjuster is used open the retaining clamp and unhook Figure 9 22 Removing the Carburetor Mounting Screws Section 9 Disassembly 4 Remove the carburetor throttle linkage and governor lever as an assembly See Figure 9 23 Figure 9 25 Removing the Breather Cover Screws 2 Carefully pry under the protruding edge
119. es 1 TPS related a b TPS rotated on throttle shaft assembly out of allowable range TPS bad 2 Engine wiring harness related a Broken or shorted wire in harness ECU pin 18 to TPS pin 1 ECU pin 4 to TPS pin 2 ECU pin 8 to TPS pin 3 3 Throttle body related a Throttle shaft inside TPS worn broken or damaged b Throttle plate loose or misaligned Throttle plate bent or damaged allowing extra airflow past or restricting movement 4 ECU related a Circuit providing voltage or ground to TPS damaged b TPS signal input circuit damaged Code 51 Source Injector 1 circuit open shorted to ground or shorted to battery Explanation Injector 1 is not functioning because the circuit is open shorted to ground or shorted to battery Expected Engine Response Engine will run very poorly with only one cylinder functioning Possible Causes 1 Injector related a 5B 32 Injector coil shorted or opened 2 Engine wiring harness related a b Broken or shorted wire in harness ECU pin 14 to injector pin 2 ECU pin 28 to fuel pump relay pin 86 Note After key off then key on code 56 would be set also Fuel pump relay pin 87 to injector pin 1 Open main fuse F1 3 Fuel pump relay related a Bad fuel pump relay Primary side functional but pin 30 to pin 87 remains open Primary side pin 85 to pin 86 is either open or shorted during engine operation Note After
120. et in position then mount the solenoid Torque the screws to 4 0 6 0 N m 35 53 in Ib Connect the positive brush lead bracket to the solenoid and secure with the hex nut Torque the nut to 8 11 N m 71 97 in Ib Do not overtighten See Figure 8 44 Figure 8 44 Positive Brush Lead Connection Solenoid Test Procedure Solenoid Shift Style Starters Disconnect all leads from the solenoid including the positive brush lead attached to the lower stud terminal Remove the mounting hardware and separate the solenoid from the starter for testing Test 1 Solenoid Pull In Coil Plunger Actuation Test Use a 12 volt power supply and two test leads Connect one lead to the flat spade S start terminal on the solenoid Momentarily connect the other lead to the lower large post terminal See Figure 8 45 When the connection is made the solenoid should energize audible click and the plunger retract Repeat the test several times If the solenoid fails to activate it should be replaced NOTE DO NOT leave the 12 volt test leads connected to the solenoid for any time over what is necessary for performing each of the individual tests Internal damage to the solenoid may otherwise occur 12 volt Test Leads Momentary Connection Only Figure 8 45 Testing Pull In Coil Plunger Actuation Test 2 Solenoid Pull In Coil Contact Continuity Test Use an ohmmeter set to the audible or Rx2K scale and connect the two
121. f the crankshaft gear at the 12 o clock position Turn the governor cross shaft clockwise until the lower end of shaft contacts the crankcase 1 side Make sure the cross shaft remains in this position while installing the camshaft Slide the camshaft into the bearing surface of the crankcase positioning the timing mark of the camshaft gear at the 6 o clock position Make sure that the camshaft gear and crankshaft gear mesh and the timing marks are aligned See Figure 11 11 Checking Setting Camshaft End Play 1 Install the shim removed during disassembly onto the camshaft 2 Position the end play tool on the camshaft 3 Apply pressure on the end play checking tool pushing the camshaft toward the crankshaft Use a feeler gauge to measure the end play between the shim and the end play tool See Figure 11 12 The camshaft end play should be 0 076 0 127 mm 0 003 0 005 in Tool 4 If the camshaft end play is not within the specified range remove the original shim and reinstall the end play tool Use a feeler gauge to determine the clearance between the camshaft and the tool Subtract 0 100 mm 0 004 in from the measured clearance to obtain the required shim thickness Refer to the table below and install the shim that matches the calculated thickness See Figure 11 13 Repeat steps 1 3 to verify that the correct end play exists Figure 11 13 Adding Shim for Camshaft Figure 11 12 Checking Cam
122. for buildup of dirt and debris on the radiator crankcase cooling system components and other external surfaces Dirt or debris on these areas are causes of higher operating temperatures and overheating Check for obvious fuel oil and coolant leaks or damaged components Excessive oil leakage can indicate a clogged or improperly assembled breather worn or damaged seals and gaskets or loose or improperly torqued fasteners Coolant leaks can cause higher operating temperatures and overheating Check the air cleaner assembly components for damage or indications of leakage Check the air cleaner element and inner element Look for holes tears cracked damaged sealing surfaces or other damage that could allow unfiltered air into the engine Also note if the elements are dirty or clogged These could indicate that the engine has been underserviced Check the carburetor throat for dirt Dirt in the throat is further indication that the air cleaner is not functioning properly Check the oil level Note if the oil level is within the operating range on the dipstick or if it is low or overfilled Check the coolant level within the reservoir and in the radiator A low or improperly filled cooling system can cause overheating excessive fuel consumption and a lack of power e Check the condition of the oil Drain the oil into a container the oil should flow freely Check the appearance color of the oil and for metal chips or
123. foreign particles A milky opaque color denotes the presence of engine coolant in the crankcase oil Sludge is a natural by product of combustion a small accumulation is normal Excessive sludge formation could indicate overrich carburetion weak ignition overextended oil change intervals or wrong weight or type of oil was used to name a few NOTE It is good practice to drain oil at a location away from the workbench Be sure to allow ample time for complete drainage Cleaning The Engine After inspecting the external condition of the engine clean the engine thoroughly before disassembling it Also clean individual components as the engine is disassembled Only clean parts can be accurately inspected and gauged for wear or damage There are many commercially available cleaners that will quickly remove grease oil and grime from engine parts When such a cleaner is used follow the manufacturer s instructions and safety precautions carefully Make sure all traces of the cleaner are removed before the engine is reassembled and placed into operation Even small amounts of these cleaners can quickly break down the lubricating properties of engine oil Section 3 Troubleshooting Basic Engine Tests Crankcase Vacuum Test A partial vacuum should be present in the crankcase when the engine is operating Pressure in the crankcase normally caused by a clogged or improperly assembled breather can cause oil to be forced out at oil s
124. ght is displayed in either of the tests the rectifier regulator is faulty and should not be used Figure 8 12 NOTE A flashing LOW light can also occur as a 2 Connect the tester ground lead with spring result of an inadequate ground lead clamp to the body of the rectifier regulator connection Make certain the connection location is clean and the clamp is secure 8 9 Section 8 Electrical System and Components DC Voltmeter Rectifier Regulator Flywheel Stator Ammeter Battery Figure 8 14 Connections for Testing Charging System 8 10 Section 8 Electrical System and Components Troubleshooting Guide 15 20 25 Amp Battery Charging Systems If it is difficult to keep the battery charged or the battery overcharges the problem is usually with the charging system or the battery NOTE Always zero ohmmeter on each scale before testing to ensure accurate readings Voltage tests should be made with the engine running at 3600 RPM no load The battery must be fully charged No Charge to Battery Battery Continuously Charges at High Rate Trace B lead from rectifier regulator to key switch or other accessible connection Disconnect it from switch or connection Connect an ammeter from loose end of B lead to positive terminal of battery Connect DC voltmeter from loose end of B lead to negative terminal of battery With engine running at 3600 RPM read voltage on voltmeter If vo
125. gine and remove filler cap only when cool enough to touch with bare hands Slowly loosen cap to first stop to relieve pressure before removing completely This section covers the operation and servicing of the Operation liquid cooling system The engine coolant is pumped through the cooling l system by a pump belt driven off the camshaft The Cooling System Components coolant coming out of the pump is divided and moves The cooling system consists of the following simultaneously through separate circuits within each components head and the corresponding sides of the crankcase As the coolant moves through these passages it absorbs e Radiator with removable screen heat from the engine parts After traveling through e Hoses the engine the coolant from the two separate circuits e Coolant Pump and Belt merges and moves through the intake manifold to the D lower side of the thermostat During warm up the thermostat is closed preventing circulation through the radiator The coolant circulates through the e Radiator Cap engine only and is returned to the pump via the e Cooling Fan Belt and Drive Pulleys bypass hose When engine heat brings the coolant up to a temperature of 79 4 C 175 F the thermostat will begin to open allowing coolant to circulate through the upper hose to the radiator The thermostat is completely open at 90 5 C 195 F allowing full coolant flow through the radiator where it is cooled After getting cooled i
126. gure 5B 14 Fuel Injector Details 1 Filter strainer in fuel supply The injector is opened and closed once for each crankshaft revolution however only one half the total amount of fuel needed for one firing is injected during each opening The amount of fuel injected is controlled by the ECU and determined by the length of time the valve needle is held open also referred to as the injection duration or pulse width It may vary in length from 1 5 8 milliseconds depending on the speed and load requirements of the engine Service Injector problems typically fall into three general categories electrical dirty clogged or leakage An electrical problem usually causes one or both of the injectors to stop functioning Several methods may be used to check if the injectors are operating 1 With the engine running at idle feel for operational vibration indicating that they are opening and closing 2 When temperatures prohibit touching listen for a buzzing or clicking sound with a screwdriver or mechanic s stethoscope see Figure 5B 15 Figure 5B 15 Checking Injectors Section 5B EFI Fuel System m Listen Here 3 Disconnect the electrical connector from an injector and listen for a change in idle performance only running on one cylinder or a change in injector noise or vibration If an injector is not operating it can indicate either a bad injector or a wiring electrical connection problem
127. h altitude are available 2 Disconnect the fuel line from the carburetor 5 Remove the black cap on the end of the choke 3 Clean dirt and debris from exterior of carburetor shaft only if it is necessary to inspect and clean the shaft spring 4 Remove the four screws holding the two carburetor halves together Carefully lift the 6 Remove the low idle speed adjusting screw and carburetor air horn assembly off the carburetor spring from the carburetor body body and disconnect the choke linkage 7 In order to clean the off idle vent ports and bowl vent thoroughly use a good carburetor solvent like Gumout Blow clean compressed air through the idle adjusting needle hole Be careful to use a suitable shop rag to prevent debris from hitting someone 8 Remove the formed rubber gasket only if it is to be replaced If it is removed for any reason replace it Inspection Repair Carefully inspect all components and replace those ee ot on a that are worn or damaged Figure 5 4 Carburetor Mounting Detail e Inspect the carburetor body for cracks holes and 5 Hold the carburetor air horn so that the float other wear or damage assembly hangs vertically and rests lightly against the fuel inlet needle The fuel inlet needle e Inspect the float for cracks holes and missing or should be fully seated but the needle tip should damaged float tab Check the float hinge and pin not be depressed See Figure 5 5 for wear or damag
128. h shown in Figure 10 17 10 13 Section 10 Inspection and Reconditioning Figure 10 19 Water Pump Figure 10 20 Front View of Engine Cooling System The impeller assembly is not serviceable but it Inspect the components carefully for signs of wear or should be inspected for wear or damage damage 1 Inspect the impeller to make sure the blades are 1 Inspect the fan to make sure the blades are in in good condition and free of any cracks nicks or good condition and free of any cracks nicks or damage damage The area around the fan mounting holes must also be free of any cracks or damage 2 The impeller shaft should rotate smoothly without binding or wobbling and there should be no sign that coolant has leaked past the shaft to the outer surface of the cover 3 Check that the drive pulley is not cracked or damaged in any way If your inspection causes you to doubt its reliability the water pump assembly should be replaced Always use a new O Ring whenever the water pump is removed Do not reuse the old O Ring or try to use RTV in its place Cooling Fan and Drive The cooling fan assembly consists of a fan attached to a v pulley and bearing carrier hub rotating on a dual ball bearing fan shaft arbor The assembly is mounted with a bracket to the intake manifold and EE driven via a split pulley off the flywheel See Figure out BOERS EE Ess 10 20 binding Figure 10 21 Fan Assembly Pulley Side 2 The f
129. he F mark on the dipstick This includes engines equipped with Oil Sentry Installation The Oil Sentry pressure switch is installed in the breather cover See Figure 6 5 Oil Sentry Switch Figure 6 5 Oil Sentry Location On engines not equipped with Oil Sentry the installation hole is sealed with a 1 8 27 N P T F pipe plug 6 3 Section 6 Lubrication System To install the switch follow these steps 1 Apply pipe sealant with Teflon Loctite No 59241 or equivalent to the threads of the switch 2 Install the switch into the tapped hole in the breather cover See Figure 6 5 3 Torque the switch to 4 5 N m 40 in Ib Testing Compressed air a pressure regulator pressure gauge and a continuity tester are required to test the switch 1 Connect the continuity tester to the blade terminal and the metal case of the switch With 0 psi pressure applied to the switch the tester should indicate continuity switch closed 2 Gradually increase the pressure to the switch As pressure increases through the range of 3 0 5 0 psi the tester should indicate a change to no continuity switch open The switch should remain open as the pressure is increased to 90 psi maximum 3 Gradually decrease the pressure through the range of 3 0 5 0 psi The tester should indicate a change to continuity switch closed down to 0 psi 4 Replace the switch if it does not operate as specified
130. her located under the governor assembly 3 Carefully inspect the governor gear shaft and replace it only if it is damaged After pulling damaged shaft press or lightly tap replacement shaft into closure plate to depth shown in Figure 10 14 Governor Gear Shaft 34 0 mm 1 3386 in 33 5 mm 1 3189 in _ Figure 10 14 Governor Shaft Press Depth Reassembly 1 Install the locking tab thrust washer on the governor gear shaft with the tab down 2 Position the regulating pin to the governor gear flyweight assembly and slide both onto the governor shaft Oil Pump Assembly Disassembly 1 Remove the two hex flange screws 10 12 2 Remove the oil pump assembly from the closure plate Figure 10 15 Removing Oil Pump and Oil Pickup 3 Remove the oil pump rotor 4 Remove the oil pickup by unhooking the locking clip and pulling it free from the oil pump body 5 If the relief valve is a one piece style staked to the oil pump housing See Figure 10 16 removal should not be attempted nor is internal servicing possible If a problem with the relief valve is encountered the oil pump should be replaced Figure 10 16 Oil Pump Oil Pickup and One Piece Relief Valve Inspection Inspect the oil pump housing gear and rotors for nicks burrs wear or any visible damage If any parts are worn or damaged replace oil pump Section 10 Inspection and Reconditioning Reassembly 1 Install the oil pickup to
131. his step is often overlooked and if the clearances are not within specifications engine failure will usually result NOTE Do not use a feeler gauge to measure piston to bore clearance it will yield inaccurate measurements Always use a micrometer Use the following procedure to accurately measure the piston to bore clearance 1 Use a micrometer and measure the diameter of the piston 6 mm 0 24 in above the bottom of the piston skirt and perpendicular to the piston pin See Figure 10 4 10 3 Section 10 Inspection and Reconditioning Measure 6 mm Above the Bottom of Piston Skirt at Right Angles to Piston Pin Figure 10 4 Measuring Piston Diameter 2 Use an inside micrometer telescoping gauge or bore gauge and measure the cylinder bore Take the measurement approximately 63 5 mm 2 5 in below the top of the bore and perpendicular to the piston pin 3 Piston to bore clearance is the difference between the bore diameter and the piston diameter step 2 minus step 1 Flywheel Inspection Inspect the flywheel for cracks and the flywheel keyway for damage Replace flywheel if cracked Replace the flywheel the crankshaft and the key if flywheel key is sheared or the keyway is damaged Inspect the ring gear for cracks or damage Kohler does not provide ring gears as a serviceable part Replace the flywheel if the ring gear is damaged Check the charging system magnets to be sure they are not loose or cracked
132. hod of troubleshooting the EFI system The chart will enable you to review the entire system in about 10 15 minutes Using the chart the accompanying diagnostic aids listed after the chart and any signaled fault codes you should be able to quickly locate any problems within the system 5B 33 Section 5B EFI Fuel System Bosch EFI Diagnostic Flow Diagram Proceed to Start of Test for retest KEY ON MALFUNCTION INDICATOR LIGHTS ON No REFER TO DIAGNOSTIC AID 1 FAULT CODES ARE FAULT CODES PRESENT REFER TO DIAGNOSTIC AID 2 FAULT CODES CLEAR CODES DOES ENGINE START Yes gt No REFER TO DIAGNOSTIC AID 3 RUN ON Yes L y OPERATE AT VARIOUS SPEED LOAD CONDITIONS ARE FAULT CODES PRESENT No END OF TEST Yes gt REFER TO DIAGNOSTIC AID 2 FAULT CODES CLEAR CODES CRANK ENGINE DOES MIL GO OFF Yes KEY OFF AND KEY ON LISTEN FOR FUEL PUMP REFER TO DIAGNOSTIC AID 4 SPEED SENSOR DOES FUEL PUMP CYCLE ON THEN OFF AFTER 1 2 SECONDS LOCATE ELECTRICAL RELAY WHILE HOLDING RELAY KEY OFF AND KEY ON DOES RELAY CYCLE ON THEN OFF AFTER 1 2 SECONDS Proceed to Start of Test for retest Yes Yes REFER TO DIAGNOSITC AID 5 FUEL PUMP REFER TO DIAGNOSTIC AID 6 RELAY WHILE CRANKING CHECK IGNITION SYSTEM REFER TO DIAGNOSTIC AID 7 IGNITION SYSTEM Yes WHILE CHECKING
