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Kohler TT321-A User's Manual

1. ES the dust seal counterbore in carburetor is clean and free of chips and burrs i oughty clean the carburetor body in a carburetor cleaner Refer to the cleaning instructions in the Fuel System section of the appropriate Engine Service Manual 2 Cutor grind approximately 1 4 in of material off the top end of the old throttle shaft Remove any burrs or rough edges Install the old throttle shaft into carburetor body to use as a pilot 3 Coat the outside surface of throttle shaft bushing with Loctite from kit Slip bushing over shaft Using installation tool from kit and vise press bushing into counterbore until it bottoms in carburetor body Refer to Figure 2 Bushing Installation Tool Figure 2 Installing Throttle Shaft Bushing 4 Allow Loctite to set for 5 10 minutes then remove throttle shaft 5 Install new throttle shaft with lever into carburetor body Rotate shaft and check for binding NOTE If binding occurs locate cause and correct before proceeding Use throttle shaft to align bushing if necessary 6 Remove shaft and allow Loctite to set for an additional 30 minutes before proceeding 7 Wipe away all excess Loctite from bushing and throttle shaft Install Throttle Shaft and Plate 1 Install throttie shaft into carburetor with cutout portion of shaft facing out t 2 Install throttle plate to throttle shaft Make sure marks are aligned and plate is positioned pr
2. KOHLER its i eEiniGines Installation ee J Throttle Shaft Repair Kit for Kohler Carburetors To replace the throttle shaft the carburetor must be raided from the engine The existing throttle plate and throttle lever will be reused with kit components A work bench vite metal file or grinder and screwdriver with smaller fiat blade will be needed The fuel bowl and float will also have to be removed for this repair New gaskets are provided in the kit A WARNING Explosive Fuel Gasoline may be present in the carburetor and fuel system Gasoline is extremely flammable and its vapors can explode if ignited Keep sparks open flame and other sources of ignition away from engine Wipe up spilled fuel immediately This Kit Contains A WARNING Prevent Eye Injury Suitable eye protection safety glasses goggles or face Qty Description hood should be wom for any procedure involving the use 1 Tool bushing installation spacer of compressed air punches hammers chisels drills or 4 Gasket bowl grinding tools 1 Gasket bow baffle 1 Gasket bowl retaining screw I b Carefully grind or file away the riveted portion 1 Screw 2 56 x 7 32 in brass of shaft remove throttle lever 1 Shaft throttle control 1 Bushing throttle shaft c Install throttle lever to new throttle shaft Make 1 Tube Loctite 609 sealer sure lever is installed correctly as noted in 3 Screw 3 56 x 7 32 in brass Step a 1 d Apply Loctite
3. ES the dust seal counterbore in carburetor is clean and free of chips and burrs i oughty clean the carburetor body in a carburetor cleaner Refer to the cleaning instructions in the Fuel System section of the appropriate Engine Service Manual 2 Cutor grind approximately 1 4 in of material off the top end of the old throttle shaft Remove any burrs or rough edges Install the old throttle shaft into carburetor body to use as a pilot 3 Coat the outside surface of throttle shaft bushing with Loctite from kit Slip bushing over shaft Using installation tool from kit and vise press bushing into counterbore until it bottoms in carburetor body Refer to Figure 2 Bushing Installation Tool Figure 2 Installing Throttle Shaft Bushing 4 Allow Loctite to set for 5 10 minutes then remove throttle shaft 5 Install new throttle shaft with lever into carburetor body Rotate shaft and check for binding NOTE If binding occurs locate cause and correct before proceeding Use throttle shaft to align bushing if necessary 6 Remove shaft and allow Loctite to set for an additional 30 minutes before proceeding 7 Wipe away all excess Loctite from bushing and throttle shaft Install Throttle Shaft and Plate 1 Install throttie shaft into carburetor with cutout portion of shaft facing out t 2 Install throttle plate to throttle shaft Make sure marks are aligned and plate is positioned properly
