SV710-SV740

SV810-SV840
Service Manual

IMPORTANT: Read all safety precautions and instructions carefully before operating equipment. Refer to operating
instruction of equipment that this engine powers.
Ensure engine is stopped and level before performing any maintenance or service.

2 Safety
3 Maintenance
5 Specifications
13 Tools and Aids
16 Troubleshooting
20 Air Cleaner/Intake
21 Fuel System
28 Governor System
29 Lubrication System
31 Electrical System
43 Starter System
49 Emission Compliant Systems
52 Disassembly/Inspection and Service
64 Reassembly

32 690 01 Rev. D KohlerEngines.com 1

Safety

SAFETY PRECAUTIONS
WARNING: A hazard that could result in death, serious injury, or substantial property damage.
CAUTION: A hazard that could result in minor personal injury or property damage.
NOTE: is used to notify people of important installation, operation, or maintenance information.

WARNING WARNING CAUTION

Explosive Fuel can cause Accidental Starts can Electrical Shock can
fires and severe burns. cause severe injury or cause injury.
Do not fill fuel tank while death. Do not touch wires while
engine is hot or running. Disconnect and ground engine is running.
Gasoline is extremely flammable spark plug lead(s) before
and its vapors can explode if servicing. CAUTION
ignited. Store gasoline only in
approved containers, in well Before working on engine or Damaging Crankshaft
ventilated, unoccupied buildings, equipment, disable engine as and Flywheel can cause
away from sparks or flames. follows: 1) Disconnect spark plug personal injury.
Spilled fuel could ignite if it comes lead(s). 2) Disconnect negative (–)
in contact with hot parts or sparks battery cable from battery.
from ignition. Never use gasoline
as a cleaning agent. WARNING Using improper procedures can
Hot Parts can cause lead to broken fragments. Broken
WARNING severe burns. fragments could be thrown from
engine. Always observe and use
Rotating Parts can cause Do not touch engine precautions and procedures when
severe injury. while operating or just installing flywheel.
Stay away while engine after stopping.
is in operation. Never operate engine with heat
Keep hands, feet, hair, and shields or guards removed.
clothing away from all moving
parts to prevent injury. Never WARNING
operate engine with covers,
shrouds, or guards removed. Cleaning Solvents can
cause severe injury or
death.
WARNING
Use only in well
Carbon Monoxide can ventilated areas away
cause severe nausea, from ignition sources.
fainting or death.
Carburetor cleaners and solvents
Avoid inhaling exhaust are extremely flammable. Follow
fumes. cleaner manufacturer’s warnings
Engine exhaust gases contain and instructions on its proper and
poisonous carbon monoxide. safe use. Never use gasoline as a
Carbon monoxide is odorless, cleaning agent.
colorless, and can cause death if
inhaled.

2 KohlerEngines.com 32 690 01 Rev. D

 Maintenance

MAINTENANCE INSTRUCTIONS

WARNING
Accidental Starts can cause severe injury or Before working on engine or equipment, disable engine as
death. follows: 1) Disconnect spark plug lead(s). 2) Disconnect
Disconnect and ground spark plug lead(s) negative (–) battery cable from battery.
before servicing.

Normal maintenance, replacement or repair of emission control devices and systems may be performed by any repair
establishment or individual; however, warranty repairs must be performed by a Kohler authorized dealer.
MAINTENANCE SCHEDULE
Every 25 Hours¹
● Service/replace precleaner. Air Cleaner/Intake
● Replace air cleaner element (if not equipped with precleaner). Air Cleaner/Intake

Every 100 Hours¹

● Replace air cleaner element (if equipped with precleaner). Air Cleaner/Intake
● Change oil and filter. Lubrication System
● Remove cooling shrouds and clean cooling areas. Air Cleaner/Intake

Every 100 Hours

● Check that all fasteners are in place and components are properly secured. Reassembly
● Replace fuel filter.

Every 200 Hours²

● Have valve lash checked/adjusted. Reassembly

Every 500 Hours

● Replace spark plugs and set gap. Electrical System
¹ Perform these procedures more frequently under severe, dusty, dirty conditions.
² Have a Kohler authorized dealer perform this service.

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

32 690 01 Rev. D KohlerEngines.com 3

Maintenance

OIL RECOMMENDATIONS STORAGE

We recommend use of Kohler oils for best performance. If engine will be out of service for 2 months or more
Other high-quality detergent oils (including synthetic) follow procedure below.
of API (American Petroleum Institute) service class SJ 1. Add Kohler PRO Series fuel treatment or equivalent
or higher are acceptable. Select viscosity based on to fuel tank. Run engine 2-3 minutes to get stabilized
air temperature at time of operation as shown in table fuel into fuel system (failures due to untreated fuel
below. are not warrantable).
2. Change oil while engine is still warm from operation.
Remove spark plug(s) and pour about 1 oz. of
engine oil into cylinder(s). Replace spark plug(s) and
crank engine slowly to distribute oil.
3. Disconnect negative (-) battery cable.
4. Store engine in a clean, dry place.

FUEL RECOMMENDATIONS

WARNING
Explosive Fuel can cause fires and severe
burns.
Do not fill fuel tank while engine is hot or
running.
Gasoline is extremely flammable and its vapors can
explode if ignited. Store gasoline only in approved
containers, in well ventilated, unoccupied buildings,
away from sparks or flames. Spilled fuel could ignite
if it comes in contact with hot parts or sparks from
ignition. Never use gasoline as a cleaning agent.

NOTE: E15, E20 and E85 are NOT approved and

should NOT be used; effects of old, stale or
contaminated fuel are not warrantable.
Fuel must meet these requirements:
● Clean, fresh, unleaded gasoline.
● Octane rating of 87 (R+M)/2 or higher.
● Research Octane Number (RON) 90 octane minimum.
● Gasoline up to 10% ethyl alcohol, 90% unleaded is
acceptable.
● Methyl Tertiary Butyl Ether (MTBE) and unleaded
gasoline blend (max 15% MTBE by volume) are
approved.
● Do not add oil to gasoline.
● Do not overfill fuel tank.
● Do not use gasoline older than 30 days.

4 KohlerEngines.com 32 690 01 Rev. D

 Specifications

Engine Dimensions
Dimensions in millimeters.
Inch equivalents shown in [ ].