133. hown See Figure 11 58 Figure 11 59 Plug in Intake Manifold for Temperature Sensor 11 17 Section 11 Reassembly 5 Connect the wire leads to the temperature warning switch audible alarm and or Oil Sentry switch as equipped If the thermostat and thermostat housing were removed from the intake manifold reassemble them at this time 6 Make sure the sealing surfaces of housing and manifold are clean and free of nicks or damage 7 Install the thermostat into the recess in the intake manifold so the larger spring end is down Place a new thermostat housing gasket onto the manifold surface aligning the screw holes Make sure that one of the notches in the gasket is aligned with the by pass slot in the manifold and the thermostat housing Do not use a substitute gasket See Figure 11 60 Figure 11 61 Torquing Thermostat Housing Screws 9 Apply rubber lubricant to the inside end of the upper radiator hose and install the hose to the thermostat housing if separated for servicing Secure with the clamp Make sure tangs of clamp point toward the 1 cylinder away from the fan Install Coolant By pass Hose If separated from intake manifold through individual component servicing 1 If the connector fitting for the by pass hose was removed from the manifold reinstall it at this time Apply pipe sealant with Teflon Loctite 59241 or equivalent onto the threads and tighten so the fitting faces points to
134. id range 3 Check all cooling system components and joint connections for leaks 11 34 Make sure the maximum engine speed does not exceed 3750 RPM no load Adjust the throttle choke controls and high speed stop as necessary Refer to the Fuel System and Governor section Place the throttle control into the idle or slow position and check the low idle speed RPM Refer to Section 5 if adjustment is required Stop the engine Recheck the oil and coolant levels Oil level should be at the F mark on the dipstick and the coolant level in the reservoir should be midway between the ADD and FULL marks Add additional amounts as required KOHLER ENGINES FOR SALES AND SERVICE INFORMATION IN U S AND CANADA CALL 1 800 544 2444 ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 FORM NO TP 2527 A ISSUED 9 03 REVISED 3 06 LITHO IN U S A ni 6 UI 50531 4557 i
135. if used Install Radiator Assembly 1 Reassemble the components of the radiator assembly including upper and lower radiator hoses Rubber lubricant may be applied to the inner surfaces of the hoses to make installation easier Secure with the hose clamps The radiator subassembly should look as shown in Figure 11 109 11 29 Section 11 Reassembly Figure 11 109 Preassembled Radiator for Figure 11 111 Setting Radiator Assembly into Installation Place 2 Tighten the radiator drain plug See Figure 4 Position the upper radiator support brackets on 11 110 top of the air cleaner mounting bracket Install and finger tighten the four mounting screws Figure 11 112 Installing Upper Support Screws 5 Connect the upper and lower radiator hoses to the inlets of the radiator and water pump Secure with the hose clamps See Figures 11 113 and 11 114 Make sure the tangs of upper clamp face away from the fan Figure 11 110 Tightening Drain Plug 3 Carefully set the radiator assembly into place guiding the lower radiator hose inside RH support bracket Make sure that cooling fins do not come in contact with the fan blades as radiator is installed 11 30 Section 11 Reassembly Figure 11 116 Torquing Side Support Screws 7 Hold the radiator assembly in position then torque the screws securing the two upper radiator supports to 9 9 N m 88 in Ib See Figure 11 117 ta A Figure 11 114 Inst
136. igure 9 33 Figure 9 35 Removing Upper Fan Mounting Bracket Screws Figure 9 33 Removing Front Flange Nut and Flat Washer 3 The fan shaft may be removed from the mounting bracket by removing the rear hex flange nut if individual servicing of either part is required 9 9 Section 9 Disassembly Remove Ignition Modules 1 Disconnect the kill leads from the ignition modules See Figure 9 36 Figure 9 36 Removing Kill Leads from Ignition Modules 2 Rotate the flywheel so the magnet is away from the ignition modules 3 Remove the mounting screws and take off each ignition module See Figure 9 37 d 2o Figure 9 37 Removing Ignition Modules Remove Flywheel 1 Use a flywheel strap wrench or holding tool see Section 2 to hold the flywheel Remove the hex flange screw and flat washer See Figure 9 38 9 10 Figure 9 38 Removing Flywheel Screw and Washer 2 Use a puller to remove the flywheel from the crankshaft See Figure 9 39 Figure 9 39 Removing Flywheel with Puller NOTE Always use a flywheel puller to remove the flywheel from the crankshaft Do not strike the crankshaft or flywheel as these parts could become cracked or damaged 3 Remove the woodruff key from the crankshaft keyway Section 9 Disassembly Remove Stator Assembly 2 Remove the six mounting screws and carefully 1 Remove the two mounting screws and pull the separate the intake manifold from the c
137. ing the new sensor to the ECU TPS Initialization Procedure 32 Pin MSE 1 1 Plastic Cased ECU Auto Learn Initialization 1 Check that the basic engine all sensors fuel fuel pressure and battery are good and functionally within specifications Important 2 Remove disconnect ALL external loads from the engine belts pumps electric PTO clutch alternator rectifier regulator etc 5B 7 Section 5B EFI Fuel System 3 Locate the service connector plug in the wiring harness To initiate the TPS auto learn function connect a jumper wire from the TPS initialization pin 24 violet wire to the battery voltage pin red wire or use a jumper connector plug with the blue jumper wire See Figure 5B 6 If using the PC based diagnostic tool and software see Section 2 go to Special Tests and follow the prompts to complete Figure 5B 6 Service Connector Plug 4 Start the engine and immediately observe the Malfunction indicator Light MIL The light should start blinking 4 consecutive times every 2 seconds 5 Remove the jumper wire or plug from the service connector plug in wiring harness 6 Run the engine at full throttle above 3000 RPM to warm up the engine and initiate O sensor function in closed loop operation 7 Watch the MIL When the light starts blinking rapidly 5 blinks per second move the throttle lever to the low idle speed position Check and adjust the idle spe
138. into the cylinder head and tighten to 24 4 29 8 N m 18 22 ft Ib 8 1 Section 8 Electrical System and Components Inspection Inspect each spark plug as it is removed from the cylinder head The deposits on the tip can be an indication of the general condition of the engine and or adverse operating conditions Normal and fouled plugs are shown in the following photos Normal A plug taken from an engine operating under normal conditions will have light tan or gray colored deposits If the center electrode is not worn a plug in this condition could be set to the proper gap and reused Carbon Fouled Soft sooty black deposits indicate incomplete combustion caused by a restricted air cleaner overrich carburetion weak ignition or poor compression 8 2 Worn On a worn plug the center electrode will be rounded and the gap will be greater than the specified gap Replace a worn spark plug immediately Wet Fouled A wet plug is caused by excess fuel or oil in the combustion chamber Excess fuel could be caused by a restricted air cleaner a carburetor problem or operating the engine with too much choke Oil in the combustion chamber is usually caused by a restricted air cleaner a breather problem worn piston rings or valve guides Section 8 Electrical System and Components A WARNING Explosive Gas Batteries produce explosive hydrogen gas while being charged To prevent a fire or explosion charge batterie
139. ion modules away from the flywheel as far as possible and tighten the four screws 3 Rotate the flywheel to position the magnet directly under one of the ignition modules 4 Insert a 0 25 mm 0 010 in flat feeler gauge or shim stock between the magnet and ignition module Loosen the hex flange screws enough to allow the magnet to pull the module against the feeler gauge 5 Torque the two hex flange screws to 4 0 N m 35 in lb See Figure 11 72 Section 11 Reassembly Figure 11 72 Torquing Setting Ignition Module Gap 6 Repeat steps 3 to 5 for the other ignition module 7 Rotate the flywheel back and forth checking for clearance between the magnet and ignition modules Make sure the magnet does not strike the modules Recheck the gap with a feeler gauge and readjust if necessary Final air gap 0 203 0 305 mm 0 008 0 012 ml 8 Connect the kill leads to the ignition modules Route the wiring harness and kill leads as shown in Figures 11 73 and 11 74 Push bend the loop portion of the clamp on the 1 side back as far as possible for maximum clearance from fan Figure 11 73 By pass Hose and Wiring Routed within Cutout of Intake Manifold Some Models 11 21 Section 11 Reassembly Figure 11 74 Wiring and Harness in Clamp on 1 Figure 11 76 Torquing Starter Bolts Side 3 Attach the leads to the appropriate starter Install Spark Plugs solenoid terminals See Figure 11 77 1 Use new Champion
140. ir temperature at the time of operation as shown in the following table RECOMMENDED SAE VISCOSITY GRADES 10W 30 a EE 5W 20 5W 30 Kohler 10W 30 TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE Use of synthetic oil having 5W 20 or 5W 30 rating is acceptable up to 4 C 40 F Synthetic oils will provide better starting in extreme cold below 23 C 10 F NOTE Using other than service class SG SH SJ or higher oil or extending oil change intervals longer than recommended can cause engine damage NOTE Synthetic oils meeting the listed classifications may be used with oil changes performed at the recommended intervals However to allow piston rings to properly seat a new or rebuilt engine should be operated for at least 50 hours using standard petroleum based oil before switching to synthetic oil A logo or symbol on oil containers identifies the API service class and SAE viscosity grade See Figure 1 3 Figure 1 3 Oil Container Logo 1 4 Refer to Section 6 Lubrication System for detailed procedures on checking the oil changing the oil and changing the oil filter Coolant Recommendations Use equal parts of ethylene glycol and water only Distilled or deionized water is recommended especially in areas where the water contains a high mineral content Propylene glycol based antifreeze is not recommended This mixture will provide protection from 37 C 34 F to 108 C 226 F For
141. ir cleaner housing are properly installed and tight Breather Hose Make sure the hose is in good condition not cracked and properly secured to the breather cover and adapter fitting Figure 4 7 Air Cleaner Assembly Section 5 Fuel System and Governor Description The Aegis horizontal twins use two different types of fuel systems carbureted or electronic fuel injection EFI This section covers the standard carbureted fuel systems The EFI systems are covered in subsection 5B The governor system covered at the end of this section is the same for both fuel systems A WARNING Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent Fuel System Components The typical carbureted fuel system and related components include the following Fuel Tank In line Fuel Filter Fuel Pump Carburetor Fuel Lines Operation The fuel from the tank is moved through the in line filter and fuel lines by the fuel pump On engines not equipped with a fuel pump the fuel tank outlet is located above the carburetor inlet allowing gravity to feed f
142. is recommended as it leaves less combustion chamber deposits and reduces harmful exhaust emissions Leaded gasoline is not recommended and must not be used on EFI engines Section 1 Safety and General Information Gasoline Alcohol blends Gasohol up to 10 ethyl alcohol 90 unleaded gasoline by volume is approved as a fuel for Kohler engines Other gasoline alcohol blends are not or on other models where exhaust emissions are regulated approved Gasoline Ether blends Methyl Tertiary Butyl Ether MTBE and unleaded gasoline blends up to a maximum of 15 MTBE by volume are approved as a fuel for Kohler engines Other gasoline ether blends are not approved Periodic Maintenance A WARNING Accidental Starts Disabling engine Accidental starting can cause severe injury or death Before working on the engine or equipment disable the engine as follows 1 Disconnect the spark plug lead s 2 Disconnect negative battery cable from battery Maintenance Schedule These required maintenance procedures should be performed at the frequency stated in the table They should also be included as part of any seasonal tune up e Fill fuel tank Section 5 e Check oil level Section 6 e Check coolant level Section 7 e Check air cleaner for dirty Loose or damaged parts Section 4 e Check the screen radiator and cooling areas clean as necessary Section 7 Every 100 Hours e Clean and check cooling areas e Change oil an
143. ition of the radiator hoses If they swell excessively while testing the system they may be weak and should be replaced Gauge Needle Drops Quickly A steady drop or loss of pressure indicates serious leakage is occurring within the system which must be located and corrected before the engine is returned to service 7 8 If a pressure loss is noted 1 With pressure on the system apply a soap water solution and check all joint connections hoses and cooling system components for external leakage Repair or replace as required Remove the dipstick and check the appearance of the oil in the crankcase Another method would be to remove an oil drain plug and drain a small amount of oil for inspection A milky or an opaque color similar to chocolate milk indicates the presence of engine coolant in the oil Check for a blown head gasket step 3 below or a possible crack or internal leakage from the water jacket Remove the spark plugs Apply 14 15 lbs of pressure and listen inspect for internal coolant leakage into the cylinder combustion chambers This can denote a head gasket failure leak If required further test by performing a Cylinder Leakdown Test as described in Section 3 Section 8 Electrical System and Components This section covers the operation service and repair 2 Remove the plug and check its condition See of the electrical system components Systems and Inspection following this procedur
144. jection EFI Fuel System Contents Page s Description bake E E Ee 5B 2 Fel Recommendation seier rn n Ea eror i a E E T E 5B 2 FER ES ys FCT OCC e E ET O E T E E A bedep wtse ee ahiaasteteoensoe aeetedsyees 5B 3 Bo A o A E E N E E E E E E E E 5B 3 Kueren E 5B 4 Electrical Components Electronice nde ER ER EE 5B 4 5B 5 TE MNS SC EE 5B 5 5B 6 Throttle Position Sensor TPS amp Auto Learn Initialization Procedures ceceesseeesteeeeeneeeeeees 5B 6 5B 8 Eire Coolant lemperalure SOUS E 5B 8 5B 9 OR OE gedet 5B 9 5B 11 e 5B 11 5B 12 Pae Eege 5B 12 5B 15 IK 5 SCS a aces P EA EA E A E E anes oi A E E E saving 5B 15 5B 16 GEES 5B 16 A 5B 16 parey Ga EE 5B 16 Fuel Components EE 5B 16 5B 17 PEET e 5B 17 5B 18 FS PEGE eege 5B 19 a EE 5B 19 IR Bn E E E A E E E E E E E e eeeaaE 5B 19 Kate e EK imake Minifold ASSEDI E 5B 20 VCS CC FSS EE 5B 20 Daar e Ee E E EE 5B 20 5B 22 Troubleshooting EE Eo ae ebe 5B 22 5B 25 FLY SU ta cst ep reece seen E EENE EEA EE E E E E E E E EE E 5B 26 e E 5B 26 5B 33 TOU les eri TION C Aa a E E S T E S 5B 33 5B 34 How Chart RE E 5B 35 5B 36 Common Complains E 5B 36 5B 37 5B 1 Section 5B EFI Fuel System Description AA WARNING Explosive Fuel can cause fires and severe burns Fuel system ALWAYS remains under HIGH PRESSURE A WARNING Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well v
145. ll ignition related wires are connected including the spark plug leads Be certain all terminal connections fit snugly Make sure the ignition switch is in the run position NOTE The CD ignition systems are sensitive to excessive load on the kill lead If a customer complains of hard starting low power or misfire under load it may be due to excessive draw on the kill circuit Perform the preliminary test which follows Preliminary Test To be certain the reported problem is in the engine ignition system it should be isolated from the unit 1 Locate the plug connectors where the wiring harnesses from the engine and unit are joined Separate the connectors and remove the white kill lead from the engine connector Rejoin the connectors and position or insulate the kill lead terminal so it cannot touch ground Try to start the engine to verify whether the reported problem is still present a Ifthe problem is gone the electrical system on the unit is suspect Check the key switch wires connections safety interlocks etc b If the problem persists follow the test procedure on the next page Leave the kill lead isolated until all testing is completed NOTE If the engine starts or runs during any of the testing you may need to ground the kill lead to shut it down As you have interrupted the kill circuit it may not stop with the switch 2 Test for spark on both cylinders with Kohler ignition tester see Section
146. ll new exhaust gaskets and attach the muffler and mounting hardware Torque the screws to 9 9 N m 88 in Ib 2 Install the hex flange nuts to the exhaust studs Torque the nuts to 24 4 N m 216 in Ib Install Oil Filter and Fill Crankcase with Ou Figure 11 119 Fuel Line and Pump Pulse Fuel pa i Pump 1 Place a new oil filter in a shallow pan with the open end up Pour new oil of the proper type through the threaded center hole Stop pouring when the oil reaches the bottom of the threads Allow a minute or two for the oil to be absorbed by the filter material Install Lower Flywheel Cover Rectifier Regulator and Mounting Plate 1 Install make sure the small metal spacers are positioned in the mounting holes of the lower flywheel cover 2 Apply a thin film of oil to the rubber gasket on the new filter 2 Attach the lower flywheel cover to the 2 oil filter side lower radiator support bracket using a two M screws and flat washers Finger tighten only at this time Install the new oil filter to the filter adapter Turn the oil filter clockwise until the rubber gasket contacts the surface then tighten the filter an additional 3 4 1 turn See Figure 11 121 11 32 4 Figure 11 121 Installing Oil Filter Remove the oil fill cap from the valve cover Fill the crankcase with new oil to the F mark on the dipstick Refer to Oil Type and Check Oil Level on pages 6 1 and 6 2 Check oil level again
147. lower pulley and reinstall Torque the four bolts in a criss cross sequence to 24 3 N m 215 in 1b See Figure 11 100 Figure 11 102 Installing Elbow Adapter Gasket 2 Set the air cleaner mounting bracket assembly with the hose and elbow attached in position on the engine Align all of the mounting holes Start and finger tighten each of the mounting screws Make sure the fuel line is outside of the main bracket when installed See Figures 11 103 and 11 104 Figure 11 100 Torquing Lower Pulley Screws 9 Mount the RH and LH lower radiator supports with cross support bracket attached to the crankcase using the four hex flange screws Snug the screws only at this time See Figure 11 101 Figure 11 101 Mounting Lower Radiator Supports 11 28 Ba DN j a F Ge d F ei Figure 11 104 Fuel Line Hose Routing Outside Leg of Air Cleaner Bracket 3 Torque the two elbow mounting screws to 7 3 N m 65 in lb See Figure 11 105 Then torque the eight valve cover mounting screws to 6 2 N m 55 in Ib in the sequence shown in Figure 11 107 Section 11 Reassembly Figure 11 107 Torque Sequence 4 If removed install the rain cap and secure with the clamp Check the position of the dust ejector it should face downward Adjust the end cap position as required See Figure 11 108 Figure 11 108 Dust Ejector Valve and Rain Cap Position 5 Connect the wires for the audible alarm