4. HLER its i eEiniGines Installation ee J Throttle Shaft Repair Kit for Kohler Carburetors To replace the throttle shaft the carburetor must be raided from the engine The existing throttle plate and throttle lever will be reused with kit components A work bench vite metal file or grinder and screwdriver with smaller fiat blade will be needed The fuel bowl and float will also have to be removed for this repair New gaskets are provided in the kit A WARNING Explosive Fuel Gasoline may be present in the carburetor and fuel system Gasoline is extremely flammable and its vapors can explode if ignited Keep sparks open flame and other sources of ignition away from engine Wipe up spilled fuel immediately This Kit Contains A WARNING Prevent Eye Injury Suitable eye protection safety glasses goggles or face Qty Description hood should be wom for any procedure involving the use 1 Tool bushing installation spacer of compressed air punches hammers chisels drills or 4 Gasket bowl grinding tools 1 Gasket bow baffle 1 Gasket bowl retaining screw I b Carefully grind or file away the riveted portion 1 Screw 2 56 x 7 32 in brass of shaft remove throttle lever 1 Shaft throttle control 1 Bushing throttle shaft c Install throttle lever to new throttle shaft Make 1 Tube Loctite 609 sealer sure lever is installed correctly as noted in 3 Screw 3 56 x 7 32 in brass Step a 1 d Apply Loctite to threa
5. ds of 1 2 56 x 7 32 in To Install brass screw use 3 48 x 7 32 in brass screw Remove Throttle Shaft with 2 49 64 in shaft secure lever to shaft i Installation Instructions 1 To ensure correct reassembly mark throttle plate l t and carburetor body with a marking pen Also take 2 56 x 7 32 in or note of throttle plate position in bore and throttle 3 48 x 7 32 in Brass Screw SED lever position Throttle t a y Shaft 2 Carefully and slowly remove the screws securing 3 48 x 7 32 in the throttle plate to throttle shaft Remove and save the throttle plate as it will be reused Discard the Brass Screws eS AS N o Nay Throttle screws 3 File off any burrs which may have been left on 2 a X i Shaft throttle shaft when screws were removed to prevent Bushing scratching the bore when removed i Throttle Plate 4 Remove the throttle shaft from carburetor body Reused Remove and discard the foam rubber dust seal from throttle shaft Temporarily save the old shaft for use Body in Step 2 in bushing installation procedure Baffle Se Gasket Bowl Throttle Shaft 5 Remove and transfer throttle lever as follows S Gasket Bushing Installation a Note the position of the throttle lever with Tool respect to the cutout portion of throttle shaft Figure 1 Throttle Shaft Repair Details Litho In U S A 3 93 Rev 6 00 ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044
6. in bore Apply Loctite to threads of 2 3 48 x 7 32 in screws Install screws so they are slightly loose 3 Apply finger pressure to throttle shaft to keep it firmly seated against pivot in carburetor body Rotate the throttle shaft until throttle plate fully closes the bore around its entire perimeter then tighten screws 4 Operate the throttle lever and check for binding between the throttle plate and carburetor bore Loosen screws and adjust plate as necessary then tighten screws securely Reassemble Carburetor 1 Install the fuel inlet needle into inlet seat Install float and slide float pin through float hinge and float hinge towers on carburetor body Main Fuel Needle Spring Carburetor Body 4 Idle Fuel Needle Fuel Inlet _ Seat Gasket Fuel niet S Seat Float Fuel Inlet Needle Float S Ftoat Pin Fuel Bowl Bowi Retaining _ Bowl Retaining Screw Screw Gasket Figure 3 Kohler Built Adjustable Jet Carburetor Exploded View 2 Set float level Invert carburetor so the float tab rests on the fuel inlet needle There should be 11 64 in 41 32 in clearance between the machined surface of body and the free end of float Bend the float tab with a small screwdriver to adjust Refer to Figure 4 Bend Tab to Adjust 11 64 in Inverted Carburetor Figure 4 Setting Float Level 3 Set float drop Turn the carburetor over to its normal operating p
7. operly in bore Apply Loctite to threads of 2 3 48 x 7 32 in screws Install screws so they are slightly loose 3 Apply finger pressure to throttle shaft to keep it firmly seated against pivot in carburetor body Rotate the throttle shaft until throttle plate fully closes the bore around its entire perimeter then tighten screws 4 Operate the throttle lever and check for binding between the throttle plate and carburetor bore Loosen screws and adjust plate as necessary then tighten screws securely Reassemble Carburetor 1 Install the fuel inlet needle into inlet seat Install float and slide float pin through float hinge and float hinge towers on carburetor body Main Fuel Needle Spring Carburetor Body 4 Idle Fuel Needle Fuel Inlet _ Seat Gasket Fuel niet S Seat Float Fuel Inlet Needle Float S Ftoat Pin Fuel Bowl Bowi Retaining _ Bowl Retaining Screw Screw Gasket Figure 3 Kohler Built Adjustable Jet Carburetor Exploded View 2 Set float level Invert carburetor so the float tab rests on the fuel inlet needle There should be 11 64 in 41 32 in clearance between the machined surface of body and the free end of float Bend the float tab with a small screwdriver to adjust Refer to Figure 4 Bend Tab to Adjust 11 64 in Inverted Carburetor Figure 4 Setting Float Level 3 Set float drop Turn the carburetor over to its normal ope