32 690 01 Rev. D KohlerEngines.com 5

Specifications

Engine Dimensions
Dimensions in millimeters.
Inch equivalents shown in [ ].

6 KohlerEngines.com 32 690 01 Rev. D

 Specifications

ENGINE IDENTIFICATION NUMBERS

Kohler engine identification numbers (model, specification and serial) should be referenced for efficient repair,
ordering correct parts, and engine replacement.

Model. . . . . . . . . . . . . . . . . . . . . SV710
Courage Engine
Vertical Shaft
Numerical Designation
Specification . . . . . . . . . . . . . . . SV710-0001
Serial. . . . . . . . . . . . . . . . . . . . . 3923500328
Year Manufactured Code Factory Code
Code Year
39 2009
40 2010
41 2011

GENERAL SPECIFICATIONS3.6 SV710 SV715 SV720 SV725 SV730 SV735 SV740

SV810 SV820 SV830 SV840
Bore 83 mm (3.27 in.)
Stroke 67 mm (2.64 in.)
Displacement 725 cc (44 cu. in.)
Oil Capacity (refill) 1.6-1.8 L (1.7-1.9 qt.)
Maximum Angle of Operation (@ full oil level)4 25°

TORQUE SPECIFICATIONS3,5 SV710 SV715 SV720 SV725 SV730 SV735 SV740

SV810 SV820 SV830 SV840

Blower Housing and Sheet Metal

M4 HI-LO Screw 2.8 N·m (25 in. lb.)
M5 Fasteners 6.2 N·m (55 in. lb.) into new hole
4.0 N·m (35 in. lb.) into used hole
M6 Fasteners 10.7 N·m (95 in. lb.) into new hole
7.3 N·m (65 in. lb.) into used hole

Carburetor
Mounting Nut 6.2-7.3 N·m (55-65 in. lb.)

Connecting Rod
Cap Fastener (torque in increments) 11.3 N·m (100 in. lb.)

Crankcase
Breather Assembly
Inner Cover Fastener 10.7 N·m (95 in. lb.) into new hole
7.3 N·m (65 in. lb.) into used hole

Outer Cover Stud 6.2 N·m (55 in. lb.) into new hole
4.0 N·m (35 in. lb.) into used hole

Outer Cover Hex Nut 1.3 N·m (11.5 in. lb.)

Oil Drain Plug 13.6 N·m (10 ft. lb.)

3
Values are in Metric units. Values in parentheses are English equivalents.
4
Exceeding maximum angle of operation may cause engine damage from insufficient lubrication.
5
Lubricate threads with engine oil prior to assembly.
6
Any and all horsepower (hp) references by Kohler are Certified Power Ratings and per SAE J1940 & J1995 hp
standards. Details on Certified Power Ratings can be found at KohlerEngines.com.
32 690 01 Rev. D KohlerEngines.com 7
Specifications

TORQUE SPECIFICATIONS3,5 SV710 SV715 SV720 SV725 SV730 SV735 SV740

SV810 SV820 SV830 SV840

Cylinder Head
Head Bolt Fastener (torque in 2 increments) first to 22.6 N·m (200 in. lb.)
finally to 41.8 N·m (370 in. lb.)
Rocker Arm Screw 11.3 N·m (100 in. lb.)
Rocker Arm Stud (AVT) 11.3 N·m (100 in. lb.)
Rocker Arm/Valve Adjustment Jam Nut 7.3 N·m (65 in. lb.)
Rocker Arm/Valve Adjustment Setscrew (AVT) 7.9 N·m (70 in. lb.)

Flywheel
Retaining Screw 74.5 N·m (55 ft. lb.)

Fuel Pump
Screw 2.3 N·m (20 in. lb.)

Governor
Lever Nut 6.8 N·m (60 in. lb.)

Ignition
Spark Plug 27 N·m (20 ft. lb.)
Module Fastener 4.0-6.2 N·m (35-55 in. lb.)
Rectifier-Regulator Fastener 4.0 N·m (35 in. lb.)

Intake Manifold
Mounting Fastener (torque in 2 increments) first to 7.4 N·m (66 in. lb.)
finally to 9.9 N·m (88 in. lb.)

Muffler
M8 Hex Nuts 24.4 N·m (216 in. lb.)
5/16-18 Capscrew 16.9 N·m (150 in. lb.)
Bracket Screw 9.9 N·m (88 in. lb.)

Oil Filter
Nipple 33.9 N·m (300 in. lb.)

Oil Pan
Fastener 24.4 N·m (216 in. lb.)

Oil Sentry™
Pressure Switch 4.5 N·m (40 in. lb.)

Solenoid (Starter)
Mounting Hardware 4.0-6.0 N·m (35-53 in. lb.)
Nut, Positive (+) Brush Lead 8.0-11.0 N·m (71-97 in. lb.)

Speed Control Bracket

Fastener 10.7 N·m (95 in. lb.) into new holes
7.3 N·m (65 in. lb.) into used holes

3
Values are in Metric units. Values in parentheses are English equivalents.
5
Lubricate threads with engine oil prior to assembly.
8 KohlerEngines.com 32 690 01 Rev. D
 Specifications

TORQUE SPECIFICATIONS3,5 SV710 SV715 SV720 SV725 SV730 SV735 SV740

SV810 SV820 SV830 SV840

Starter Assembly
Thru Bolt
Inertia Drive 4.5-5.7 N·m (40-50 in. lb.)
Solenoid Shift 5.6-9.0 N·m (49-79 in. lb.)
Mounting Screw 15.3 N·m (135 in. lb.)
Brush Holder Mounting Screw 2.5-3.3 N·m (22-29 in. lb.)

Stator
Mounting Screw 6.2 N·m (55 in. lb.)

Valve Cover
Fastener 6.2 N·m (55 in. lb.)

CLEARANCE SPECIFICATIONS3 SV710 SV715 SV720 SV725 SV730 SV735 SV740

SV810 SV820 SV830 SV840

Camshaft
End Play (with shim) 0.076/0.127 mm (0.0030/0.0050 in.)
Running Clearance 0.025/0.063 mm (0.0010/0.0025 in.)
Bore I.D.
New 20.000/20.025 mm (0.7874/0.7884 in.)
Max. Wear Limit 20.038 mm (0.7889 in.)
Bearing Surface O.D.
New 19.962/19.975 mm (0.7859/0.7864 in.)
Max. Wear Limit 19.959 mm (0.7858 in.)