148. ltage is 13 8 volts or more place a minimum load of 5 amps on battery to reduce voltage Observe ammeter NOTE Turn on lights if 60 watts or more or place a 2 5 ohm 100 watt resistor across battery terminals Remove connector from rectifier regulator With engine running at 3600 RPM measure AC voltage across stator leads using an AC voltmeter With engine stopped measure the resistance across stator leads using an ohmmeter With the engine stopped measure the resistance from each stator lead to ground using an ohmmeter Perform same test as step 1 above If voltage is 13 8 14 7 and charge rate increases when load is applied the charging system is OK and battery was fully charged If voltage is less than 13 8 or charge rate does not increase when load is applied test stator Tests 2 and 3 If voltage is 28 volts or more stator is OK Rectifier regulator is faulty Replace the rectifier regulator If voltage is less than 28 volts stator is probably faulty and should be replaced Test stator further using an ohmmeter Test 3 If resistance is 0 064 0 2 ohms the stator is OK If the resistance is infinity ohms stator is open Replace stator If the resistance is infinity ohms no continuity the stator is OK not shorted to ground If resistance or continuity is measured the stator leads are shorted to ground Replace stator If the voltage is 14 7 volts or less the charging system is OK Th
149. lugged Clean vent ports and air bleeds Blow out all passages with compressed air Leaky cracked or damaged float Submerge float to check for leaks Engine runs lean indicated by Float level too low Separate fuel bowl from carburetor body Free misfiring loss of speed and power if stuck or replace float governor hunting or excessive Idle holes plugged dirt in fuel delivery channels Clean main throttle opening fuel jet and all passages blow out with compressed air 4 Fuel leaks from carburetor Float stuck See Remedy 2d Dirt under fuel inlet needle See Remedy Ze Bowl vents plugged Blow out with compressed air Carburetor bowl gasket leaks Replace gasket Troubleshooting Checklist e Make sure the air cleaner base and carburetor are When the engine starts hard runs roughly or stalls at securely fastened to the engine using gaskets in low idle speed check the following areas before good condition adjusting or disassembling the carburetor e Make sure the air cleaner element is clean and all e Make sure the fuel tank is filled with clean fresh air cleaner components are fastened securely gasoline e Make sure the ignition system governor system e Make sure the fuel tank cap vent is not blocked exhaust system and throttle and choke controls and that it is operating properly are operating properly e Make sure fuel is reaching the carburetor This If the engine is hard starting or runs roughly
150. move See Figure 9 14 Figure 9 14 Removing LH and RH Mounting Brackets Screws Section 9 Disassembly 8 Further disassembly for component servicing 3 Lift the air cleaner mounting bracket assembly may be performed as required off the engine See Figure 9 17 Remove Air Cleaner Assembly 1 Remove the two screws securing the elbow adapter and gasket to the carburetor See Figure 9 15 Figure 9 17 Removing Air Cleaner From Engine Remove Throttle and Choke Controls 1 Remove the four hex flange screws securing the main control bracket to the cylinder heads See Figure 9 18 Figure 9 15 Removing Elbow Adapter Mounting Screws 2 Remove the two upper valve cover mounting screws on each side which also secure the main mounting bracket for the air cleaner See Figure 9 16 Control Bracket S 2 Mark the hole location and disconnect the Eoi governor spring from the governor lever Figure 9 16 Removing Upper Valve Cover Mounting Bracket Screws 9 5 Section 9 Disassembly 3 Tilt the main bracket and disconnect the choke linkage from the choke lever See Figure 9 19 Remove the main control bracket ee si A L ff Figure 9 19 Tilting Bracket and Unhooking Choke Link 4 Unhook the choke linkage from the actuator lever on carburetor See Figure 9 20 Figure 9 20 Disconnecting Choke Linkage from Carburetor Remove External Governor Controls 1 Loosen the hex flange nut of the gov
151. moved during head servicing Pare Apply pipe sealant with Teflon Loctite 59241 Figure 11 42 Installing Camshaft Key into Keyway or equivalent to the threads and reinstall the plugs Torque the plugs to 13 5 N m 120 in Ib See Figure 11 41 11 13 Section 11 Reassembly Figure 11 43 Test Fitting Pulley Figure 11 45 Using Grease in O Ring Groove of Pump Cavity 2 Ifthe water pump by pass hose fitting was removed previously apply pipe sealant with Teflon Loctite 59241 or equivalent on the threads and tighten it into pump Orient the fitting so the outlet points in the 11 o clock position as shown in Figure 11 44 Figure 11 46 Installing O Ring in Groove 5 Apply rubber lubricant to the inner surfaces of the short hose section Assemble the hose to the outlet of the water pump and secure with the j larger diameter clamp Orient the clamp so the Figure 11 44 Water Pump By pass Fitting tangs extend out in the 3 to 4 o clock position See Figures 11 47 and 11 48 3 Check the sealing surfaces of the water pump and crankcase They must be clean and free of any nicks or damage 4 Apply asmall amount of grease in several locations to hold the new water pump O Ring in place Install a new O Ring in the groove of crankcase See Figures 11 45 and 11 46 Do not use RTV sealant in place of the O Ring or attempt to reinstall a used O Ring Figure 11 47 Assembling Hose to Water Pump 11 1
152. mption may be symptoms of faulty valves Although these symptoms could also be attributed to worn rings remove and check the valves first After removal clean the valve heads faces and stems with a power wire brush Then carefully inspect each valve for defects such as warped head excessive corrosion or worn stem end Replace valves found to be in bad condition A normal valve and valves in bad condition are shown in the accompanying illustrations Normal Even after long hours of operation a valve can be reconditioned and reused if the face and margin are in good shape If a valve is worn to where the margin is less than 1 32 do not reuse it The valve shown was in operation for almost 1000 hours under controlled test conditions Leakage A poor grind on face or seat of valve will allow leakage resulting in a burned valve on one side only 10 6 Bad Condition The valve depicted here should be replaced Note the warped head margin damaged and too narrow These conditions could be attributed to excessive hours or a combination of poor operating conditions Gum Gum deposits usually result from using stale gasoline Gum is a prevalent cause of valve sticking The cure is to ream the valve guides and clean or replace the valves depending on their condition Section 10 Inspection and Reconditioning Stem Corrosion Moisture in fuel or from Coking Coking is normal on intake valves and is not condensation a
153. n Ib See Figure 11 86 Connect the choke lever of the main control bracket to the choke linkage from the carburetor Mount the main control bracket to the cylinder heads with the four screws Torque the screws to 10 7 N m 95 in Ib into new holes or 7 3 N m 65 in Ib into used holes See Figure 11 87 Section 11 Reassembly Install Lower Crankshaft Pulley Pulley Adapter and Cooling Fan Assembly 1 Make sure the shoulder of the flywheel hub and the adjacent face surface are clean and free of any nicks or damage 2 Install the crankshaft pulley adapter onto the flywheel hub so the offset for the pulley is out and the holes are aligned Make sure the adapter rests squarely on the face of the flywheel See Figure 11 89 5 Connect the dampening spring to the throttle lever as shown Hook the governor spring from the throttle control bracket in the appropriate governor lever hole as indicated in the chart below Note that the hole positions are counted from the pivot point of the governor lever See Figure 11 88 Figure 11 89 Lower Adapter on Flywheel 3 Assemble the front and rear pulley halves placing the shims as indicated a For a new belt Assemble with two or three shims between the pulley halves and remaining shim if any on the outside front of the outer pulley half b For a used belt Assemble with two shims Figure 11 88 Governor Throttle Linkage petween the pulley Nalves ana remani
154. n ohmmeter set on the Rx10K scale between the spark plug boot terminal and the red primary terminal Secondary resistance should be 13 000 17 500 Q 4 If the secondary resistance is not within the specified range unscrew the spark plug lead nut from the coil secondary tower and remove the plug lead Repeat step b3 testing from the secondary tower terminal to the red primary terminal If resistance is now correct the coil is good but the spark plug lead is faulty replace the lead If step b2 resistance was incorrect and or the secondary resistance is still incorrect the coil is faulty and needs to be replaced Spark Plugs EFI engines require resistor spark plugs Do not try to substitute non resistor plugs Wiring Harness The wiring harness used in the EFI system connects the electrical components providing current and eround paths for the system to operate All input and output signaling occurs through a special all weather connector that attaches and locks to the ECU see Figure 5B 19 Figure 5B 19 32 Pin MSE 1 1 Plastic Cased ECU Connector The condition of the wiring connectors and terminal connections is essential to system function and performance Corrosion moisture and poor connections are more likely the cause of operating problems and system errors than an actual component Refer to the Troubleshooting Electrical section for additional information 5B 16 Battery Charging System
155. n the radiator the coolant is drawn into the pump through the lower radiator hose and circulation starts all over again A cooling fan driven off the flywheel by a belt draws ambient air through the radiator to maintain the cooling process e Thermostat e Intake Manifold with Thermostat Housing e Overflow Reservoir e Crankcase and Heads with Integral Cooling Passages Coolant Recommendations Use equal parts of ethylene glycol antifreeze and water only Distilled or deionized water is recommended especially in areas where the water contains a high mineral content Propylene glycol based antifreeze is not recommended Cleaner Removed For Clarity This mixture will provide protection from 37 C 34 F to 108 C 226 F For protection and use outside the indicated temperature limits follow the antifreeze manufacturer s instructions on the container but do not exceed 70 antifreeze 7 1 Section 7 Cooling System DO NOT use antifreeze with stop leak additive s or put any other additives in the cooling system Cooling System Maintenance and Service Maintenance Maintaining the correct coolant level cleaning any debris accumulation from the radiator surfaces and insuring all parts are in proper operating condition is critical to ensuring long life proper system performance and preventing overheating To ensure proper air circulation make sure the radiator cooling fan drive belt pulleys cooling fins an
156. nd Adapter Plate 1 Disconnect the leads attached to the starter solenoid terminals 2 Remove the two hex flange screws securing the starter to the adapter plate See Figure 9 2 Radiator Drain Plug Figure 9 2 Removing Starter Assembly Drain Plug 3 Remove the two hex flange screws attaching the adapter to the crankcase Note the orientation of the cutout The upper screw may also secure a clamp for the stator leads Figure 9 4 Radiator Drain Plug 2 If equipped remove the coolant drain plugs on each side of block Allow any remaining coolant to drain out See Figure 9 5 Dispose of the coolant properly according to local regulations Figure 9 3 Removing the Adapter Plate Screws Figure 9 5 Removing Coolant Drain Plugs in Block 9 2 Section 9 Disassembly Drain Oil from Crankcase and Remove Oil Remove Flywheel Cover Radiator Filter Assembly Mounting Brackets and 1 Remove the oil fill cap and dipstick and one or Attached Components both of the drain plugs See Figures 9 6 and 9 7 1 Remove the screws or nuts and flat washers 2 Allow sufficient time for the oil to drain out on each side securing the lower flywheel cover to the LH and RH radiator support brackets See Figure 9 8 The mounting plate for the rectifier regulator will become detached when the LH lt n screws are removed Do not lose the small Oil Fill Cap K bet e wm dE spacers located within the holes of the lower cover Clips a
157. nd set the meter to the Rx1 scale Check for circuit continuity from pin 19 of the ECU connector see page 5B 24 to the shell of the oxygen sensor and from pin 20 to the sensor terminal of the main harness Both tests should indicate continuity a If there is no continuity displayed in either of the tests check the harness circuit for breaks or damage and the connections for poor contact moisture or corrosion If no continuity was found in the first test also check for a poor broken ground path back through the exhaust system engine and mounting sensor is grounded through its shell b If continuity is indicated go to step 6 6 With the key switch in the on run position using a high impedance voltmeter check the voltage from the wiring harness oxygen sensor connector to the engine ground location Look for a steady voltage from 350 550 mv 0 35 0 55 v a Ifthe voltage reading is not as specified move the black voltmeter lead to the negative post of the battery to be certain of a good ground If the voltage is still not correct the ECU is probably bad b If the voltage readings are correct clear the fault codes and run the engine to check if any fault codes reappear To Replace Oxygen Sensor 1 Disconnect the oxygen sensor connector from wiring harness 2 Loosen and remove the oxygen sensor from the exhaust manifold muffler assembly 3 Apply anti seize compound sparingly to threads of new ox
158. neral Information General Specifications cont Compression Ratio IERT LEHOR 3 LAGI E 8 5 1 LRU LH Voce Holic ECHA Toenis er ren tere ere errr rer 8 7 1 Dry Weight Be Core OB alee OF Bl E e Ble Wis o erent ene eer erent Unter ote ea trier ec 51 7 kg 114 1b OO Ee 52 6 kg 116 1b Oil Capacity w filter approximate BEER 1 6 1 8 L 1 7 1 9 U S qt Coolant Capacity equal parts of water and ethylene glycol un 20 L 215 US gt Angle of Operation Maximum At Full Oil Level All Directions 0 0 0 0 20 Camshaft End Play Viti S E 0 076 0 127 mm 0 0030 0 0050 in Runni CEN E e a R E 0 025 0 063 mm 0 0010 0 0025 in Bore I D DIC a ee coe pice cise ena pret ste ene eect peter see cannes enrcausen ses a eenes eeuee 20 000 20 025 mm 0 7874 0 7884 in IVE WV E 20 038 mm 0 7889 in Camshaft Bearing Surface O D DIOU ee 19 962 19 975 mm 0 7859 0 7864 in MNE Er 19 959 mm 0 7858 in Carburetor and Intake Manifold Intake Manifold Fastener Torque torque in 2 increments 00 0 cesses first to 7 4 N m 66 in lb finally to 9 9 N m 88 in 1b Thermostat Housing Mounting Fastener Torque sccisssssessssenscisosssvetsssvasseoneeeeasecess 6 2 7 3 N m 55 65 in Ib Carburetor Mounting Fastener Torque EE 9 9 N m 88 in Ib Connecting Rod Cap Fastener Iorque torque in increments E 11 3 N m 100 in Ib Connecting Rod to Crankpin Running Clearance DNV ee 0 043 0 068 mm 0 0016 0 0026 in er VV es EE eene 0
159. ness e Pin circuit 20 wiring or connectors c ECU to harness connection problem 3 TPS Sensor Related 4 Systems Related a Throttle plate position incorrectly set or a Ignition spark plug plug wire ignition coil registered during Initialization b Fuel fuel type quality injector fuel pressure b TPS problem or malfunction fuel pump c Combustion air air cleaner dirty restricted 4 Engine Wiring Harness Related intake leak throttle bore a Difference in voltage between sensed voltage d Base engine problem rings valves pin circuit 2 and actual injector voltage e Exhaust system leak muffler flange oxygen circuit 45 sensor mounting boss etc f Fuel in the crankcase oil 5 Systems Related g Altitude a Ignition spark plug plug wire ignition coil h Blocked or restricted fuel return circuit to b Fuel fuel type quality injector fuel pump tank fuel pressure c Combustion air air cleaner dirty restricted Code 42 intake leak throttle bores Source Engine Coolant Temperature Sensor d Base engine problem rings valves Explanation Not sending proper signal to ECU e Exhaust system leak Expected Engine f Fuel in the crankcase oil Response Engine may be hard to start because g Blocked or restricted fuel return circuit to ECU can t determine correct fuel tank mixture 6 ECU Related Possible Causes a ECU to harness connection problem 1 Temperature Sensor Related a Sensor wiring o
160. ng Connection Details shim s on the outside front of the outer pulley half Governor Spring Chart Install and snug the pulley assembly See Figures Hidh Idle RPM Governor Lever Governor Spring 11 90 and 11 91 Final belt tension and pulley a Hole No Color Code assembly will be made after fan upper pulley 3888 assembly is installed 3780 3672 11 25 Section 11 Reassembly Figure 11 91 Installing Lower Pulley Figure 11 93 Wiring Through Intake Manifold Cutout and Behind Upper Bracket 4 Install the upper fan mounting bracket to the intake manifold with the two screws See Figure 5 If disassembled reassemble the fan and pulley 11 92 Torque assembly as shown in Figures 11 94 11 95 and 11 96 M6 Screws to 7 3 N m 65 in 1b M8 Screws to 24 4 N m 216 in Ib The by pass hose and wires must be positioned within the cutout in the intake manifold as shown in Figure 11 93 Be careful not to pinch the harness wires between the bracket and intake manifold when tightening Figure 11 94 Fan Assembly Components Disassembled Layout 11 26 Section 11 Reassembly Figure 11 95 Fan Assembly Front View Figure 11 97 Torquing Upper Pulley Assembly 8 Carefully work the belt into place on the pulleys See Figure 11 98 Check the belt tension There should be no more than 9 53 12 7 mm 3 8 1 2 belt deflection per side with 10 Ibs of applied tension See Figure 11 99 Figure 11 96
161. nnect the remaining black lead from the tester to one of the outer AC terminals on the rectifier regulator See Figure 8 13 a Ifthe OK green light comes on and stays steady the part is good and may be used A b If any other light is displayed the rectifier regulator is faulty and should not be used NUL NOTE A flashing LOW light can also occur as a result of an inadequate ground lead connection Make certain connection location is clean and clamp is secure Figure 8 13 5 Plug the tester into the proper AC outlet power for tester being used Turn on the power switch E The POWER light should be illuminated and 20 25 Amp Rectifier Regulators one of the four status lights may be on as well 1 Connect the single lead adapter in between the See Figure 8 10 This does not represent the B center terminal of rectifier regulator being condition of the part tested and the squared single end of the tandem adapter lead See Figure 8 12 6 Press the TEST button until a click is heard and then release See Figure 8 11 Momentarily one of the four lights will illuminate indicating the partial condition of the part a Ifthe OK green light comes on disconnect the tester black lead attached to one AC terminal and reconnect it to the other AC terminal Repeat the test If the OK green light comes on again the part is good and may be used b If any other li