8. osition and allow float to drop to its lowest level The float drop should be limited to 1 1 32 in between the machined surface of body and the bottom of the free end of float Bend the float tab with a small screwdriver to adjust Refer to Figure 5 1 1 32 in Figure 5 Setting Float Drop 4 inverted Carburetor Check float to float hinge tower clearance Invert the carburetor so the float tab rests on the fuel inlet needle Insert a 010 in feeler gauge between fioat and float hinge towers If the feeler gauge cannot be inserted or there is interference between the float and towers file the towers to obtain the proper clearance Refer to Figure 6 0 010 in Feeler Gauge Both Sides Float Hinge Towers On Carburetor Body Figure 6 Checking Float Clearance 5 Install the bow gasket and baffle gasket Position baffle gasket so the inner edge is against the float hinge towers Install the fuel bowl so it is centered on the baffle gasket Make sure the baffle gasket and bow are positioned properly to ensure a good seal Remove and discard the gasket from the bowl retaining screw Install new gasket from kit on bowl retaining screw Instali bowl retaining screw Torque screw to 50 60 in Ib Reinstall the carburetor to the engine using a new gasket If readjustment is needed refer to the carburetor adjustment section of the appropriate Engine Service Manual
9. rating position and allow float to drop to its lowest level The float drop should be limited to 1 1 32 in between the machined surface of body and the bottom of the free end of float Bend the float tab with a small screwdriver to adjust Refer to Figure 5 1 1 32 in Figure 5 Setting Float Drop 4 inverted Carburetor Check float to float hinge tower clearance Invert the carburetor so the float tab rests on the fuel inlet needle Insert a 010 in feeler gauge between fioat and float hinge towers If the feeler gauge cannot be inserted or there is interference between the float and towers file the towers to obtain the proper clearance Refer to Figure 6 0 010 in Feeler Gauge Both Sides Float Hinge Towers On Carburetor Body Figure 6 Checking Float Clearance 5 Install the bow gasket and baffle gasket Position baffle gasket so the inner edge is against the float hinge towers Install the fuel bowl so it is centered on the baffle gasket Make sure the baffle gasket and bow are positioned properly to ensure a good seal Remove and discard the gasket from the bowl retaining screw Install new gasket from kit on bowl retaining screw Instali bowl retaining screw Torque screw to 50 60 in Ib Reinstall the carburetor to the engine using a new gasket If readjustment is needed refer to the carburetor adjustment section of the appropriate Engine Service Manual KO
10. to threads of 1 2 56 x 7 32 in To Install brass screw use 3 48 x 7 32 in brass screw Remove Throttle Shaft with 2 49 64 in shaft secure lever to shaft i Installation Instructions 1 To ensure correct reassembly mark throttle plate l t and carburetor body with a marking pen Also take 2 56 x 7 32 in or note of throttle plate position in bore and throttle 3 48 x 7 32 in Brass Screw SED lever position Throttle t a y Shaft 2 Carefully and slowly remove the screws securing 3 48 x 7 32 in the throttle plate to throttle shaft Remove and save the throttle plate as it will be reused Discard the Brass Screws eS AS N o Nay Throttle screws 3 File off any burrs which may have been left on 2 a X i Shaft throttle shaft when screws were removed to prevent Bushing scratching the bore when removed i Throttle Plate 4 Remove the throttle shaft from carburetor body Reused Remove and discard the foam rubber dust seal from throttle shaft Temporarily save the old shaft for use Body in Step 2 in bushing installation procedure Baffle Se Gasket Bowl Throttle Shaft 5 Remove and transfer throttle lever as follows S Gasket Bushing Installation a Note the position of the throttle lever with Tool respect to the cutout portion of throttle shaft Figure 1 Throttle Shaft Repair Details Litho In U S A 3 93 Rev 6 00 ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044

Kohler TT321-A User's Manual

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