Connecting Rod
Connecting Rod-to-Crankpin Running Clearance
New 0.030/0.055 mm (0.0012/0.0022 in.)
Max. Wear Limit 0.070 mm (0.0028 in.)
Connecting Rod-to-Crankpin Side Clearance 0.26/0.63 mm (0.0102/0.0248 in.)
Connecting Rod-to-Piston Pin Running Clearance 0.015/0.028 mm (0.0006/0.0011 in.)
Piston Pin End I.D.
New 17.015/17.023 mm (0.6699/0.6702 in.)
Max. Wear Limit 17.036 mm (0.6707 in.)

Crankcase
Governor Cross Shaft Bore I.D.
New 8.025/8.075 mm (0.3159/0.3179 in.)
Max. Wear Limit 8.088 mm (0.3184 in.)

3
Values are in Metric units. Values in parentheses are English equivalents.
32 690 01 Rev. D KohlerEngines.com 9
Specifications

CLEARANCE SPECIFICATIONS3 SV710 SV715 SV720 SV725 SV730 SV735 SV740

SV810 SV820 SV830 SV840

Crankshaft
End Play (free) 0.070/0.590 mm (0.0028/0.0230 in.)
Bore (in crankcase)
New 40.965/41.003 mm (1.6128/1.6143 in.)
Max. Wear Limit 41.016 mm (1.6148 in.)
Bore (in oil pan)
New 40.974/40.987 mm (1.6131/1.6136 in.)
Crankshaft Bore (in oil pan)-to-Crankshaft Running
Clearance 0.039/0.074 mm (0.0015/0.0029 in.)
New
Flywheel End Main Bearing Journal
O.D. - New 40.913/40.935 mm (1.6107/1.6116 in.)
O.D. - Max. Wear Limit 40.84 mm (1.608 in.)
Max. Taper 0.022 mm (0.0009 in.)
Max. Out-of-Round 0.025 mm (0.0010 in.)
Oil Pan End Main Bearing Journal
O.D. - New 40.913/40.935 mm (1.6107/1.6116 in.)
O.D. - Max. Wear Limit 40.84 mm (1.608 in.)
Max. Taper 0.022 mm (0.0009 in.)
Max. Out-of-Round 0.025 mm (0.0010 in.)
Connecting Rod Journal
O.D. - New 35.955/35.973 mm (1.4156/1.4163 in.)
O.D. - Max. Wear Limit 35.94 mm (1.415 in.)
Max. Taper 0.018 mm (0.0007 in.)
Max. Out-of-Round 0.025 mm (0.0010 in.)
T.I.R.
PTO End, Crank in Engine 0.279 mm (0.0110 in.)
Entire Crank, in V-Blocks 0.10 mm (0.0039 in.)

Cylinder Bore
Bore I.D.
New 83.031/83.006 mm (3.2689/3.2679 in.)
Max. Wear Limit 83.069 mm (3.2704 in.)
Max. Out-of-Round 0.12 mm (0.0047 in.)
Max. Taper 0.05 mm (0.0020 in.)

Cylinder Head
Max. Out-of-Flatness 0.076 mm (0.003 in.)

Governor
Governor Cross Shaft-to-Crankcase Running Clearance 0.025/0.126 mm (0.0009/0.0049 in.)
Cross Shaft O.D.
New 7.949/8.000 mm (0.3129/0.3149 in.)
Max. Wear Limit 7.936 mm (0.3124 in.)
Governor Gear Shaft-to-Governor Running Clearance 0.015/0.140 mm (0.0006/0.0055 in.)
Gear Shaft O.D.
New 5.990/6.000 mm (0.2358/0.2362 in.)
Max. Wear Limit 5.977 mm (0.2353 in.)

3
Values are in Metric units. Values in parentheses are English equivalents.
7
Measure 6 mm (0.236 in.) above bottom of piston skirt at right angles to piston pin.
10 KohlerEngines.com 32 690 01 Rev. D
 Specifications

CLEARANCE SPECIFICATIONS3 SV710 SV715 SV720 SV725 SV730 SV735 SV740

SV810 SV820 SV830 SV840

Ignition
Spark Plug Gap 0.76 mm (0.030 in.)
Module Air Gap 0.28/0.33 mm (0.011/0.013 in.)

Piston, Piston Rings, and Piston Pin

Piston-to-Piston Pin Running Clearance 0.006/0.017 mm (0.0002/0.0007 in.)
Pin Bore I.D.
New 17.006/17.012 mm (0.6695/0.6698 in.)
Max. Wear Limit 17.025 mm (0.6703 in.)
Pin O.D.
New 16.995/17.000 mm (0.6691/0.6693 in.)
Max. Wear Limit 16.994 mm (0.6691 in.)
Top Compression Ring-to-Groove Side Clearance 0.025/0.048 mm (0.0010/0.0019 in.)
Middle Compression Ring-to-Groove Side Clearance 0.015/0.037 mm (0.0006/0.0015 in.)
Oil Control Ring-to-Groove Side Clearance 0.026/0.176 mm (0.0010/0.0070 in.)
Top and Center Compression Ring End Gap
New Bore 0.25/0.56 mm (0.0100/0.0224 in.)
Used Bore (Max.) 0.94 mm (0.037 in.)
Thrust Face O.D.7
New 82.947 mm (3.2656 in.)
Max. Wear Limit 82.802 mm (3.2599 in.)
Piston Thrust Face-to-Cylinder Bore7 Running Clearance
New 0.06/0.100 mm (0.0023/0.0039 in.)