162. ocation as either intake or exhaust and cylinder 1 or 2 The push rods should always be reinstalled in their IMPORTANT The 90 fitting in the crankcase original position which the transfer tube is connected to is sealed and installed at the factory in a specific position Do not loosen remove or alter the mounted position of this fitting at any time Contact the factory service department for specific instructions if the fitting is damaged or its mounting is affected in any way 3 Repeat for the opposite cylinder 9 13 Section 9 Disassembly 4 Remove the four hex flange nuts and washers from the cylinder head studs Carefully remove the cylinder heads and head gaskets See Figure 9 52 Figure 9 52 Removing Cylinder Heads and Gaskets 5 Remove the hydraulic lifters using a hydraulic lifter removing tool do not use a magnet Mark them similar to the push rods intake or exhaust and cylinder 1 or 2 Hydraulic lifters should always be reinstalled in their original location See Figure 9 53 Figure 9 53 Removing Lifters NOTE Itis not necessary to remove the cylinder studs from the crankcase unless replacement is intended If studs are removed for any reason discard the old stud s do not reuse reinstall Use new studs and refer to the assembly sequence for proper installation 9 14 Disassemble Cylinder Heads 1 Remove the two hex flange screws rocker arms and pivots from the cylinder head s
163. of the breather cover to separate and remove the cover from the gasket See Figure 9 26 Figure 9 23 Removing Carburetor from Engine 5 Remove the carburetor gasket 6 The carburetor adapter throttle linkage and governor lever may be separated for individual component servicing as required If the linkages are separated reattach the bushings to the linkages to prevent them from being lost Remove Oil Sentry If So Equipped 1 Disconnect the wire lead from the Oil Sentry switch and remove the switch from the breather cover See Figure 9 24 Figure 9 26 Prying Off the Breather Cover Do not pry on the sealing surfaces as it could cause damage resulting in leaks 3 Remove the breather gasket and fiber filter from the breather chamber See Figure 9 27 Figure 9 24 Oil Sentry Location on Engine Remove Breather Cover 1 Remove the four hex flange screws securing the breather cover to the crankcase See Figure 9 25 a Lh 7 i i S Figure 9 27 Removing the Breather Gasket and Filter 9 7 Section 9 Disassembly 4 Remove the hex flange screw breather reed retainer and breather reed from the breather chamber See Figure 9 28 Figure 9 30 Removing Valve Covers and Gaskets Remove Lower Drive Pulley and Fan Belt 1 Remove the four screws attaching the lower drive pulley assembly to the pulley adapter and flywheel See Figure 9 31 E g the Breather Reed Figur
164. off with compressed air to remove any remaining fuel Take the solenoid to a location with good ventilation and no fuel vapors present You will also need a 12 volt power source that can be switched on and off 3 Be sure the power source is switched off Connect the positive power source lead to the red lead of the solenoid Connect the negative power source lead to the solenoid bracket 4 Turn the power source on and observe the pin in the center of the solenoid The pin should retract with the power on and return to its original position with the power off Test several times to verify operation Carburetor Adjustments General In compliance with government emission standards the carburetor is calibrated to deliver the correct air to fuel mixture to the engine under all operating conditions Both the low and the high speed mixture circuits are preestablished and cannot be adjusted The low idle speed RPM is the only adjustment available NOTE Low idle speed RPM adjustment should be made only after the engine has warmed up Section 5 Fuel System and Governor Adjusting Low Idle Speed RPM Setting 1 Start the engine and run at half throttle for 5 to 10 minutes to warm up The engine must be warm before making final low idle speed RPM G adjustment Check that the throttle and choke l Tue Zaut oi Solenoid plates can fully open 2 Place the throttle control into the idle or Adjusting slow
165. ohler 24 761 01 S Individual Components Available Design Technology Inc Pressure Tester DTI 019 Noid Light DTI 021 90 Adapter DTI 023 Oetiker Clamp Pliers DTI 025 Code Plug Red Wire DTI 027 Code Plug Blue Wire DTI 029 Flywheel Holding Tool CS Series SE Tools KLR 82407 a SE Tools KLR 82408 To remove flywheel from engine 2 1 Section 2 Tools amp Aids Tools cont Flywheel Strap Wrench To hold flywheel during removal SE Hydraulic Valve Lifter Tool To remove and install hydraulic lifters PAE OCL Ignition System Tester For testing output on all systems except CD Kohler 25 455 01 S For testing output on capacitive discharge CD ignition system Kohler 24 455 02 S Offset Wrench K amp M Series To remove and reinstall cylinder barrel retaining nuts EE Ge Ee Kohler 25 761 06 S To test and verify oil pressure Rectifier Regulator Tester 120 volt current Kohler 25 761 20 S Rectifier Regulator Tester 240 volt current Kohler 25 761 41 S Used to test rectifier regulators Individual Components Available Design Technology Inc CS PRO Regulator Test Harness DTI 031 Special Regulator Test Harness with Diode DTI 033 Spark Advance Module SAM Tester To test the SAM ASAM and DSAM on engines with SMART SPARK EE Starter Brush Holding Tool Solenoid Shift SE Tools KLR 82416 To hold brushes during servicing Starter Retaining Ring Tool Inertia Drive To remove and reinstall drive retaining
166. ohmmeter leads to the two large post terminals Perform the preceding test 1 and check for continuity See Figure 8 46 The ohmmeter should indicate continuity if no continuity is indicated the solenoid should be replaced Repeat test several times to confirm condition Section 8 Electrical System and Components 12 volt Test Leads Momentary Connection Only VOM Leads Ge Ai a Figure 8 46 Testing Pull In Coil Solenoid Contact Continuity Test 3 Solenoid Hold In Coil Function Test Connect one 12 volt test lead to the flat spade S start terminal on the solenoid and the other lead to the body or mounting surface of the solenoid Then manually push the plunger In and check if the Hold In coil holds the plunger retracted See Figure 8 47 Do not allow the test leads to remain connected to the solenoid for a prolonged period of time If the plunger fails to stay retracted the solenoid should be replaced Manually Push Plunger In 12 volt Test Leads Connect Only Long Enough to Test Figure 8 47 Testing Hold In Coil Function Test 8 21 Section 8 Electrical System and Components Test 4 Solenoid Hold In Coil Contact Continuity Test Use an ohmmeter set to the audible or Rx2K scale and connect the two ohmmeter leads to the two large post terminals Perform the preceding test 3 and check for continuity See Figure 8 48 The meter should indicate continuity if no continuity
167. old and the injectors Disconnect the throttle linkage and damper spring from the throttle lever Disconnect the TPS lead from the harness Remove the manifold mounting bolts and separate the throttle body manifold from the engine leaving the TPS fuel rail air baffle injectors and line connections intact Discard the old gaskets Position the manifold assembly over an appropriate container and turn the key switch on to activate the fuel pump and pressurize the system Do not turn switch to start position If either injector exhibits leakage of more than two to four drops per minute from the tip or shows any sign of leakage around the outer shell turn the ignition switch off and replace injector as follows 13 Depressurize the fuel system following the procedure in the fuel warning on page 5B 2 Remove the two fuel rail mounting screws 14 Clean any dirt accumulation from the sealing mounting area of the faulty injector s and disconnect the electrical connector s 15 Pull the retaining clip off the top of the injector s and remove from manifold 16 Reverse the appropriate procedures to install the new injector s and reassemble the engine Use new O Rings any time an injector is removed new replacement injectors include new O Rings Lubricate O Rings lightly with oil Torque fuel rail and blower housing mounting screws to 3 9 N m 35 in lb and the intake manifold and air cleaner mounting screw
168. ols the amount of fuel injected and the ignition timing by monitoring the primary sensor signals for engine temperature speed RPM and throttle position load These primary signals are compared to preprogrammed maps in the ECU computer chip and the ECU adjusts the fuel delivery to match the mapped values An oxygen sensor provides continual feedback to the ECU based upon the amount of unused oxygen in the exhaust indicating whether the fuel mixture being delivered is rich or lean Based upon this feedback the ECU further adjusts fuel input to re establish the ideal air fuel ratio This operating mode is referred to as closed loop operation The EFI system operates closed loop when all three of the following conditions are met a The engine coolant temperature is greater than 5B 35 C 95 F b The oxygen sensor has warmed sufficiently to provide a signal minimum 375 C 709 F c Engine operation is at a steady state not starting warming up accelerating etc During closed loop operation the ECU has the ability to readjust temporary and learned adaptive controls providing compensation for changes in overall engine condition and operating environment so it will be able to maintain the ideal air fuel ratio of 14 7 1 The system requires a minimum engine coolant temperature greater than 55 C 130 F to properly adapt These adaptive values are maintained as long as the ECU is powered
169. one of the screws install it in the 10 location Install the silver plated ground screw in its original location normally the 4 or 6 location Torque the fasteners in the torque sequence shown in Figure 11 19 to 24 4 N m 216 in Ib Figure 11 19 Closure Plate Torque Sequence Section 11 Reassembly Figure 11 20 Torquing Closure Plate Screws Install Cylinder Studs NOTE Do not reinstall or attempt to reuse any cylinder studs that have been removed Discard any removed stud s and replace with new If any of the cylinder studs were removed install new stud s as follows 1 Identify the longer threaded end of the new stud containing the Loctite Dri Loc See Figure 11 21 ieee Stud End with Loctite Dri Loc Figure 11 21 New Cylinder Stud 2 Tighten two hex nuts together on the shorter threaded section with the identification mark on the end 3 Thread the end of the stud with the Loctite into the crankcase until an exposed stud height of 75 mm 2 61 64 in is obtained The end with the dash mark must be out See Figure 11 22 When threading in the studs use a steady tightening motion without interruption until the proper 11 8 height is obtained The frictional heat from the engaging threads may otherwise cause the locking compound to set up prematurely Remove the two nuts 4 Repeat steps 1 3 for each of the studs Install Reed and Breather Cover Assembly 1 Make s
170. open at a temperature 10 to 15 degrees above the specified opening the thermostat should be replaced If the valve in the thermostat can be moved or pushed off its seat with a slight effort when the thermostat is cold the unit may be considered defective and should be replaced The thermostat should be replaced if operation is found to be questionable or faulty Installation 1 Thoroughly clean the sealing surfaces of the intake manifold and thermostat housing with an aerosol gasket remover Make sure the sealing surfaces are clean and free of nicks or damage Make sure the notch in the intake manifold is clean 2 Install a new thermostat into the intake manifold so the larger spring end is down into the well of the intake manifold Position a new thermostat gasket on the intake manifold 3 Install the thermostat housing onto the intake manifold 4 Install and torque the two hex flange screws to 9 9 N m 88 in lb 7 6 5 Reconnect the radiator hose and secure with the hose clamp if separated previously High Temperature Sensor A high temperature sensor may be mounted in the intake manifold and is used to activate a warning light audible alarm or kill the engine depending on the application if the safe operating temperature is exceeded The sensor is a normally open switch which completes a circuit when the coolant temperature reaches the rated temperature limit of the switch For these engines the temper
171. operating or warm to the touch Hot Liquid The liquid coolant can get extremely hot from operation Turning the radiator cap when the engine is hot can allow steam and scalding liquid to blow out and burn you severely Shut off machine Only remove radiator cap when cool enough to touch with bare hands Slowly loosen cap to first stop to relieve pressure before removing completely amp WARNING Explosive Gas can cause fires and severe acid burns Charge battery only in a well ventilated area Keep sources of ignition away Explosive Gas Batteries produce explosive hydrogen gas while being charged To prevent a fire or explosion charge batteries only in well ventilated areas Keep sparks open flames and other sources of ignition away from the battery at all times Keep batteries out of the reach of children Remove all jewelry when servicing batteries Before disconnecting the negative ground cable make sure all switches are OFF If ON a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or gasoline vapors are present k Electrical Shock can cause injury Do not touch wires while engine is running Electrical Shock Never touch electrical wires or components while the engine is running They can be sources of electrical shock Section 1 Safety and General Information Engine Identification Numbers When ordering parts or in any communication
172. or Related a Sensor connector or wiring problem b Exhaust leak c Poor ground path to engine sensor is case grounded Code 32 Source Oxygen Sensor Explanation No change in the sensor output signal Expected Engine Response Open loop operation only may cause a drop in system performance and fuel efficiency Possible Causes 1 Engine Wiring Harness Related a Pin circuit 20 wiring or connectors 2 Oxygen Sensor Related a Sensor connector or wiring problem b Sensor contaminated or damaged c Sensor below the minimum operating temperature 375 C 709 F d Poor ground path to engine sensor grounds through shell see Oxygen Sensor section Code 33 Source Oxygen Sensor Fuel System Explanation System to Rich Temporary fuel adaptation control is at the upper limit Expected Engine Response Erratic performance Will run rich smoke Possible Causes 1 Fuel Supply Related nothing lean only rich a Restricted return line causing excessive fuel pressure b Fuel inlet screen plugged in tank fuel pump only c Incorrect fuel pressure at fuel rail Section 5B EFI Fuel System 2 Oxygen Sensor Related 3 Engine Wiring Harness Related a Sensor connector or wiring problem a Difference in voltage between sensed voltage b Sensor contaminated or damaged pin circuit 2 and actual injector voltage c Exhaust leak circuit 45 d Poor ground path b Problem in wiring har
173. or stalls includes checking the fuel shut off valve fuel at low idle speed it may be necessary to service the tank filter screen in line fuel filter fuel lines and carburetor fuel pump for restrictions or faulty components as necessary 5 6 Section 5 Fuel System and Governor Disassembly e The choke plate is spring loaded Check to make Disassemble the carburetor using the following steps sure it moves freely on the shaft See Figure 5 6 Always use new gaskets when servicing or reinstalling 1 Remove the intake elbow and hose if attached carburetors Repair kits are available which include breather hose and carburetor Refer to Section 9 new gaskets and other components These kits are Disassembly described on page 5 10 2 Remove the four screws and carefully separate Float the air horn assembly from the carburetor body If symptoms described in the carburetor troubleshooting guide indicate possible float level 3 Loosen the screw securing the float assembly to problems a check of the existing float level may be the air horn and remove the float float shaft and performed as follows It is not necessary to remove the fuel inlet needle carburetor from the engine to check or adjust the float level 4 Remove the slow jet from the carburetor body 1 Remove the air cleaner and breather hose Refer NOTE The main jet is a fixed jet and can be to Section 9 Disassembly removed if required Fixed jets for hig
174. ostic Display 1 Diagnostic display initiated through ignition key sequencing 2 La Pas a a oe 6 E een H ZC Light remains on at end of transmission Figure 5B 35 Diagnostic Display After the problem has been corrected the fault codes may be cleared as follows 1 Disconnect the negative battery cable from battery terminal or remove the main fuse for the ECU for approximately 1 minute 2 Reconnect the cable and tighten securely or reinstall the main fuse Start the engine and allow it to run for several minutes The MIL should remain off if the problem was corrected and the fault codes should not reappear codes 31 32 33 and 34 may require 10 15 minutes of running to reappear The following chart lists the fault codes what they correspond to and what the visual indications will be Following the chart is a list of the individual codes with an explanation of what triggers them what symptoms might be expected and the probable causes 5B 27 Section 5B EFI Fuel System Blink OBD2 Condition or Failure Description MIL Code P Code Illuminated Y No RPM Signal g D 5 O D O O si D d 3 3 D lt a Engine SpeedSensor SS z Po i 3 P0171 Maximum Adaption Limit Reached P0172 Minimum Adaption Limit Reached PO P0175 System too Rich P0118 Temperature Sensor Circuit Open Circuit or Short to Battery Temperature Sensor Circuit Shorted to Ground P167
175. other than service class SG SH SJ or higher oil or extending oil change intervals longer than recommended can cause engine damage NOTE Synthetic oils meeting the listed classifications may be used with oil changes performed at the recommended intervals However to allow piston rings to properly seat anew or rebuilt engine should be operated for at least 50 hours using standard D petroleum based oil before switching to synthetic oil A logo or symbol on oil containers identifies the API service class and SAE viscosity grade See Figure 6 1 Figure 6 1 Oil Container Logo The top portion of the symbol shows service class such as API SERVICE CLASS SJ The symbol may show additional categories such as CC or CD The center portion shows the viscosity grade such as SAE 10W 30 If the bottom portion shows Energy Conserving it means that oil is intended to improve fuel economy in passenger car engines Checking Oil Level The importance of checking and maintaining the proper oil level in the crankcase cannot be overemphasized Check oil BEFORE EACH USE as follows 6 1 Section 6 Lubrication System 1 Make sure the engine is stopped level and cool so the oil has had time to drain into the sump 2 Clean the area around the dipstick before removing it This will help to keep dirt grass clippings etc out of the engine 3 Pull out the dipstick and wipe off the oil Reinstall the dipstick into the tube and p
176. own in Figure 7 14 Figure 7 14 A Typical Tester and Adapter Section 7 Cooling System Test Instructions 1 Figure 7 15 Adapter Installed onto the Tester A J With the engine cool carefully remove the radiator cap see Pressure Radiator Cap Section Make sure all parts of the cap and adapter are clean Install the cap on the corresponding adapter and make sure it is completely seated Install the adapter onto the tester and lock in place See Figure 7 15 Pressurize the tester to 15 psi Observe the indicated pressure It should hold steady and not decrease or leak down If leakage is detected the cap should be replaced If the tester pressure is increased to 16 psi or above the cap should then bleed off this excess pressure Install and lock the system adapter and tester onto the neck of the cooling system Pressurize the tester to 14 15 psi See Figure 7 16 Figure 7 16 Adapter and Tester Installed T T Section 7 Cooling System 5 Observe the system pressure on the gauge Gauge Needle Holds Steady If the gauge needle holds steady there should be no serious leaks in the system It is however recommended that all connections be checked for overall condition anyway using a flashlight Gauge Needle Drops Slowly If the gauge needle drops slowly it indicates the presence of a small leak or seepage Check all components and connections for signs of leakage Check the cond
177. ppears dirty typically every other time the main element is replaced Before removing it from the housing clean the area around the base of the inner element so dirt does not get into the engine See Figure 4 6 4 The elements must be replaced when dirty Do not attempt to clean the elements with pressurized air or other means as the elements will be ruined Handle new elements carefully do not use if the sealing surfaces are bent or damaged Replace any damaged or questionable components 5 If it is being replaced install the new inner element Kohler Part No 25 083 04 S followed by the canister outer element Kohler Part No 25 083 01 S Slide each fully into place in the housing 4 2 6 Reinstall the end cap so the dust ejector valve faces down and secure with the two retaining clips Air Cleaner Components Air Cleaner Housing End Cap Assembly Make sure air cleaner housing including the dust ejector valve and the end cap is in good condition and not cracked The two retainer clips should positively lock when the cap is installed Air Cleaner Hose Inspect the air cleaner hose to make sure it is not cracked split or damaged Check that the air cleaner hose is securely clamped to both the air cleaner outlet and the inlet elbow on the carburetor Air Cleaner Mounting Base Make sure the base is securely fastened to the upper valve cover screw locations and the screws securing the clamp bracket for the a
178. protection and use outside the indicated temperature limits follow the antifreeze manufacturer s instructions on the container but do not exceed 70 antifreeze DO NOT use antifreeze with stop leak additive s or put any other additives in the cooling system Fuel Recommendations A WARNING Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the engine is hot or running since spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent General Recommendations Purchase gasoline in small quantities and store in clean approved containers A container with a capacity of 2 gallons or less with a pouring spout is recommended Such a container is easier to handle and helps eliminate spillage during refueling Do not use gasoline left over from the previous season to minimize gum deposits in your fuel system and to ensure easy starting Do not add oil to the gasoline Do not overfill the fuel tank Leave room for the fuel to expand Fuel Type For best results use only clean fresh unleaded gasoline with a pump sticker octane rating of 87 or higher In countries using the Research method it should be 90 octane minimum Unleaded gasoline
179. r connection Code 34 Source Oxygen Sensor Fuel System 2 Engine Wiring Harness Related Components a Pin circuits 4 6 and or 4A damaged wires Explanation Long term fuel adaptation control is connectors or routed near noisy signal coils at the upper or lower limit alternator etc Expected Engine b ECU to harness connection problem Response System operates closed loop No appreciable performance loss as long 3 System Related as the temporary adaptation can a Engine is operating above the 176 C 350 F provide sufficient compensation coolant temperature sensor limit b ECU to harness connection problem Possible Causes 1 Oxygen Sensor Related a Sensor connector or wiring b Sensor contaminated or damaged c Exhaust leak d Poor ground path e Pin circuit 20 wiring or connectors 2 TPS Sensor Related a Throttle plate position incorrect during Initialization procedure b TPS problem or malfunction 5B 31 Section 5B EFI Fuel System Code 43 and 44 Source TPS Auto Learn initialization function failed throttle angle out of learning range Explanation While performing the TPS Auto Learn function the measured throttle angle was not within acceptable limits Expected Engine Response MIL illuminated Engine will continue to run but not properly Upon restart TPS Auto Learn function will run again unless voltage to ECU disconnected to clear memory Possible Caus
180. r gauge to see that there is at least 3 17 mm 0 125 in clearance between the underside of the pulley and the hose tube and clamps Remove the pulley and reposition the tube or clamps if required Install the flat washer and hex flange screw to secure the pulley in place Torque the screw to 9 9 N m 88 in Ib See Figure 11 55 Section 11 Reassembly Figure 11 55 Torquing Mounting Screw of Cam Pulley Install Intake Manifold Assembly 1 Check that the gasket surfaces of the intake manifold and cylinder heads are clean and free of any nicks or damage 2 Install new intake manifold gaskets onto the port surfaces of the cylinder heads See Figure 11 56 Figure 11 58 Intake Manifold Torque Sequence 4 Install and tighten the pipe plug or temperature warning switch if removed previously from the threaded port of the intake manifold Use pipe sealant with Teflon Loctite 59241 or equivalent on the threads Torque to 22 6 N m 200 in Ib See Figure 11 59 E 3 Set the intake manifold with by pass hose and wiring harness attached down into position onto the gaskets and cylinder heads Install and finger tighten the six hex flange screws in their appropriate locations Make sure the clamps for the wiring harness are positioned on the long screw on each side Torque the six intake manifold mounting screws in two steps first to 7 4 N m 66 in Ib finally to 9 9 N m 88 in Ib in the sequence s
181. re plate Pack the thrust bearing with heavy grease and stick the bearing into the race Wipe some grease on the face of the thrust washer and stick it onto the thrust bearing Wipe some grease on the face of the original shim and stick it onto the thrust washer Install the closure plate onto the crankcase without applying RTV sealant and secure it with only two or three of the fasteners at this time Use a dial indicator to check the crankshaft end play End play should be 0 070 0 590 mm 0 0027 0 0232 in Shims are available in the five color coded thicknesses listed below if adjustment is needed Crankshaft End Play Shims BLUE 0 48 0 52 mm 0 050 mm Nominal 0 019 in BLACK 0 667 0 705 mm 0 686 mm Nominal 0 27 in GREEN 0 8366 0 9127 mm 0 8750 mm Nominal 0 34 in YELLOW 1 9652 1 1414 mm 1 1033 mm Nominal 0 043 in RED 1 2938 1 3700 mm 1 3319 mm Nominal 0 052 in Remove the closure plate If end play requires adjustment remove the original shim and install the appropriate size replacement Install Closure Plate Oil Seal 1 Check to make sure that there are no nicks or burrs in the crankshaft bore of the closure plate 2 Apply a light coat of engine oil to the outside diameter of the oil seal 3 Drive the oil seal into the closure plate using a seal driver Make sure the oil seal is installed straight and true in bore to depth shown in Figure 11 15 11 6 Closure Plate 0 31
182. re the clamping screw goes through the governor lever See Figure 5B 33 There should be a gap of at least 1 32 If the tips are touching and there is no gap present the lever should be replaced If not already installed position the governor lever on the cross shaft but leave the clamping screw loose Figure 5B 30 Throttle Linkage Governor Lever Connection 2 Pivot the throttle shaft and plate into the Full Throttle position so the tang of the throttle shaft plate is against the manifold casting See Figure 5B 31 Temporarily clamp in this position Figure 5B 33 Checking Split of Clamp 2 Follow the instructions in Step 2 of Checking the Initial Adjustment then reattach the throttle linkage to the governor lever with the bushing clip It is not necessary to reattach the damper or governor springs at this time Figure 5B 31 Clamping Throttle Against Stop 5B 21 Section 5B EFI Fuel System 3 Insert a nail into the hole in the top of the cross shaft Using light pressure rotate the governor shaft counterclockwise as far as it will turn then torque the hex nut on the clamping screw to 6 8 N m 60 in Ib See Figure 5B 34 Make sure that the governor arm has not twisted up or down after the nut has been tightened bh OK h al H D R Se K Ba d Be T Ca i P A L wi CH a k z a k J iJ a d Ce F e d l H P D Figure 5B 34 Adjusting Governor Sh
183. re the most common causes of valve harmful If the seat is good the valve could be reused stem corrosion Condensation occurs from improper after cleaning preservation during storage and when engine is repeatedly stopped before it has a chance to reach normal operating temperatures Replace corroded valves Overheating An exhaust valve subject to overheating will have a dark discoloration in the area above the valve guide Worn guides and faulty valve springs may cause this condition Also check for Excessive Combustion Temperatures The white clogged air intake and blocked fins when this deposits seen here indicate very high combustion condition is noted temperatures usually due to a lean fuel mixture 10 7 Section 10 Inspection and Reconditioning Valve Guides If a valve guide is worn beyond specifications it will not guide the valve in a straight line This may result in burnt valve faces or seats loss of compression and excessive oil consumption To check valve guide to valve stem clearance thoroughly clean the valve guide and using a split ball gauge measure the inside diameter Then using an outside micrometer measure the diameter of the valve stem at several points on the stem where it moves in the valve guide Use the largest stem diameter to calculate the clearance If the intake clearance exceeds 0 038 0 076 mm 0 0015 0 003 in or the exhaust clearance exceeds 0 050 0 088 mm 0 0020 0 0035 in de
184. re used on some models instead of hex nuts Figure 9 8 Removing Lower Flywheel Cover 2 Ifa pulse style fuel pump is used disconnect the fuel line from the pump outlet and disconnect the pulse line from the fuel pump fitting See Figure 9 9 Oil Filter Oil Drain Plug Figure 9 7 Oil Drain Plugs and Oil Filter 2 Remove and discard the oil filter Figure 9 9 Fuel Line and Pump Pulse Line 3 Disconnect the upper radiator hose from the radiator and the lower radiator hose from the inlet of the water pump See Figure 9 10 9 3 Section 9 Disassembly Figure 9 10 Disconnecting Upper and Lower Radiator Hose 4 Figure 9 11 Remove U Remove the four screws securing the two upper radiator supports to the air cleaner mounting bracket See Figure 9 11 a H pper Radiator Support Screws 9 9 4 Carefully tilt pull the radiator forward slightly to clear the fan and lift the complete assembly out of the lower mounting bracket See Figure GE NOTE Do not allow the cooling fins of the radiator to contact the fan blades Figure 9 12 Removing the Radiator 6 Disconnect the connector plug from the rectifier regulator and remove the mounting plate with rectifier regulator attached N Figure 9 13 Disconnecting the Rectifier Regulator 7 Remove the four screws securing the LH and RH side mounting brackets to the crankcase Pull the complete mount assembly forward to re
185. rest When fuel is being consumed the float will drop and fuel pressure will push the inlet needle away from the seat allowing more fuel to enter the bowl When demand ceases the buoyant force of the float will again overcome the fuel pressure and stop the flow High Altitude Operation When operating the engine at altitudes of 1500 m 5000 ft and above the fuel mixture tends to get overrich This can cause conditions such as black sooty exhaust smoke misfiring loss of speed and power poor fuel economy and poor or slow governor response To compensate for the effects of high altitude a special high altitude main jet can be installed High altitude jets are sold in kits which include the jet and necessary gaskets Refer to the Parts Manual for the correct kit number 5 4 Fuel Shut Off Solenoid Most carburetors are equipped with a fuel shut off solenoid The solenoid has a spring loaded pin that retracts when 12 volts is applied to the lead When power ceases the spring loaded pin extends and blocks the main jet Below is a simple test made with the engine off that can determine if the solenoid is functioning properly Use a separate switched 12 volt power supply to test 1 Shut off the fuel and remove the solenoid from the carburetor When the solenoid is loosened and removed gas will leak out of the carburetor Have a container ready to catch the fuel 2 Wipe the tip of the solenoid with a shop towel or blow it
186. rings excluding FASCO starters EE Starter Servicing Kit All Starters To remove and reinstall drive retaining rings and brushes SE Tools KLR 82411 Individual Component Available Starter Brush Holding Tool Solenoid Shift SE Tools KLR 82416 Tachometer Digital Inductive Design Technology Inc For checking operating speed RPM of an engine DTI 110 Vacuum Pressure Tester Kohler 25 761 22 5 Alternative to a water manometer e A A bran ed SE Tools KLR 82413 For sizing valve guides after installation Valve Guide Service Kit Courage Aegis Command OHC SE Tools KLR 82415 For servicing worn value guides 2 2 Section 2 Tools amp Aids mooo Electric Starter Drive Lubricant Inertia Drive Kohler 52 357 01 S Electric Starter Drive Lubricant Solenoid Shift Kohler 52 357 02 S RTV Silicone Sealant Kohler 25 597 07 S Loctite 5900 Heavy Body in 4 oz aerosol dispenser Only oxime based oil resistant RTV sealants such as those listed are approved for use Loctite Nos 5900 or 5910 are recommended for best sealing characteristics Loctite 5910 Loctite Ultra Black 598 Loctite Ultra Blue 587 Loctite Ultra Copper Spline Drive Lubricant Kohler 25 357 12 S 2 3 Section 2 Tools amp Aids Special Tools You Can Make 2 Remove the studs of a Posi Lock rod or grind off the aligning steps of a Command rod so the joint Flywheel Holding Tool surface is flat A flywheel holding tool can be ma
187. rods are available in STD crankpin size and 0 25 mm 0 010 in undersize The undersized rod is marked US 0 25 mm with purple ink on the rod shank Always refer to the appropriate parts information to ensure that correct replacements are used Closure Plate Assembly Inspection Inspect the oil seal in the closure plate and remove it if it is worn or damaged The new oil seal is installed after the closure plate is assembled to the crankcase See Install Closure Plate Oil Seal in Section 11 Inspect main bearing if so equipped for wear or damage refer to Section 1 Specifications Tolerances and Special Torque Values Replace closure plate assembly if required Governor Assembly Internal Inspection Inspect the governor gear teeth Replace the gear if it is worn chipped or if any teeth are missing Inspect the governor weights They should move freely in the governor gear Disassembly The governor gear must be replaced once it is removed from the closure plate NOTE The governor gear is held onto the shaft by small molded tabs in the gear When the gear 10 is removed from the shaft these tabs are destroyed and the gear must be replaced Therefore remove the gear only if absolutely necessary 1 Remove the regulating pin and governor gear assembly See Figure 10 13 10 11 Section 10 Inspection and Reconditioning Figure 10 13 Removing Governor Gear 2 Remove the locking tab thrust was
188. s 4 If the adapter was separated from the carburetor install a new gasket and mount the adapter with the breather hose connection port facing the rear Install and torque the mounting screws to 7 3 N m 65 in Ib Figure 11 82 Installing Carburetor Breather Adapter 11 23 Section 11 Reassembly 5 Connect the upper end of the breather hose to the fitting on the rear of the adapter See Figure 11 82 6 Connect the long end of the choke linkage to carburetor as shown in Figure 11 83 Figure 11 83 Connecting Choke Linkage 7 Ifamechanical fuel pump is used install the fuel line between the outlet of the fuel pump and the carburetor inlet and secure with the clamps See Figure 11 84 Figure 11 84 Connecting Fuel Line Mechanical Fuel Pump 4 Install External Governor Controls and Main Control Bracket 1 Install the governor lever onto the governor cross shaft If separated connect the throttle link to governor lever with the plastic bushing Hook the dampening spring into the small middle hole 11 24 Figure 11 85 Installing Connecting Governor Linkage 2 Figure 11 86 Setting Governor and Tightening Nut mm A Move the governor lever TOWARDS the carburetor as far as it will go wide open throttle and hold in this position Insert a nail into the hole in the cross shaft and rotate the shaft COUNTERCLOCKWISE as far as it will turn Then torque the hex nut to 6 8 N m 60 i
189. s Engine Cranks But Will Not Start 1 Empty fuel tank Fuel shut off valve closed Dirt or water in the fuel system Clogged fuel line Spark plug lead s disconnected Key switch or kill switch in off position Faulty spark plugs Faulty ignition module s Carburetor solenoid malfunction Diode in wiring harness failed in open circuit mode Vacuum fuel pump malfunction or oil in vacuum hose 12 Vacuum hose to fuel pump leaking cracked 13 Battery connected backwards 14 Safety interlock system engaged Se SS eee Ze EN Engine Starts But Does Not Keep Running 1 Restricted fuel tank cap vent 2 Poor fuel dirt or water in the fuel system 3 Faulty misadjusted choke or throttle controls 4 Loose wires or connections that short the kill terminal of ignition module to ground 5 Faulty cylinder head gasket 6 Faulty carburetor 7 Vacuum fuel pump malfunction or oil in vacuum hose 8 Leaking cracked vacuum hose to fuel pump 9 Intake system leak 10 Diode in wiring harness failed in open circuit mode Engines Starts Hard PTO drive is engaged Dirt or water in the fuel system Clogged fuel line Loose or faulty wires or connections Faulty or misadjusted choke or throttle controls Faulty spark plugs Low compression Weak spark Fuel pump malfunction causing lack of fuel Engine overheated cooling system problem Quality of fuel Flywheel key sheared Intake system leak