Valves and Valve Tappets

Clearance 0.101/0.152 mm (0.004/0.006 in.)
Valve Tappet to Crankcase Running Clearance 0.013/0.073 mm (0.0005/0.0029 in.)
Intake Valve Stem-to-Valve Guide Running Clearance 0.038/0.076 mm (0.0015/0.0030 in.)
Exhaust Valve Stem-to-Valve Guide Running Clearance 0.050/0.088 mm (0.0020/0.0035 in.)
Intake Valve Guide I.D.
New 7.038/7.058 mm (0.2771/0.2779 in.)
Max. Wear Limit 7.134 mm (0.2809 in.)
Exhaust Valve Guide I.D.
New 7.038/7.058 mm (0.2771/0.2779 in.)
Max. Wear Limit 7.159 mm (0.2819 in.)
Valve Guide Reamer Size
Standard 7.048 mm (0.2775 in.)
0.25 mm O.S. 7.298 mm (0.2873 in.)
Intake Valve Minimum Lift 8.07 mm (0.3177 in.)
Exhaust Valve Minimum Lift 8.07 mm (0.3177 in.)
Nominal Valve Face Angle 45°

3
Values are in Metric units. Values in parentheses are English equivalents.
32 690 01 Rev. D KohlerEngines.com 11
Specifications

GENERAL TORQUE VALUES

English Fastener Torque Recommendations for Standard Applications

Bolts, Screws, Nuts and Fasteners Assembled Into Cast Iron or Steel
Grade 2 or 5 Fasteners
Into Aluminum

Size Grade 2 Grade 5 Grade 8

Tightening Torque: N·m (in. lb.) ± 20%
8-32 2.3 (20) 2.8 (25) — 2.3 (20)
10-24 3.6 (32) 4.5 (40) — 3.6 (32)
10-32 3.6 (32) 4.5 (40) — —
1/4-20 7.9 (70) 13.0 (115) 18.7 (165) 7.9 (70)
1/4-28 9.6 (85) 15.8 (140) 22.6 (200) —
5/16-18 17.0 (150) 28.3 (250) 39.6 (350) 17.0 (150)
5/16-24 18.7 (165) 30.5 (270) — —
3/8-16 29.4 (260) — — —
3/8-24 33.9 (300) — — —

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

5/16-24 — — 40.7 (30) —
3/8-16 — 47.5 (35) 67.8 (50) —
3/8-24 — 54.2 (40) 81.4 (60) —
7/16-14 47.5 (35) 74.6 (55) 108.5 (80) —
7/16-20 61.0 (45) 101.7 (75) 142.5 (105) —
1/2-13 67.8 (50) 108.5 (80) 155.9 (115) —
1/2-20 94.9 (70) 142.4 (105) 223.7 (165) —
9/16-12 101.7 (75) 169.5 (125) 237.3 (175) —
9/16-18 135.6 (100) 223.7 (165) 311.9 (230) —
5/8-11 149.5 (110) 244.1 (180) 352.6 (260) —
5/8-18 189.8 (140) 311.9 (230) 447.5 (330) —
3/4-10 199.3 (147) 332.2 (245) 474.6 (350) —
3/4-16 271.2 (200) 440.7 (325) 637.3 (470) —

Metric Fastener Torque Recommendations for Standard Applications

Property Class Noncritical
Fasteners
Size 4.8 5.8 8.8 10.9 12.9
Into Aluminum
Tightening Torque: N·m (in. lb.) ± 10%
M4 1.2 (11) 1.7 (15) 2.9 (26) 4.1 (36) 5.0 (44) 2.0 (18)
M5 2.5 (22) 3.2 (28) 5.8 (51) 8.1 (72) 9.7 (86) 4.0 (35)
M6 4.3 (38) 5.7 (50) 9.9 (88) 14.0 (124) 16.5 (146) 6.8 (60)
M8 10.5 (93) 13.6 (120) 24.4 (216) 33.9 (300) 40.7 (360) 17.0 (150)

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

M10 21.7 (16) 27.1 (20) 47.5 (35) 66.4 (49) 81.4 (60) 33.9 (25)
M12 36.6 (27) 47.5 (35) 82.7 (61) 116.6 (86) 139.7 (103) 61.0 (45)
M14 58.3 (43) 76.4 (56) 131.5 (97) 184.4 (136) 219.7 (162) 94.9 (70)

Torque Conversions
N·m = in. lb. x 0.113 in. lb. = N·m x 8.85
N·m = ft. lb. x 1.356 ft. lb. = N·m x 0.737

12 KohlerEngines.com 32 690 01 Rev. D

 Tools and Aids

Certain quality tools are designed to help you perform specific disassembly, repair, and reassembly procedures. By
using these tools, you can properly service engines easier, faster, and safer! In addition, you’ll increase your service
capabilities and customer satisfaction by decreasing engine downtime.
Here is a list of tools and their source.
SEPARATE TOOL SUPPLIERS
Kohler Tools SE Tools Design Technology Inc.
Contact your local Kohler source of 415 Howard St. 768 Burr Oak Drive
supply. Lapeer, MI 48446 Westmont, IL 60559
Phone 810-664-2981 Phone 630-920-1300
Toll Free 800-664-2981 Fax 630-920-0011
Fax 810-664-8181

TOOLS
Description Source/Part No.
Alcohol Content Tester Kohler 25 455 11-S
For testing alcohol content (%) in reformulated/oxygenated fuels.
Camshaft Endplay Plate SE Tools KLR-82405
For checking camshaft endplay.
Camshaft Seal Protector (Aegis) SE Tools KLR-82417
For protecting seal during camshaft installation.
Cylinder Leakdown Tester Kohler 25 761 05-S
For checking combustion retention and if cylinder, piston, rings, or valves are worn.
Individual component available: Design Technology Inc.
Adapter 12 mm x 14 mm (Required for leakdown test on XT-6 engines) DTI-731-03
Dealer Tool Kit (Domestic) Kohler 25 761 39-S
Complete kit of Kohler required tools.
Components of 25 761 39-S
Ignition System Tester Kohler 25 455 01-S
Cylinder Leakdown Tester Kohler 25 761 05-S
Oil Pressure Test Kit Kohler 25 761 06-S
Rectifier-Regulator Tester (120 V AC/60Hz) Kohler 25 761 20-S
Dealer Tool Kit (International) Kohler 25 761 42-S
Complete kit of Kohler required tools.
Components of 25 761 42-S
Ignition System Tester Kohler 25 455 01-S
Cylinder Leakdown Tester Kohler 25 761 05-S
Oil Pressure Test Kit Kohler 25 761 06-S
Rectifier-Regulator Tester (240 V AC/50Hz) Kohler 25 761 41-S
Digital Vacuum/Pressure Tester Design Technology Inc.
For checking crankcase vacuum. DTI-721-01
Individual component available: Design Technology Inc.
Rubber Adapter Plug DTI-721-10
Electronic Fuel Injection (EFI) Diagnostic Software Kohler 25 761 23-S
For Laptop or Desktop PC.
EFI Service Kit Kohler 24 761 01-S
For troubleshooting and setting up an EFI engine.
Components of 24 761 01-S Design Technology Inc.
Fuel Pressure Tester DTI-019
Noid Light DTI-021
90° Adapter DTI-023
In-line "T" Fitting DTI-035
Code Plug, Red Wire DTI-027
Code Plug, Blue Wire DTI-029
Shrader Valve Adapter Hose DTI-037
Flywheel Holding Tool (CS) SE Tools KLR-82407
For holding flywheel of CS series engines.
Flywheel Puller SE Tools KLR-82408
For properly removing flywheel from engine.
Flywheel Strap Wrench SE Tools KLR-82409
For holding flywheel during removal.

32 690 01 Rev. D KohlerEngines.com 13

Tools and Aids

TOOLS
Description Source/Part No.
Hydraulic Valve Lifter Tool Kohler 25 761 38-S
For removing and installing hydraulic lifters.
Ignition System Tester Kohler 25 455 01-S
For testing output on all systems, including CD.
Inductive Tachometer (Digital) Design Technology Inc.
For checking operating speed (RPM) of an engine. DTI-110
Offset Wrench (K and M Series) Kohler 52 455 04-S
For removing and reinstalling cylinder barrel retaining nuts.
Oil Pressure Test Kit Kohler 25 761 06-S
For testing/verifying oil pressure on pressure lubricated engines.
Radiator Tester Kohler 25 455 10-S
For pressure testing radiator and cap on Aegis liquid-cooled engines.
Rectifier-Regulator Tester (120 volt current) Kohler 25 761 20-S
Rectifier-Regulator Tester (240 volt current) Kohler 25 761 41-S
For testing rectifier-regulators.
Components of 25 761 20-S and 25 761 41-S Design Technology Inc.
CS-PRO Regulator Test Harness DTI-031
Special Regulator Test Harness with Diode DTI-033
Spark Advance Module (SAM) Tester Kohler 25 761 40-S
For testing SAM (ASAM and DSAM) on engines with SMART-SPARK™.
Starter Servicing Kit (All Starters) SE Tools KLR-82411
For removing and reinstalling drive retaining rings and brushes.
Individual component available:
Starter Brush Holding Tool (Solenoid Shift) SE Tools KLR-82416
Triad/OHC Timing Tool Set Kohler 28 761 01-S
For holding cam gears and crankshaft in timed position while installing timing belt.
Valve Guide Reamer (K and M Series) Design Technology Inc.
For properly sizing valve guides after installation. DTI-K828
Valve Guide Reamer O.S. (Command Series) Kohler 25 455 12-S
For reaming worn valve guides to accept replacement oversize valves. Can be used
in low-speed drill press or with handle below for hand reaming.
Reamer Handle Design Technology Inc.
For hand reaming using Kohler 25 455 12-S reamer. DTI-K830
Valve Guide Service Kit (Courage, Aegis, Command, OHC) SE Tools KLR-82415
For servicing worn valve guides.

AIDS
Description Source/Part No.
Camshaft Lubricant (Valspar ZZ613) Kohler 25 357 14-S
Dielectric Grease (GE/Novaguard G661) Kohler 25 357 11-S
Dielectric Grease Loctite® 51360
Kohler Electric Starter Drive Lubricant (Inertia Drive) Kohler 52 357 01-S
Kohler Electric Starter Drive Lubricant (Solenoid Shift) Kohler 52 357 02-S
RTV Silicone Sealant
Loctite® 5900® Heavy Body in 4 oz. aerosol dispenser. Kohler 25 597 07-S
Only oxime-based, oil resistant RTV sealants, such as those listed, are approved Loctite® 5910®
for use. Loctite® Nos. 5900® or 5910® are recommended for best sealing Loctite® Ultra Black 598™
characteristics. Loctite® Ultra Blue 587™
Loctite® Ultra Copper 5920™
Spline Drive Lubricant Kohler 25 357 12-S

14 KohlerEngines.com 32 690 01 Rev. D

 Tools and Aids

FLYWHEEL HOLDING TOOL ROCKER ARM/CRANKSHAFT TOOL

A flywheel holding tool can be made out of an old junk A spanner wrench to lift rocker arms or turn crankshaft
flywheel ring gear and used in place of a strap wrench. may be made out of an old junk connecting rod.
1. Using an abrasive cut-off wheel, cut out a six tooth 1. Find a used connecting rod from a 10 HP or larger
segment of ring gear as shown. engine. Remove and discard rod cap.
2. Grind off any burrs or sharp edges. 2. Remove studs of a Posi-Lock rod or grind off
3. Invert segment and place it between ignition bosses aligning steps of a Command rod, so joint surface is
on crankcase so tool teeth engage flywheel ring flat.
gear teeth. Bosses will lock tool and flywheel in 3. Find a 1 in. long capscrew with correct thread size to
position for loosening, tightening, or removing with a match threads in connecting rod.
puller. 4. Use a flat washer with correct I.D. to slip on
capscrew and approximately 1 in. O.D. Assemble
capscrew and washer to joint surface of rod.

32 690 01 Rev. D KohlerEngines.com 15

Troubleshooting

TROUBLESHOOTING GUIDE
When troubles occur, be sure to check 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 general common causes of engine troubles are listed below and vary by engine specification. Use these to
locate causing factors.