190. s proceed as follows NOTE Rings must be installed correctly Ring installation instructions are usually included with new ring sets Follow instructions carefully Use a piston ring expander to install rings see Figure 10 11 Install the bottom oil control ring first and the top compression ring last Refer to Figure 10 12 Figure 10 11 Installing Piston Rings With Expander Piston Ring End Gap Ss Identification Mark Top Compression Ring Oil Control Ring Three piece Expander Figure 10 12 Piston Ring Installation 1 Oil Control Ring Bottom Groove Install the expander and then the rails Make sure the ends of expander are not overlapped 2 Second Compression Ring Center Groove Install the center ring using a piston ring installation tool Make sure the pip mark is up 3 First Compression Ring Top Groove Install the top ring using a piston ring installation tool If no identification mark exists to denote up the ring is symmetrical and may be installed with either side up Connecting Rods Offset Stepped Cap Connecting Rods are used in all these engines Inspection and Service Check bearing area big end for excessive wear score marks running and side clearances refer to Section 1 Specifications Tolerances and Special Torque Values Replace rod and cap if scored or excessively worn Section 10 Inspection and Reconditioning Service replacement connecting
191. s only in well ventilated areas Keep sources of ignition away from the battery at all times Keep batteries out of the reach of children Remove all jewelry when servicing batteries Before disconnecting the negative ground cable make sure all switches are OFF If ON a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or gasoline vapors are present eer 1 Regularly check the level of electrolyte Add Overheated Chalky white deposits indicate very high distilled water as necessary to maintain the combustion temperatures This condition is usually recommended level accompanied by excessive gap erosion Lean carburetor settings an intake air leak or incorrect NOTE Do not overfill the battery Poor spark timing are normal causes for high combustion performance or early failure due to loss HEM Peravures of electrolyte will result Battery 2 Keep the cables terminals and external surfaces of the battery clean A build up of corrosive acid General or grime on the external surfaces can cause the battery to self discharge Self discharge occurs rapidly when moisture is present A 12 volt battery with 400 cold cranking amps is generally recommended for starting in all conditions A smaller capacity battery is often sufficient if an application is started only in warmer temperatures 3 Wash the cables terminals and external surfaces D Refer to the following table for minimum capacitie
192. s to 9 9 N m 88 in Ib Injector problems due to dirt or clogging are generally unlikely due to the design of the injectors the high fuel pressure and the detergent additives in the gasoline Symptoms that could be caused by dirty clogged injectors include rough idle hesitation stumble during acceleration or triggering of fault codes related to fuel delivery Injector clogging is usually caused by a buildup of deposits on the director plate restricting the flow of fuel resulting in a poor spray pattern Some contributing factors to injector clogging include higher than normal operating temperatures short operating intervals and dirty incorrect or poor quality fuel Cleaning of clogged injectors is not recommended they should be replaced Additives and higher grades of fuel can be used as a preventative measure if clogging has been a problem Ignition System General A high voltage solid state battery ignition system is used with the EFI system The ECU controls the ignition output and timing through transistorized control of the primary current delivered to the coils Based on input from the speed sensor the ECU determines the correct firing point for the speed at which the engine is running At the proper instant it releases the flow of primary current to the coil The primary current induces high voltage in the coil secondary which is then delivered to the spark plug Each coil fires every revolution but every oth
193. s with a mild baking soda and water solution cca based on anticipated ambient temperatures The Rinse thoroughly with clear water actual cold cranking requirement depends on engine size application and starting temperatures The cranking requirements increase as temperatures decrease and battery capacity shrinks Refer also to the NOTE Do not allow the baking soda solution to enter the cells as this will destroy the operating instructions of the equipment being this electrolyte engine powers for specific battery requirements Battery Test Battery Size Recommendations To test the battery you will need a DC voltmeter Perform the following steps See Figure 8 2 Above 32 F 0 C 200 cea minimum 1 Connect the voltmeter across the battery terminals 0 F to 32 F 18 C to 0 C 250 cca minimum 5F to 0 F 21 C to 18 C 300 cca minimum 2 Crank the engine If the battery drops below 9 volts while cranking the battery is too small 10 F 23 C or below 400 cca minimum discharged or faulty If the battery charge is not sufficient to turn over the engine recharge the battery Battery Maintenance Regular maintenance is necessary to prolong battery life 8 3 Section 8 Electrical System and Components Electronic CD Ignition Systems Operation of CD Ignition Systems Capacitive Discharge with Fixed Timing This system consists of the following components See Figure 8 3 e A magnet assembly which is p
194. shaft End Play with Section 11 Reassembly Camshaft Shims White 0 69215 0 73025 mm 0 02725 0 02875 in Blue 0 74295 0 78105 mm 0 02925 0 03075 in Red 0 79375 0 83185 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 0 94615 0 98425 mm 0 03725 0 03875 in Black 0 99695 1 03505 mm 0 03925 0 04075 in Oil Pump Assembly The oil pump is mounted to the inside of the closure plate If service was required and the oil pump was removed refer to the assembly procedures under Oil Pump Assembly in Section 10 Governor Assembly The governor assembly is located inside the closure plate If service was required and the governor was removed refer to the assembly procedures under Governor Assembly in Section 10 Thrust Bearing Washer and Shim Some specifications use a thrust bearing thrust washer and shim to control the end play of the crankshaft See Figure 11 14 If these items were noted during disassembly make sure they were reinstalled in the proper sequence as illustrated A different procedure must be followed to check and adjust crankshaft end play on these models D Ve e Sg Figure 11 14 Thrust Bearing Washer and Shim used on Some Models 11 5 Section 11 Reassembly The race for the thrust bearing presses loosely into the closure plate If it is not already installed push it into the crankshaft bore inside the closu
195. smoke When rings fail oil is allowed to enter the combustion chamber where it is burned along with the fuel High oil consumption can also occur when the piston ring end gap is incorrect because the ring cannot properly conform to the cylinder wall Oil control is Overheated or Deteriorated Oil Section 10 Inspection and Reconditioning also lost when ring gaps are not staggered during installation When cylinder temperatures get too high lacquer and varnish collect on pistons causing rings to stick which results in rapid wear A worn ring usually takes on a shiny or bright appearance Scratches on rings and pistons are caused by abrasive material such as carbon dirt or pieces of hard metal Detonation damage occurs when a portion of the fuel charge ignites spontaneously from heat and pressure shortly after ignition This creates two flame fronts which meet and explode to create extreme hammering pressures on a specific area of the piston Detonation generally occurs from using low octane fuels Preignition or ignition of the fuel charge before the timed spark can cause damage similar to detonation Preignition damage is often more severe than detonation damage Preignition is caused by a hot spot in the combustion chamber from sources such as glowing carbon deposits improperly seated valve or wrong spark plug See Figure 10 8 for some common types of piston and ring damage Ke RI K S HERTE a a ee ee x p RM
196. soline left over from the previous season to minimize gum deposits in your fuel system and to ensure easy starting e Donot add oil to the gasoline e Do not overfill the fuel tank Leave room for the fuel to expand Fuel Type Do not use leaded gasoline as component damage will result Any costs damages incurred as a result of using leaded fuel will not be warranted Use only clean fresh unleaded gasoline with a pump sticker octane rating of 87 or higher In countries using the Research method it should be 90 octane minimum Gasoline Alcohol blends Gasohol up to 10 ethyl alcohol 90 unleaded gasoline by volume is approved as a fuel for Kohler EFI engines Other gasoline alcohol blends are not approved Gasoline Ether blends Methyl Tertiary Butyl Ether MTBE and unleaded gasoline blends up to a maximum of 15 MTBE by volume are approved as a fuel for Kohler EFI engines Other gasoline ether blends are not approved EFI Fuel System Components General The Electronic Fuel Injection EFI system is a complete engine fuel and ignition management design The system includes the following principal components Fuel Pump Fuel Filter Fuel Rail Fuel Line s Fuel Pressure Regulator Fuel Injectors Throttle Body Intake Manifold Engine Control Unit ECU Ignition Coils Engine Coolant Temperature Sensor Throttle Position Sensor TPS Speed Sensor Oxygen Sensor Wire Harness Assembly amp Affiliated Wiring
197. sor MIL light will not go out when cranking Expected Engine Response None engine will not start or run as ECU is unable to estimate speed Possible Causes 1 Engine Speed Sensor Related a Sensor connector or wiring b Sensor loose or air gap incorrect 2 Speed Sensor Wheel Related a Damaged teeth b Gap section not registering 3 Engine Wire Harness Related a Pin circuit 9 and or 10 wiring or connectors 4 ECU Harness Related a ECU to harness connection problem Code 31 Source Fuel Mixture or Oxygen Sensor Explanation System to Lean Oxygen sensor not sending expected voltage to ECU Expected Engine Response System operates under open loop control only Until fault is detected and registered by ECU engine will run rich if oxygen sensor is shorted to ground or lean if it is shorted to battery voltage After fault is detected performance can vary depending on cause If performance is pretty good the problem is probably with the oxygen sensor wiring or connectors If the engine is still running rich laboring short on power or lean popping or misfiring 5B 30 the fuel mixture is suspect probably incorrect TPS initialization or low fuel pressure Possible Causes 1 TPS Initialization Incorrect a Lean condition check oxygen sensor signal with VOA and see Oxygen Sensor section 2 Engine Wire Harness Related a Pin circuit 20 wiring or connectors 3 Oxygen Sens
198. steady motion without interruption until the proper torque is achieved The frictional heat from the engaging threads may otherwise cause the locking compound to set prematurely If new screws are not available apply Loctite No 242 to the bottom four or five threads Then install and torque the screws to 11 3 N m 100 in Ib See Figure 11 38 2 Cylinder Head Figure 11 36 Cylinder Head Torque Sequence 7 Repeat the installation procedure for the 2 side cylinder head Install Push Rods and Rocker Arms 1 Note the mark or tag identifying the push rod as either intake or exhaust for cylinder 1 Lightly apply engine oil or grease to the ends of push 7 i rods and install Make sure that each push rod Figure 11 38 Installing and Torquing Rocker Arm ball seats in its respective hydraulic lifter socket Mounting Screws See Figure 11 37 4 Use a spanner wrench or rocker arm lifting tool NOTE Push rods must always be installed in see Section 2 to lift the rocker arms and position the same position as before disassembly the push rods underneath 5 Rotate the crankshaft so the piston in cylinder 2 is at top dead center on the compression stroke and repeat the steps for the remaining cylinder Do not interchange parts from one cylinder head with parts from the other cylinder head 6 Rotate the crankshaft to check for free operation of the valve train Check the clearance between valve spring coils at full lift
199. sults and recommended corrective action are covered in Section 7 3 4 eee Defective rings worn cylinder walls or blown head gasket ois Defective exhaust valve improper seating PT Defective intake valve improper seating dees Piston rings and cylinder in good condition been Engine is still usable but there is some wear present Customer should start planning for overhaul or replacement rr Rings and or cylinder have considerable wear Engine should be reconditioned or replaced Section 4 Air Cleaner System Air Cleaners General These engines are equipped with Kohler s heavy duty cyclonic air cleaner system See Figure 4 1 The air cleaner includes a high density pleated paper main element see Figure 4 2 and inner safety element see Figure 4 3 Figure 4 3 Air Cleaner Element with Inner Element Air Cleaner Element Service Every 250 hours of operation more often under extremely dusty or dirty conditions replace the paper element and cylindrical inner element Follow these steps Figure 4 1 Heavy duty Air Cleaner Assembly 1 Unhook the two retaining clips and remove the end cap from the air cleaner housing See Figure 4 4 2 Pull the air cleaner element out of the housing See Figure 4 5 4 1 Section 4 Air Cleaner and Air Intake System Figure 4 5 Removing Air Cleaner Element 3 Check the condition of the inner safety element It should be replaced whenever it a
200. t it can be checked to determine its operating condition When proper tension is obtained individually Before removing and testing the thermostat make remove each capscrew of the lower pulley apply sure all other possible causes such as debris Loctite No 242 to the threads and reinstall Torque accumulation obstruction leaks belt or fan failure each of the four capscrews in a criss cross sequence to COOlant level and damaged components are 24 5 N m 215 in Ib See Figure 7 11 eliminated as possible causes For a new belt assemble the lower pulley with all three shims between the pulley halves For a used original belt being reinstalled assemble with two or one shim s between the pulley halves and remaining shim s on the outside front of the outer pulley half Check the belt tension as described above 7 5 Section 7 Cooling System ntake Manif d em D WA H n i d Zi Kaes per Es F 8 Figure 7 12 Intake Thermostat To Test Remove the thermostat from the system Hang or suspend the thermostat by its frame in a container of water so the thermostat does not touch the bottom of the container Heat the water and measure the temperature an oven thermometer can be used The spring loaded valve of the thermostat should begin to open at 79 4 C 175 F and can be completely open at 90 C 195 F If the valve opens at a temperature more than 10 degrees below the specified opening or fails to
201. t see Section 2 replacement is necessary to the lever and shaft Clean and check the other starter parts for wear or damage as required 1 Perform steps 1 5 in Starter Disassembly Starter Reassembly 2 Remove the two screws securing the brush 1 holder assembly to the end cap plate Note the orientation for reassembly later See Figure 8 30 Discard the old brush holder assembly Apply drive lubricant see Section 2 to the armature shaft splines Install the drive pinion onto the armature shaft 2 Install and assemble the stop collar retainer assembly a Install the stop collar down onto the armature shaft with the counter bore recess up b Install a new retainer in the larger rear groove of the armature shaft Squeeze with a pliers to compress it in the groove c Slide the stop collar up and lock it into place so the recess surrounds the retainer in the Fa groove If necessary rotate the pinion Figure 8 30 Removing Brush Holder outward on the armature splines against the retainer to help seat the collar around the 3 Clean the component parts as required retainer 4 The new brushes and springs come preassembled in a brush holder with a protective sleeve that will also serve as an installation tool See Figure 8 31 Figure 8 32 Installing Stop Collar and Retainer NOTE Always use a new retainer Do not reuse old retainers which have been removed Figure 8 31 Service Brush Kit
202. tem Terminal 85 e Terminal 87 Ignition Switch ee Feed To Ignition Voltage Hl Coils Fuel Injectors and Fuel Pump Terminal 86 ECU Controlled Ground Terminal 87A i Not used Terminal 30 Permanent Battery Voltage Figure 5B 11 Relay Connector a Clean the connection and check wiring if circuit was not completed 3 Set the meter for DC voltage Touch the red tester lead to the 30 terminal in relay connector A reading of 12 volts should be indicated at all times 4 Connect the red lead of meter to the 85 terminal in the relay connector Turn the key switch to the on position Battery voltage should be present a No voltage present indicates a problem in the wiring or at the connector b If voltage is present the wiring to the connector is good Turn ignition switch off and proceed to test 5 to test the relay Terminal 87 Terminal 86 Feed To ECU Controlled Ignition Coils Ground Fuel Injectors and Fuel Pump Terminal 85 7 Ignition Switch 874 EG pi Voltage Not used i Terminal a Terminal 30 Permanent Battery Voltage Figure 5B 12 Relay Terminal Details 5B 12 5 Connect an ohmmeter Rx1 scale between the 85 and 86 terminals in the relay There should be continuity 6 Attach ohmmeter leads to the 30 and 87 terminals in relay Initially there should be no continuity Using a 12 volt power supply connect the positive lead
203. termine whether the valve stem or guide is responsible for the excessive clearance Maximum I D wear on the intake valve guide is 7 134 mm 0 2809 in while 7 159 mm 0 2819 in is the maximum allowed on the exhaust guide The guides are not removable but can be reamed 0 25 mm 0 010 in oversize Valves with 0 25 mm oversize stems must then be used If the guides are within limits but the valve stems are worn beyond limits replace with new valves Valve Seat Inserts Hardened steel alloy intake and exhaust valve seat inserts are press fitted into the cylinder head The inserts are not replaceable on the engines but can be reconditioned if not too badly pitted or distorted If cracked or badly warped the cylinder head should be replaced Recondition the valve seat inserts following the instructions provided with the valve seat cutter being used A typical cutter is shown in Figure 10 7 The final cut should be made with an 89 cutter as specified for the valve seat angle in Figure 10 6 With the proper 45 valve face angle as specified in Figure 10 6 and the valve seat cut properly 44 5 as measured from centerline when cut 89 this would result in the desired 0 5 1 0 full cut interference angle where the maximum pressure occurs on the outside diameters of valve face and seat 10 8 Valve Seat Cutter Figure 10 7 Typical Valve Seat Cutter Lapping Valves Reground or new valves must be lapped in to provid