Engine Cranks But Will Not Start Engine Will Not Crank
● Battery connected backwards. ● Battery is discharged.
● Blown fuse. ● Faulty electric starter or solenoid.
● Carburetor solenoid malfunction. ● Faulty key switch or ignition switch.
● Choke not closing. ● Interlock switch is engaged or faulty.
● Clogged fuel line or fuel filter. ● Loose wires or connections that intermittently ground
● Diode in wiring harness failed in open circuit mode. ignition kill circuit.
● DSAI or DSAM malfunction. ● Pawls not engaging in drive cup.
● Empty fuel tank. ● Seized internal engine components.
● Faulty electronic control unit.
● Faulty ignition coil(s). Engine Runs But Misses
● Faulty spark plug(s). ● Carburetor adjusted incorrectly.
● Fuel pump malfunction-vacuum hose clogged or ● Engine overheated.
leaking. ● Faulty spark plug(s).
● Fuel shut-off valve closed. ● Ignition module(s) faulty or improperly gapped.
● Ignition module(s) faulty or improperly gapped. ● Incorrect crankshaft position sensor air gap.
● Insufficient voltage to electronic control unit. ● Interlock switch is engaged or faulty.
● Interlock switch is engaged or faulty. ● Loose wires or connections that intermittently ground
● Key switch or kill switch in OFF position. ignition kill circuit.
● Low oil level. ● Quality of fuel (dirt, water, stale, mixture).
● Quality of fuel (dirt, water, stale, mixture). ● Spark plug lead(s) disconnected.
● SMART-SPARKTM malfunction. ● Spark plug lead boot loose on plug.
● Spark plug lead(s) disconnected. ● Spark plug lead loose.
Engine Starts But Does Not Keep Running Engine Will Not Idle
● Faulty carburetor. ● Engine overheated.
● Faulty cylinder head gasket. ● Faulty spark plug(s).
● Faulty or misadjusted choke or throttle controls. ● Idle fuel adjusting needle(s) improperly set.
● Fuel pump malfunction-vacuum hose clogged or ● Idle speed adjusting screw improperly set.
leaking. ● Inadequate fuel supply.
● Intake system leak. ● Low compression.
● Loose wires or connections that intermittently ground ● Quality of fuel (dirt, water, stale, mixture).
ignition kill circuit. ● Restricted fuel tank cap vent.
● Quality of fuel (dirt, water, stale, mixture).
● Restricted fuel tank cap vent. Engine Overheats
● Cooling fan broken.
Engine Starts Hard ● Excessive engine load.
● Clogged fuel line or fuel filter. ● Fan belt failed/off.
● Engine overheated. ● Faulty carburetor.
● Faulty ACR mechanism. ● High crankcase oil level.
● Faulty or misadjusted choke or throttle controls. ● Lean fuel mixture.
● Faulty spark plug(s). ● Low cooling system fluid level.
● Flywheel key sheared. ● Low crankcase oil level.
● Fuel pump malfunction-vacuum hose clogged or ● Radiator, and/or cooling system components clogged,
leaking. restricted, or leaking.
● Interlock switch is engaged or faulty. ● Water pump belt failed/broken.
● Loose wires or connections that intermittently ground ● Water pump malfunction.
ignition kill circuit.
● Low compression. Engine Knocks
● Quality of fuel (dirt, water, stale, mixture). ● Excessive engine load.
● Weak spark. ● Hydraulic lifter malfunction.
● Incorrect oil viscosity/type.
● Internal wear or damage.
● Low crankcase oil level.
● Quality of fuel (dirt, water, stale, mixture).

16 KohlerEngines.com 32 690 01 Rev. D

 Troubleshooting

Engine Loses Power EXTERNAL ENGINE INSPECTION

● Dirty air cleaner element. NOTE: It is good practice to drain oil at a location away
● Engine overheated. from workbench. Be sure to allow ample time for
● Excessive engine load. complete drainage.
● Restricted exhaust. Before cleaning or disassembling engine, make a
● Faulty spark plug(s). thorough inspection of its external appearance and
● High crankcase oil level. condition. This inspection can give clues to what
● Incorrect governor setting. might be found inside engines (and cause) when it is
● Low battery. disassembled.
● Low compression. ● Check for buildup of dirt and debris on crankcase,
● Low crankcase oil level. cooling fins, grass screen, and other external surfaces.
● Quality of fuel (dirt, water, stale, mixture). Dirt or debris on these areas can cause overheating.
Engine Uses Excessive Amount of Oil ● Check for obvious fuel and oil leaks, and damaged
components. Excessive oil leakage can indicate a
● Loose or improperly torqued fasteners. clogged or inoperative breather, worn or damaged
● Blown head gasket/overheated. seals or gaskets, or loose fasteners.
● Breather reed broken. ● Check air cleaner cover and base for damage or
● Clogged, broken, or inoperative crankcase breather. indications of improper fit and seal.
● Crankcase overfilled. ● Check air cleaner element. Look for holes, tears,
● Incorrect oil viscosity/type. cracked or damaged sealing surfaces, or other
● Worn cylinder bore. damage that could allow unfiltered air into engine. A
● Worn or broken piston rings. dirty or clogged element could indicate insufficient or
● Worn valve stems/valve guides. improper maintenance.
Oil Leaks from Oil Seals, Gaskets ● Check carburetor throat for dirt. Dirt in throat is further
indication that air cleaner was not functioning properly.
● Breather reed broken. ● Check if oil level is within operating range on dipstick.
● Clogged, broken, or inoperative crankcase breather. If it is above, sniff for gasoline odor.
● Loose or improperly torqued fasteners. ● Check condition of oil. Drain oil into a container; it
● Piston blow by, or leaky valves. should flow freely. Check for metal chips and other
● Restricted exhaust. foreign particles.

Sludge is a natural by-product of combustion; a small

accumulation is normal. Excessive sludge formation
could indicate over rich fuel settings, weak ignition,
overextended oil change interval or wrong weight or
type of oil was used.

CLEANING ENGINE
WARNING
Cleaning Solvents can cause severe injury or
death.
Use only in well ventilated areas away from
ignition sources.
Carburetor cleaners and solvents are extremely
flammable. Follow cleaner manufacturer’s warnings
and instructions on its proper and safe use. Never use
gasoline as a cleaning agent.

After inspecting external condition of engine, clean

engine thoroughly before disassembly. Clean individual
components as engine is disassembled. Only clean
parts can be accurately inspected and gauged for wear
or damage. There are many commercially available
cleaners that will quickly remove grease, oil, and grime
from engine parts. When such a cleaner is used, follow
manufacturer’s instructions and safety precautions
carefully.
Make sure all traces of cleaner are removed before
engine is reassembled and placed into operation. Even
small amounts of these cleaners can quickly break down
lubricating properties of engine oil.