204. tes an interrupted input signal corresponding to specific crankshaft position 84 BTDC for cylinder 1 This signal serves as a reference for the control of ignition timing by the ECU Synchronization of the inductive speed pickup and crankshaft position takes place during the first two Section 5B EFI Fuel System revolutions each time the engine is started The sensor must be properly connected at all times If the sensor becomes disconnected for any reason the engine will quit running Figure 5B 2 Engine Speed Sensor Service The engine speed sensor is a sealed non serviceable assembly If diagnosis indicates a problem within this area check and test as follows 1 Check the mounting and air gap of sensor It must be 1 5 mm 0 25 mm 0 059 0 010 in 2 Inspect the wiring and connections for damage or problems 3 Make sure the engine has resistor type spark plugs 4 Disconnect main harness connector from ECU 5 Connect an ohmmeter between pin terminals 9 and 10 in the plug See chart on page 5B 24 A resistance value of 750 1000 Q at room temperature 20 C 68 F should be obtained If resistance is correct check the mounting air gap toothed ring gear damage runout etc and flywheel key 6 Disconnect the speed sensor connector from wiring harness It is the connector with one heavy black lead see Figure 5B 3 Viewing the connector as shown dual aligning rails on top test the resistanc
205. that the key is properly seated and parallel with the shaft See Figure 3 Install the hex flange screw and washer See 11 67 Figure 11 69 NOTE Make sure the flywheel key is installed properly in the keyway The flywheel can become cracked or damaged if the key is improperly installed Figure 11 69 Installing Flywheel Mounting Hardware 4 Use a flywheel holding tool to hold the flywheel zu and torque the hex flange screw to 66 4 N m nd of 49 ft Ib See Figure 11 70 Figure 11 67 Installing Key in Flywheel E Crankshaft 2 Thread the two starter mounting bolts into the hub of flywheel or use the flywheel puller to serve as a handle and set the flywheel in place See Figure 11 68 Figure 11 70 Torquing Flywheel Bolt 11 20 5 Using a light visually check that sufficient clearance exists between the cooling system components and bottom of flywheel See Figure 11 71 e If clearance is OK continue with installation of ignition modules e If clearance is insufficient or contact is noted remove the flywheel and adjust as required Reinstall the flywheel and recheck for adequate clearance i Figure 11 71 Clearance Check Verification Install Ignition Modules 1 Rotate the flywheel magnet away from the ignition module mounting bosses 2 Install the two ignition modules with the ground terminal out onto the crankcase mounting bosses using the four hex flange screws Slide the ignit
206. the fuel pump 3 Ifthe pump did not activate step 2 disconnect the plug from the fuel pump Connect a DC voltmeter across the terminals in the plug turn on the key switch and observe if a minimum of 7 volts is present If voltage is between 7 and 14 turn key switch off and connect an ohmmeter between the terminals on the pump to check for continuity a If there was no continuity between the pump terminals replace the fuel pump b If the voltage was below 7 test the wiring harness and relay as covered in the Electrical Relay section Section 5B EFI Fuel System 4 If voltage at the plug was good and there was continuity across the pump terminals reconnect the plug to the pump making sure you have a good connection Turn on the key switch and listen for the pump to activate a If the pump starts repeat steps 1 and 2 to verify correct pressure b Ifthe pump still does not operate replace it Fuel Pressure Regulator Figure 5B 21 External Fuel Pressure Regulator with Base General The fuel pressure regulator assembly maintains the required operating system pressure of 39 psi 3 A rubber fiber diaphragm see Figure 5B 22 divides the regulator into two separate sections the fuel chamber and the pressure regulating chamber The pressure regulating spring presses against the valve holder part of the diaphragm pressing the valve against the valve seat The combination of atmospheric pressure and reg
207. the oil pump body 2 0 mm Governor Cross Lubricate the O Ring with oil and make sure it 0 0787 In Shaft Seal remains in the groove as the pickup is being y installed 2 Install the rotor 3 Install the oil pump body to the closure plate and secure with the two hex flange screws Torque the hex flange screws as follows a Install fastener into location No 1 and lightly tighten to position pump b Install fastener into location No 2 and fully torque to the recommended value Figure 10 17 Governor Cross Shaft Oil Seal Position c Torque fastener in location No 1 to the recommended value First Time Installation 10 7 N m 95 in 1b All Reinstallations 6 7 N m 60 in Ib Water Pump The water coolant pump consists of a sealed impeller 4 After torquing rotate the gear and check for assembly which includes the outer cover and a freedom of movement Make sure there is no cogged drive pulley When the pump is mounted to binding If binding occurs loosen the screws the crankcase the impeller fits into a cast recess and reposition the pump retorque the hex flange the cover seals against an O Ring outside the screws and recheck the movement perimeter of the recess See Figure 10 19 Governor Cross Shaft Oil Seal If the governor cross shaft seal is damaged and or leaks replace it using the following procedure Remove the oil seal from the crankcase and replace it with a new one Install the new seal to dept
208. the regulator housing Pull the regulator out of 6 Install the new regulator by carefully pushing the housing See Figure 5B 23 and rotating it slightly into the base or housing Internal In Tank Regulator 7 Secure with the retaining ring Be careful not to Remove the three screws securing the retaining dent or damage the body of the regulator as ring and regulator in the base holder assembly operating performance can be affected Grasp and pull the regulator out of the base holder See Figure 5B 24 8 Reassemble any parts removed in step 3 9 Reconnect the negative battery cable 10 Recheck the regulated system pressure at the fuel rail test valve 5B 18 Fuel Filter EFI engines use a high volume high pressure 10 15 micron in line fuel filter Figure 5B 25 In Line Fuel Filter Service Fuel filter replacement is recommended every 1500 hours of operation or more frequently under extremely dusty or dirty conditions Use only the specified filter and install it according to the directional arrows DO NOT use a substitute filter as operating performance and safety can be affected Relieve system pressure through the safety valve in the fuel rail before servicing Fuel Rail e E ZA 7 G L Fuel Rail Figure 5B 26 Manifold Assembly General The fuel rail is a formed tube assembly that feeds fuel to the top of the injectors The tops of the injectors fit into formed cups in the fuel rail When the
209. ther sensor signals is processed by the ECU and compared to the internal pre programmed maps to determine the required fuel and ignition settings for the amount of load The correct position of the TPS is established and set at the factory Do not loosen the TPS or alter the mounting position unless absolutely required by fault code diagnosis or throttle shaft service If the TPS is loosened or repositioned the TPS Initialization Procedure see pages 5B 7 and 5B 8 must be performed to re establish the baseline relationship between the ECU and the TPS Service The TPS is a sealed non serviceable assembly If diagnosis indicates a bad sensor complete replacement is necessary If a blink code indicates a problem with the TPS it can be tested as follows 1 Counting the number of turns back out the idle speed adjusting screw counterclockwise until the throttle plate can be closed completely 2 Disconnect the main harness connector from the ECU but leave the TPS mounted to the throttle body manifold 3 Connect the ohmmeter leads as follows See chart on page 5B 24 Connect the Red positive ohmmeter lead to 8 pin terminal and the Black negative ohmmeter lead to 4 pin terminal Hold the throttle closed and check the resistance It should be 800 1200 Q 4 Leave the leads connected to the pin terminals as described in step 3 Rotate the throttle shaft slowly counterclockwise to the full throttle position Monitor
210. to the threaded section of the fitting IMPORTANT The 90 fitting in the crankcase is installed and sealed at the factory in a specific position Special tools and procedures are involved Do not loosen remove or alter the mounting position of this fitting at any time 11 15 Section 11 Reassembly Figure 11 51 Water Pump Torque Sequence NOTE When installation is complete the tangs of the two hose clamps should face outward away from the flywheel and slightly down See Figure 11 52 Figure 11 52 Transfer Tube Hose Clamp s Detail 9 Push down on the formed tube and hold in this position to prevent it from pivoting upward when tightening the hex cap Torque the hex cap to 22 6 N m 200 in lb to secure the joint connection Support the fitting with a wrench while torquing if possible to prevent applying unnecessary pressure on fitting and joint See Figure 11 53 Check that the formed tube and hose section have not been pulled up 11 16 10 11 Figure 11 54 Installing Cam Pulley and Belt Figure 11 53 Torquing the Hex Cap on Fitting After Pump Installation Install the drive belt onto the cogged pulley of water pump then around the cam pulley Slide the cam pulley with the belt attached down onto the keyway end of the camshaft Be careful not to push the key out of the keyway and or into the seal when installing the pulley See Figure 11 54 L NE eg e ES Check or use a feele
211. tor leads within the clamp and close the loop See Figure 11 65 me Figure 11 65 Routing Stator Leads through Clamp on Adapter 3 If the violet B charge lead is separate from the main harness secure it to the wiring harness with a tie strap directly above the clamp See Figure 11 66 Figure 11 66 Side View of Stator and B Leads Tied to Clamp on Adapter Install Flywheel A WARNING Damaging Crankshaft and Flywheel Can Cause Personal Injury Using improper procedures to install the flywheel can crack or damage the crankshaft and or flywheel This not only causes extensive engine damage but can also cause personal injury since broken fragments could be thrown from the engine Always observe and use the following precautions and procedures when installing the flywheel 11 19 Section 11 Reassembly NOTE Before installing the flywheel make sure the crankshaft taper and flywheel hub are clean dry and completely free of lubricants The presence of lubricants can cause the flywheel to be overstressed and damaged when the hex flange screw is torqued to specifications NOTE Always use a flywheel strap wrench or holding tool to hold the flywheel when tightening the flywheel fastener Do not use any type of bar or wedge to hold the flywheel as component damage and personal injury could result 1 Install the woodruff key into the keyway of the Figure 11 68 Installing Flywheel crankshaft Make sure
212. tor switch SCS to turn on With the device switch ON the charging capacitor C1 is directly connected across the primary P of the output transformer T1 As the capacitor discharges the current initiates a fast rising flux field in the transformer core A high voltage pulse is generated from this action into the secondary winding of the transformer This pulse is delivered to the spark plug gap Ionization of the gap occurs resulting in an arc at the plug electrodes This spark ignites the fuel air mixture in the combustion chamber Troubleshooting CD Ignition Systems The CD ignition systems are designed to be trouble free for the life of the engine Other than periodically checking replacing the spark plugs no maintenance or timing adjustments are necessary or possible Mechanical systems do occasionally fail or break down however so the following troubleshooting information is provided to help you get to the root of a reported problem A CAUTION High Energy Electric Spark The CD ignition systems produce a high energy electric spark but the spark must be discharged or damage to the system can result Do not crank or run an engine with a spark plug lead disconnected Always provide a path for the spark to discharge to ground 8 5 Section 8 Electrical System and Components Reported ignition problems are most often due to poor connections Before beginning the test procedure check all external wiring Be certain a
213. tors Faulty coils Faulty spark plugs aS Set eee e Ae m Engine starts hard or fails to start when hot 1 Fuel pressure low Fuel pump not running Engine temp sensor faulty Insufficient fuel delivery TPS faulty TPS offset incorrect Speed sensor loose or faulty Faulty injectors Faulty spark plugs EE IS Engine misses hesitates or stalls under load 1 Fuel injector s fuel filter fuel line or fuel pick up dirty restricted Dirty air cleaner Insufficient fuel pressure or fuel delivery Vacuum intake air leak Improper governor setting adjustment or operation Speed sensor malfunction 7 TPS faulty mounting problem or TPS Initialization Procedure incorrect 8 Bad coil s spark plug s or wires SH Tex Sr Se gt Low Power 1 Faulty malfunctioning ignition system Dirty air filter Insufficient fuel delivery Improper governor adjustment Plugged restricted exhaust One injector not working Basic engine problem exists TPS faulty or mounting exists Throttle plates in throttle body intake manifold not fully opening to WOT stop if so equipped EC Ee Electrical System The EFI system is a 12 VDC negative ground system designed to operate down to a minimum of 7 0 volts If system voltage drops below this level the operation of voltage sensitive components such as the ECU fuel pump and injectors will be intermittent or disrupted causing erratic operation or hard starting A fully charged 12
214. ts or problems reported by customers For each problem you will find a list of the most likely causes or areas to be investigated Always start by checking if there are any stored fault codes to guide you in the right direction Engine starts hard or fails to start when cold Code 31 42 51 52 56 1 Fuel pump or relay not activating operational Engine Coolant Temperature sensor faulty Fuel pressure insufficient incorrect Fuel injector s leaking Fuel injector s fuel filter fuel line or fuel pick up dirty clogged or restricted Speed sensor malfunction Stale fuel Low system voltage Bad spark plug s or coil s Base ignition timing incorrect E E EE A GA Engine starts hard or fails to start when warm Code 42 51 52 1 Insufficient fuel system pressure Engine Coolant Temperature sensor faulty Fuel injector s leaking Fuel injector s fuel filter fuel line or fuel pick up dirty restricted Low fuel pressure Wrong grade of fuel Bad spark plug s or coil s Low system voltage Speed sensor problem Base ignition timing problem Leg bag GE E AA 1 Engine stalls or idles roughly Code 22 31 34 42 43 51 52 1 Vacuum intake air leak 2 Fuel injector s fuel filter fuel line or fuel pick up dirty clogged restricted 3 Insufficient fuel pressure delivery 4 Engine Coolant Temperature sensor faulty 5 TPS faulty or TPS Initialization Procedure incorre
215. uel to the carburetor Fuel then enters the carburetor float bowl and is moved into the carburetor body There the fuel is mixed with air This fuel air mixture is then burned in the engine combustion chamber Fuel Recommendations General Recommendations Purchase gasoline in small quantities and store in clean approved containers A container with a capacity of 2 gallons or less with a pouring spout is recommended Such a container is easier to handle and helps eliminate spillage during refueling e Do not use gasoline left over from the previous season to minimize gum deposits in your fuel system and to ensure easy starting e Do not add oil to the gasoline e Do not overfill the fuel tank Leave room for the fuel to expand Fuel Type For best results use only clean fresh unleaded gasoline with a pump sticker octane rating of 87 or higher In countries using the Research fuel rating method it should be 90 octane minimum Unleaded gasoline is recommended as it leaves less combustion chamber deposits and reduces harmful exhaust emissions Leaded gasoline is not recommended and must not be used on EFI engines or on other models where exhaust emissions are regulated Gasoline Alcohol blends Gasohol up to 10 ethyl alcohol 90 unleaded gasoline by volume is approved as a fuel for Kohler engines Other gasoline alcohol blends are not approved Gasoline Ether blends Methyl Tertiary Butyl Ether MTBE and unleaded
216. ulating spring tension equals the desired operating pressure Any time the fuel pressure against the bottom of the diaphragm exceeds the desired top pressure the valve opens relieving the excess pressure returning the excess fuel back to the tank 5B 17 Section 5B EFI Fuel System Pressure Regulating Pressure Regulating Chamber Diaphragm nat aon x S KL Lam pes Valve Seat Uf Le ll aJn Fuel Chamber S mehr en Outlet Port Return Port to tank to fuel rail Figure 5B 22 Fuel Pressure Regulator Details Service Depending on the application the regulator may be located in the fuel tank along with the fuel pump or outside the tank just down line from the pump The regulator is a sealed non serviceable assembly If it is faulty it must be separated from the base holder assembly and replaced as follows 1 Shut engine off make sure engine is cool and disconnect the negative battery cable 2 Depressurize fuel system through test valve in fuel rail see fuel warning on page SB 2 Figure 5B 24 Internal Regulator and Base Holder 3 Access the regulator assembly as required and 5 Always use new O Rings and hose clamps when clean any dirt or foreign material away from the installing a regulator A new replacement area regulator will have new O Rings already installed Lubricate the O Rings with light grease 4 External Regulator or oil Remove the retaining ring securing the regulator in
217. uld cause the rings to skip and wear excessively too steep an angle will result in high oil consumption See Figure 10 3 Figure 10 3 Cylinder Bore Crosshatch After Honing Section 10 Inspection and Reconditioning 4 After resizing check the bore for roundness taper and size Use an inside micrometer telescoping gauge or bore gauge to take measurements The measurements should be taken at three locations in the cylinder at the top middle and bottom Two measurements should be taken perpendicular to each other at each of the three locations Clean Cylinder Bore After Honing Proper cleaning of the cylinder walls following boring and or honing is very critical to a successful overhaul Machining grit left in the cylinder bore can destroy an engine in less than one hour of operation after a rebuild The final cleaning operation should always be a thorough scrubbing with a brush and hot soapy water Use a strong detergent that is capable of breaking down the machining oil while maintaining a good level of suds If the suds break down during cleaning discard the dirty water and start again with more hot water and detergent Following the scrubbing rinse the cylinder with very hot clear water dry it completely and apply a light coating of engine oil to prevent rusting Measuring Piston to Bore Clearance Before installing the piston into the cylinder bore it is necessary that the clearance be accurately checked T
218. up by the battery During certain operating periods such as cold starts warm up acceleration etc an air fuel ratio richer than 14 7 1 is required and the system operates in an open loop mode In open loop operation the monitoring of exhaust gases output is not used and the controlling adjustments are based on the primary sensor signals and programmed maps only The system operates open loop whenever the three conditions for closed loop operation above are not being met 5B 3 Section 5B EFI Fuel System Important Service Notes e Cleanliness is essential and must be maintained at all times when servicing or working on the EFI system Dirt even in small quantities can cause significant problems e Clean any joint or fitting with parts cleaning solvent before opening to prevent dirt from entering the system e Always depressurize the fuel system through the test valve in fuel rail before disconnecting or servicing any fuel system components See fuel warning on page 5B 2 e Never attempt to service any fuel system component while engine is running or ignition switch is on e Do not use compressed air if the system is open Cover any parts removed and wrap any open joints with plastic if they will remain open for any length of time New parts should be removed from their protective packaging just prior to installation e Avoid direct water or spray contact with system components e Do
219. ure sealing surfaces of the crankcase and breather cover are clean and free of all old gasket material Clean with an aerosol type gasket remover or cleaning solvent DO NOT scrape the surfaces as this can result in leakage 2 Check to make sure there are no nicks or burrs on the sealing surfaces 3 Install the breather reed and breather reed retainer onto the crankcase and secure with the hex flange screw Hold the assembly in line when tightening Torque the screw to 3 9 N m 35 in Ib See Figure 11 23 Figure 11 23 Installing Breather Reed 4 Install the breather filter into the cavity in the crankcase See Figure 11 24 Figure 11 24 Installing Breather Filter 5 Carefully install the breather cover gasket and breather cover onto the crankcase See Figure 11 25 Figure 11 25 Installing and Torquing Breather Cover Screws Figure 11 27 Oil Sentry Switch Installed 6 Install and torque the four breather cover hex flange screws to 7 3 N m 65 in Ib in the g sequence shown in Figure 11 26 G Section 11 Reassembly Figure 11 26 Breather Cover Fastener Torque Sequence Install the pipe plug or Oil Sentry switch as equipped into the tapped breather port if removed earlier Apply pipe sealant with Teflon Loctite 59241 or equivalent to the threads Torque to 4 5 N m 40 in Ib If Oil Sentry switch is mounted to the side of crankcase torque the switch to 12 4 N m 110
220. usetesctasvnenszesveuesarsmennuiromsaneossesvontses 6 2 N m 55 in lb Valves and Valve Lifters Hydraulic Valve Lifter to Crankcase Running Clearance eee 0 0124 0 0501 mm 0 0005 0 0020 in Intake Valve Stem to Valve Guide Running Clearance uu eee 0 038 0 076 mm 0 0015 0 0030 in Exhaust Valve Stem to Valve Guide Running Clearance eee 0 050 0 088 mm 0 0020 0 0035 in Intake Valve Guide I D IN E 7 038 7 058 mm 0 2771 0 2779 in ee VCO LANG eege 7 134 mm 0 2809 in Intake Valve Stem Diameter ET 6 982 7 000 mm 0 2749 0 2756 in Exhaust Valve Guide I D IT 7 038 7 058 mm 0 2771 0 2779 in Max Ee 7 159 mm 0 2819 in Measure 6 mm 0 236 in above the bottom of the piston skirt at right angles to the piston pin Section 1 Safety and General Information Valves and Valve Lifters cont Exhaust Valve Stem Diameter KT 6 970 6 988 mm 0 2744 0 2751 in Valve Guide Reamer Size MEIN Oe gsc cess gir eee ee savas E EEE E A eaeaaa es E E T 7 048 mm 0 2775 in nt KEE 7 298 mm 0 2873 in rake Viel E EE 8 88 mm 0 3496 in PEAS A E 8 88 mm 0 3496 in Nominal valve Seat ANg atacs octge psc yuaevser adenomas tats ecaueraeespeeseceensnachaepnrcaruateasoneoratts 45 Water Pump EE EEN 9 9 N m 88 in Ib Pettey Mounting ocrew Eer sessin nea are 9 9 N m 88 in Ib General Torque Values Metric Fastener Torque Recommendations for Standard Applications Tightening Torque N m in Ib or 20 Property Class Noncritical
221. ush it all the way in See Figure 6 2 Figure 6 2 Checking Oil Level 4 Remove the dipstick and check the oil level The level should be between the F and L marks If low add oil of the proper type to bring the level up to the F mark Reinstall the oil fill cap and dipstick F Mark TI Operating Range IL Figure 6 3 Oil Level Marks on Dipstick NOTE To prevent extensive engine wear or damage always maintain the proper oil level in the crankcase Never operate the engine with the oil level below the L mark or above the F mark on the dipstick 6 2 Changing Oil and Oil Filter Change oil and oil filter after every 200 hours or annually whichever comes first more often under severe conditions Refill with service class SG SH SJ or higher oil as specified in the Viscosity Grades table on previous page Always use a genuine Kohler oil filter Use chart below to determine part number to order Oil Filter Part No Length 12 050 01 5 2 1 2 52 050 02 5 3 3 8 Change the oil while the engine is still warm The oil will flow freely and carry away more impurities Make sure the engine is level when filling or checking oil Drain Plug Figure 6 4 Oil Drain Plugs and Oil Filter Change the oil and oil filter as follows See Figure 6 4 1 To keep dirt debris etc out of the engine clean the area around the oil fill cap and the dipstick before removal 2 Remove on
222. usk Holder Pas e LEET 2 5 3 3 N m 22 29 in lb larer SOlCNOIG Paste Er 4 0 6 0 N m 35 53 in Ib Starter Solenoid Positive Brush Lead Retaining Nut Torque sses 8 0 11 0 N m 71 97 in Ib Fan Flywheel Kear Fan Shaft to Mounting Bracket Nut Tor ue sri nsssisansessaterontionnnsantaapsansoesnaasensnetes 15 8 N m 140 in Ib Pront Pan Assembly to Fan Shalt Nut TOGUE a icssisesconievntecussstarsansayeashoausverneehivnterares 15 8 N m 140 in 1b Fan Pulley Hub Assembly Fastener FOr ue issscunsotscssceajnsancensst ous canisaipunsosassetehwtiees 6 8 N m 60 in Ib Flywheel Retain SCrew TORQ sectiei Rna EE 66 4 N m 49 ft Ib Lower Flywheel Cover Mounting Screw Torque seses into hex or weld nuts 9 9 N m 88 in 1b into Timmerman clips nuts 2 2 2 8 N m 20 25 in 1b Lower Pulley DOU TEE 24 3 N m 215 in Ib Governor Governor Cross Shaft to Crankcase Running Clearance 0 0 eeeeseeseeeseeseceeeeeseeeees 0 025 0 126 mm 0 0009 0 0049 in Governor Cross Shaft O D NEE ee 7 949 8 000 mm 0 3129 0 3149 in E E Wea TINIE EE 7 936 mm 0 3124 in Governor Gear Shaft O D leet 5 990 6 000 mm 0 2358 0 2362 in MaK Wear Er E 5 977 mm 0 2353 in Governor Gear Shaft to Governor Gear Running Clearance n se 0 090 0 160 mm 0 0035 0 0063 in Ee EE Ela Coice ET 6 8 N m 60 in Ib Section 1 Safety and General Information Ignition Spark Plug Type Champion or equivalent vscsesceunvivedsssnnvaniiniseannnssecncsucansra
223. ve Bearing crankcase Rimming eerste ee gebueren 0 039 0 074 mm 0 0015 0 0029 in Connecting Rod Journal KEE eege 35 955 35 973 mm 1 4156 1 4163 in BR Dae EE er 35 94 mm 1 415 in E E E EEE E ea sae oes E oie E N E E T 0 018 mm 0 0007 in Max Ot Ie ON Ci secs acescerseeteccsecat tssirini ris i Nae ren r E raii 0 025 mm 0 0010 in Crankshaft T I R PIO Eod Crank Iin EDENO ciciren a e EAEE 0 15 mm 0 0059 in Entire Crank in V BloCka lt denecstunceasenecnesctinsncainuoesecdunveninetansietaraneneduancaneacatens 0 10 mm 0 0039 in Cylinder Bore Cylinder Bore I D New Dao AE I E E E E E EE ET E E 77 000 77 025 mm 3 0315 3 0325 in LECO ET O eebe 80 000 80 025 mm 3 1496 3 1506 in LEUU LA O LER O LE O ren 83 006 83 031 mm 3 2679 3 2689 in Section 1 Safety and General Information Cylinder Bore cont Max Wear Limit EELO O LEHOI oreren oe R E 77 063 mm 3 0340 in D A ere a e EE 80 065 mm 3 1522 in LE OCU ER OG LCA a E vac doseis lt areca ceude cesteectese sched sosseaneee 83 069 mm 3 2704 in Max Ouro D e EE 0 12 mm 0 0047 in Max Lid DOL geet 0 05 mm 0 0020 in Cylinder Head Cylinder Head Fastener Torque torque in 2 increments cee eeeeeeeeeeeeeees first to 16 9 N m 150 in Ib finally to 33 9 N m 300 in Ib Max Ol Ee 0 076 mm 0 003 in Rocker Pivot Retenuen 11 3 N m 100 in Ib Electric Starter EST Eeer Ate 5 6 9 0 N m 49 79 in 1b Dbl eet EE 15 3 N m 135 in Ib Olare t Br
224. ves are installed in the cylinder head Also replace the seals if they are deteriorated or damaged in any way Never reuse an old seal See Figure 11 30 11 10 Figure 11 32 Assembling Valves with a Valve Spring Compressor Install Cylinder Heads 1 Check to make sure there are no nicks or burrs on the sealing surfaces of the cylinder head or crankcase 2 Rotate the crankshaft to position the piston in cylinder 1 to top dead center TDC on the compression stroke 3 Install a new cylinder head gasket See Figure 11 33 NOTE Match numbers embossed on cylinder heads and crankcase Figure 11 33 Installing Head Gasket 4 Install the 1 cylinder head onto the 1 side mounting studs See Figure 11 34 Section 11 Reassembly Figure 11 34 Installing Cylinder Head 5 Install a plain washer onto each stud and secure with a hex flange nut 6 Torque the four hex flange nuts in two steps first to 16 9 N m 150 in Ib and then to 33 9 N m 300 in lb using the torque sequence shown in Figure 11 36 Figure 11 35 Torquing Cylinder Head Nuts 11 11 Section 11 Reassembly 2 Apply grease to the contacting surfaces of the rocker arms and rocker arm pivots Install the rocker arms and rocker arm pivots on the cylinder head 3 Install two new hex flange rocker arm screws with Dri Loc thread locking compound on the threads Torque the screws to 11 3 N m 100 in lb When tightening use a
225. volt battery with a minimum of 350 cold cranking amps is important in maintaining steady and reliable system operation Battery condition and state of charge should always be checked first when troubleshooting an operational problem Keep in mind that EF I related problems are more often caused by the wiring harness or connections than by the EFI components Even small amounts of corrosion or oxidation on the terminals can interfere with the milliamp currents used in system operation Cleaning the connectors and grounds will solve problems in many cases In an emergency situation simply disconnecting and reconnecting the connectors may clean up the contacts enough to restore operation at least temporarily Section 5B EFI Fuel System If a fault code indicates a problem with an electrical component disconnect the ECU connector and test for continuity between the component connector terminals and the corresponding terminals in the ECU connector using an ohmmeter Little or no resistance should be measured indicating that the wiring of that particular circuit is OK An illustrated listing of numerical terminal locations is provided below NOTE When performing voltage or continuity tests avoid putting excessive pressure on or against the connector pins Flat pin probes are recommended for testing to avoid spreading or bending the terminals 5B 23 Section 5B EFI Fuel System Permanent Battery Voltage Switched Battery Voltage
226. w and flat washer securing the cogged drive pulley to the camshaft See Figure 9 45 Figure 9 47 Loosening Hex Cap Section of Fitting 2 Remove the six screws securing the water pump to the crankcase See Figure 9 48 Figure 9 45 Removing Cam Pulley Hardware 2 Carefully lift the pulley off the camshaft and remove the belt from the water pump pulley See Figure 9 46 9 12 Section 9 Disassembly Remove Spark Plugs 1 Remove the spark plugs from the cylinder heads using a spark plug socket See Figure 9 50 Figure 9 48 Removing Water Pump Screws 3 Lift the water pump up and carefully work the ferruled end of the transfer tube out of the fitting Remove the water pump with the transfer tube Figure 9 50 Removing Spark Plugs and the hose section attached Remove and l discard the O Ring from within the channel of Remove Cylinder Heads and Valve Lifters the pump housing See Figure 9 49 1 Rotate the crankshaft of the engine until the valves of one cylinder are closed Loosen the rocker arm screws until the rocker arms can be pivoted to free the push rods See Figure 9 51 Figure 9 49 Removing the Water Pump Assembly from Block 4 Inspect and if necessary separate the transfer Figure 9 51 Loosening the Rocker Arm Screws tube and hose section from the water pump Remove the hose clamps noting their size differences and position of tangs 2 Remove the push rods and mark their l
227. ward the 2 side long intake manifold screw Figure 11 60 Installing Thermostat and Gasket 2 Attach the coolant by pass hose to the fittings in the water pump and intake manifold Secure with the clamps 8 Position the thermostat housing on the gasket and intake manifold The notch in manifold gasket and thermostat housing must all be aligned Install and torque the two hex flange screws to 9 9 N m 88 in 1b See Figure 11 61 Figure 11 62 Installing the By pass Hose 11 18 3 Connect the wire leads to the temperature warning switch audible alarm and or Oil Sentry switch as equipped Install Stator Assembly 1 Place a small amount of pipe sealant with Teflon Loctite 59241 or equivalent into the holes for the two stator mounting screws Position the stator assembly onto the mounting studs so the leads are at the bottom and directed out toward the 1 side in the 3 o clock position Align the mounting holes and install the two hex flange screws Torque each screw to 6 2 N m 55 in Ib See Figure 11 63 Install Starter Adapter 1 Install the starter adapter to the crankcase so the cutout is offset down and facing away from the flywheel side Install the two mounting screws and position the clamp for the stator leads on the upper screw See Figure 11 64 Torque the screws to 15 3 N m 135 in Ib Figure 11 64 Installing Starter Adapter Section 11 Reassembly 2 Place the sta
228. y RC14YC PD EE 0 76 mm 0 030 in opar Ne ET 24 4 29 8 N m 18 22 ft Ib IGeaquhaere h Module Aii E 0 203 0 305 mm 0 008 0 012 in lgnition Mod le Fastener ee 6 2 N m 55 in lb into new hole 4 0 N m 35 in Ib into used hole Rectifier Regulator Fastener Torque ssacssssossvonsusvisevasssvncarsontovansuevaososavnesecasorinateue 4 0 N m 35 in Ib Muffler Nie Retaining Nuts e 24 4 N m 216 in Ib Oil Filter Tier eege 3 4 1 turn after gasket contact Piston Piston Rings and Piston Pin I SOMO Piston PiN E 0 006 0 018 mm 0 0002 0 0007 in Piston Pin Bore I D lee 17 006 17 013 mm 0 6695 0 6698 in E NY Sa EE 17 025 mm 0 6703 in Piston Pin O D le eege 16 995 17 000 mm 0 6691 0 6693 in E E a E E 16 994 mm 0 6691 in Top Compression Ring to Groove Side Clearance LHO O CHOI enr E A E E 0 040 0 086 mm 0 0016 0 0034 in LAHEST EHO A eege 0 050 0 096 mm 0 0020 0 0038 in dee 0 014 0 041 mm 0 0005 0 0016 in Middle Compression Ring to Groove Side Clearance PTT GO AE 0 040 0 086 mm 0 0016 0 0034 in EE eege 0 030 0 076 mm 0 0012 0 0030 in LE OLA 3 LASO LE Tir E 0 012 0 039 mm 0 0004 0 0015 in Oil Control Ring to Groove Side Clearance CHOO EH OAU eege 0 046 0 196 mm 0 0018 0 0077 in LEST EHO a E ieee sebergee atncoceaousabebecceowueenachoess 0 046 0 196 mm 0 0018 0 0077 in Eege 0 026 0 176 mm 0 0010 0 0070 in Top and Middle Compression Ring End Gap LH630 LH640 New Bore ae RE 0 180 0 380 mm 0
229. y or property damage if the caution is ignored NOTE Note is used to notify people of installation operation or maintenance information that is important but not hazard related For Your Safety These precautions should be followed at all times Failure to follow these precautions could result in injury to yourself and others AA WARNING AA WARNING AA WARNING p23 Ci Accidental Starts can cause severe injury or death Disconnect and ground spark plug leads before servicing Accidental Starts Disabling engine Accidental starting can cause severe injury or death Before working on the engine or equipment disable the engine as follows 1 Disconnect the spark plug lead s 2 Disconnect negative battery cable from battery Rotating Parts can cause severe injury Stay away while engine is in operation Rotating Parts Keep hands feet hair and clothing away from all moving parts to prevent injury Never operate the engine with covers shrouds or guards removed Hot Parts can cause severe burns Do not touch engine while operating or just after stopping Hot Parts Engine components can get extremely hot from operation To prevent severe burns do not touch these areas while the engine is running or immediately after it is turned off Never operate the engine with heat shields or guards removed 1 1 Section 1 Safety and General Information A WARNING Explosive Fuel can c
230. ygen sensor if none already exists DO NOT get any on the tip as it will contaminate the sensor Install sensor and torque to 50 60 N m 37 44 ft Ib Section 5B EFI Fuel System 4 Reconnect the lead to wiring harness connector Make sure it can not contact hot surfaces moving parts etc 5 Test run the engine Electrical Relay Figure 5B 10 Electrical Relay General The electrical relay is used to supply power to the injectors coils and fuel pump When the key switch is turned on and all safety switch requirements met the relay provides 12 volts to the fuel pump circuit injectors and ignition coils The fuel pump circuit is continuously grounded so the pump is immediately activated and pressurizes the system Activation of the ignition coils and injectors is controlled by the ECU which grounds their respective circuits at the proper times Service A malfunctioning relay can result in starting or operating difficulties The relay and related wiring can be tested as follows 1 Disconnect the relay connector plug from the relay 2 Connect the black lead of a VOA meter to a chassis ground location Connect the red lead to the 86 terminal in relay connector see Figure 5B 11 Set meter to test resistance Rx1 Turn the key switch from off to on Meter should indicate continuity ground circuit is completed for 1 to 3 seconds Turn key switch back off 5B 11 Section 5B EFI Fuel Sys
231. ylinder stator with the plug in connector attached from heads with the by pass hose and wiring harness the engine See Figure 9 40 attached See Figures 9 42 and 9 43 Figure 9 40 Removing Stator Screws Figure 9 42 Removing the Six Intake Manifold Screws Remove Intake Manifold Thermostat Housing By pass Hose and Wiring Harness 1 Disconnect the by pass hose from the fitting on the water pump See Figure 9 41 Figure 9 43 Removing the Intake Manifold Assembly from the Engine 3 Remove the intake manifold gaskets Figure 9 41 Removing By pass Hose from Water Pump Fitting 9 11 Section 9 Disassembly 4 Further disassembly of the intake manifold components may be performed as necessary If the thermostat is to be removed loosen and remove the two hex flange screws securing the thermostat housing to the intake manifold Separate the housing and remove the thermostat discard the old gasket Disassembled components are shown in Figure 9 44 Figure 9 46 Removing Cam Pulley and Belt 3 Remove the camshaft key from the keyway Remove Water Pump and Transfer Tube 1 Loosen and unscrew the hex cap section securing the transfer tube to the 90 fitting in the crankcase See Figure 9 47 Support the fitting with a wrench when loosening the hex cap section Figure 9 44 Disassembled Intake Manifold Assembly Components Remove Camshaft Pulley and Water Pump Belt 1 Remove the hex flange scre

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