32 690 01 Rev. D KohlerEngines.com 17

Troubleshooting

CRANKCASE VACUUM TEST

WARNING WARNING
Carbon Monoxide can cause severe nausea,
fainting or death. Rotating Parts can cause severe injury.
Avoid inhaling exhaust fumes. Stay away while engine is in operation.

Engine exhaust gases contain poisonous carbon Keep hands, feet, hair, and clothing away from all
monoxide. Carbon monoxide is odorless, colorless, moving parts to prevent injury. Never operate engine
and can cause death if inhaled. with covers, shrouds, or guards removed.

A partial vacuum should be present in crankcase when engine is operating. Pressure in crankcase (normally caused
by a clogged or improperly assembled breather) can cause oil to be forced out at oil seals, gaskets, or other available
spots.
Crankcase vacuum is best measured with either a water manometer or a vacuum gauge. Complete instructions are
provided in kits.
To test crankcase vacuum with manometer: To test crankcase vacuum with vacuum/pressure gauge:
1. Insert rubber stopper into oil fill hole. Be sure pinch 1. Remove dipstick or oil fill plug/cap.
clamp is installed on hose and use tapered adapters 2. Install adapter into oil fill//dipstick tube opening,
to connect hose between stopper and one upside down over end of a small diameter dipstick
manometer tube. Leave other tube open to tube, or directly into engine if a tube is not used.
atmosphere. Check that water level in manometer is Insert barbed gauge fitting into hole in stopper.
at 0 line. Make sure pinch clamp is closed.
3. Run engine and observe gauge reading.
2. Start engine and run no-load high speed.
Analog tester–needle movement to left of 0 is a
3. Open clamp and note water level in tube. vacuum, and movement to right indicates a pressure.
Level in engine side should be a minimum of 10.2 Digital tester–depress test button on top of tester.
cm (4 in.) above level in open side.
Crankcase vacuum should be a minimum of 10.2 cm
If level in engine side is less than specified (low/no (4 in.) of water. If reading is below specification, or if
vacuum), or level in engine side is lower than level in pressure is present, check table below for possible
open side (pressure), check for conditions in table causes and conclusions.
below.
4. Close pinch clamp before stopping engine.

Condition Conclusion
Crankcase breather clogged or inoperative. NOTE: If breather is integral part of valve cover and
cannot be serviced separately, replace valve
cover and recheck pressure.
Disassemble breather, clean parts thoroughly, check
sealing surfaces for flatness, reassemble, and recheck
pressure.
Seals and/or gaskets leaking. Loose or improperly torque Replace all worn or damaged seals and gaskets. Make
fasteners. sure all fasteners are tightened securely. Use appropriate
torque valves and sequences when necessary.
Piston blow by or leaky valves (confirm by inspecting Recondition piston, rings, cylinder bore, valves and
components). valves guides.
Restricted exhaust. Check exhaust screen/spark arrestor (if equipped). Clean
or replace as needed. Repair or replace any other
damaged/restricted muffler or exhaust system parts.

18 KohlerEngines.com 32 690 01 Rev. D

 Troubleshooting

COMPRESSION TEST
For Command Twins:
A compression test is best performed on a warm engine. Clean any dirt or debris away from base of spark plug(s)
before removing them. Be sure choke is off, and throttle is wide open during test. Compression should be at least 160
psi and should not vary more than 15% between cylinders.
All other models:
These engines are equipped with an automatic compression release (ACR) mechanism. It is difficult to obtain an
accurate compression reading because of ACR mechanism. As an alternative, use cylinder leakdown test described
below.
CYLINDER LEAKDOWN TEST
A cylinder leakdown test can be a valuable alternative to a compression test. By pressurizing combustion chamber
from an external air source you can determine if valves or rings are leaking, and how badly.
Cylinder leakdown tester is a relatively simple, inexpensive leakdown tester for small engines. This tester includes a
quick-connect for attaching adapter hose and a holding tool.
1. Run engine for 3-5 minutes to warm it up.
2. Remove spark plug(s) and air filter from engine.
3. Rotate crankshaft until piston (of cylinder being tested) is at top dead center (TDC) of compression stroke. Hold
engine in this position while testing. Holding tool supplied with tester can be used if PTO end of crankshaft is
accessible. Lock holding tool onto crankshaft. Install a 3/8 in. breaker bar into hole/slot of holding tool, so it is
perpendicular to both holding tool and crankshaft PTO.
If flywheel end is more accessible, use a breaker bar and socket on flywheel nut/screw to hold it in position. An
assistant may be needed to hold breaker bar during testing. If engine is mounted in a piece of equipment, it may
be possible to hold it by clamping or wedging a driven component. Just be certain that engine cannot rotate off of
TDC in either direction.
4. Install adapter into spark plug hole, but do not attach it to tester at this time.
5. Turn regulator knob completely counterclockwise.
6. Connect an air source of at least 50 psi to tester.
7. Turn regulator knob clockwise (increase direction) until gauge needle is in yellow set area at low end of scale.
8. Connect tester quick-connect to adapter hose. While firmly holding engine at TDC, gradually open tester valve.
Note gauge reading and listen for escaping air at combustion air intake, exhaust outlet, and crankcase breather.
Condition Conclusion
Air escaping from crankcase breather. Ring or cylinder worn.
Air escaping from exhaust system. Defective exhaust valve/improper seating.
Air escaping from intake. Defective intake valve/improper seating.
Gauge reading in low (green) zone. Piston rings and cylinder in good condition.
Gauge reading in moderate (yellow) zone. Engine is still usable, but there is some wear present.
Customer should start planning for overhaul or
replacement.
Gauge reading in high (red) zone. Rings and/or cylinder have considerable wear. Engine
should be reconditioned or replaced.

32 690 01 Rev. D KohlerEngines.com 19

Air Cleaner/Intake

AIR CLEANER Open air cleaner access door on blower housing and
These systems are CARB/EPA certified and components unhook latch.
should not be altered or modified in any way.
Precleaner (if equipped)
Air Cleaner Components
1. Remove precleaner.
A 2. Replace or wash precleaner in warm water with
detergent. Rinse and allow to air dry.
3. Saturate precleaner with new engine oil; squeeze
out excess oil.
4. Reinstall precleaner over paper element.
B Paper Element
1. Remove element from base; service precleaner.
Discard element.
2. Install precleaner over new paper element and install
on base.
C Hook latch; close and secure access door.
E
Air Cleaner Base
Disassembly/Reassembly
D If air cleaner base requires removal, proceed as follows:
1. Remove mounting screws for fuel pump (if
F equipped), and blower housing.
2. Raise or remove blower housing for access to air
cleaner base.
3. Remove air cleaner components from base.
4. Remove nuts securing air cleaner base onto
mounting studs.
5. Disconnect breather hose from air cleaner base,
then remove base and gasket.
6. Reverse procedure to reassemble components.
Torque nuts to 6.2-7.3 N·m (55-65 in. lb.). Torque
blower housing screws to 4.0 N·m (35 in. lb.), and
front HI-LO screws to 2.8 N·m (25 in. lb.).
BREATHER TUBE
A Precleaner B Paper Element
Ensure both ends of breather tube are properly
Air Cleaner Access connected.
C D Blower Housing
Door
AIR COOLING
E Latch F Air Cleaner Base
NOTE: Operating engine with loose or damaged air WARNING
cleaner components could cause premature
wear and failure. Replace all bent or damaged Hot Parts can cause severe burns.
components. Do not touch engine while operating or just
NOTE: Paper element cannot be blown out with after stopping.
compressed air. Never operate engine with heat shields or guards
removed.
Proper cooling is essential. To prevent over heating,
clean screens, cooling fins, and other external surfaces
of engine. Avoid spraying water at wiring harness or any
electrical components. Refer to Maintenance Schedule.

20 KohlerEngines.com 32 690 01 Rev. D

 Fuel System

Typical carbureted fuel system and related components Performance

include:
Minimum fuel delivery rate must be 7.5 L/hr. (2 gal./
● Fuel tank. hr.) with a pressure at 0.3 psi and a fuel lift of 24 in. A
● Fuel lines. 1.3 L/hr. (0.34 gal./hr.) fuel rate must be maintained at
● In-line fuel filter. 5 Hz.
● Fuel pump.
● Carburetor. Fuel Pump Replacement
Fuel from tank is moved through in-line filter and fuel NOTE: Make sure orientation of new pump is consistent
lines by fuel pump. Fuel then enters carburetor float bowl with removed pump. Internal damage may occur
and is drawn into carburetor body and mixed with air. if installed incorrectly.
This fuel-air mixture is then burned in engine combustion To replace pulse pump follow these steps. Note
chamber. orientation of pump before removing.
FUEL RECOMMENDATIONS 1. Disconnect fuel lines from inlet, outlet, and pulse
Refer to Maintenance. fittings on fuel pump.
FUEL LINE 2. Remove screws and take off pump.
Low permeation fuel line must be installed on carbureted 3. Connect pulse line to new fuel pump and make sure
Kohler Co. engines to maintain EPA and CARB opposite end is properly connected into valve cover.
regulatory compliance. 4. Attach new fuel pump using screws. Torque screws
FUEL PUMP to 2.3 N·m (20 in. lb.).
Some engines use a pulse style fuel pump. Pumping 5. Reconnect fuel lines to inlet and outlet fittings and
action of pulse style pumps is created by oscillation of secure with clamps.
positive and negative pressures within crankcase. This
pressure is transmitted to pulse pump through rubber
hose connected between pump and crankcase. Pumping
action causes diaphragm on inside of pump to pull fuel
in on its downward stroke and to push it into carburetor
on its upward stroke. Two check valves prevent fuel from
going backward through pump.

FUEL SYSTEM TESTS

When engine starts hard or turns over but will not start, fuel system might be causing problems. Test fuel system by
performing following test.
1. Check for fuel in combustion chamber. 3. Check operation of fuel pump.
a. Disconnect and ground spark plug leads. a. Remove fuel line from inlet fitting of carburetor.
b. Close choke on carburetor. b. Crank engine several times and observe flow.
c. Crank engine several times.
d. Remove spark plug and check for fuel at tip.
2. Check for fuel flow from tank to fuel pump.
a. Remove fuel line from inlet fitting of fuel pump.
b. Hold line below bottom of tank. Open shut-off
valve (if equipped) and observe flow.
Condition Conclusion
Fuel at tip of spark plug. Fuel is reaching combustion chamber.
No fuel at tip of spark plug. Check fuel flow from fuel tank (step 2).
Fuel flows from fuel line. Check for faulty fuel pump (step 3).
If fuel pump is working, check for faulty carburetor. Refer
to Carburetor.
No fuel flow from fuel line. Check fuel tank cap vent, fuel pickup screen, in-line
filter, shut-off valve, and fuel line. Correct any observed
problem and reconnect line.
Fuel line condition. Check for a clogged fuel line. If fuel line is unobstructed,
check for overfilled crankcase and/or oil in pulse line. If
checks don't reveal cause of problem, replace pump.

32 690 01 Rev. D KohlerEngines.com 21

Fuel System

CARBURETOR Keihin One-Barrel Carburetor Components

A
WARNING B
Explosive Fuel can cause fires and severe
burns. C
Do not fill fuel tank while engine is hot or
running.
Gasoline is extremely flammable and its vapors can
explode if ignited. Store gasoline only in approved J
containers, in well ventilated, unoccupied buildings,
away from sparks or flames. Spilled fuel could ignite
if it comes in contact with hot parts or sparks from G
ignition. Never use gasoline as a cleaning agent. F
D
Nikki One-Barrel Carburetor Components E

D
Z
R B F
X
E
I
A
C

Y H
G
W Idle Fuel
Q A Idle Speed Screw B
U Adjusting Screw
H
C Carburetor Body D Idle Jet
P E Plug F Main Jet
O
I Shut-off Solenoid
V G Float H Assembly
T J I Fuel Bowl J Choke Lever
S K Engines in this series are equipped with either a Keihin
or Nikki fixed main jet carburetor. Most carburetors
utilize a fuel shut-off solenoid and feature a self-relieving
N choke.
Troubleshooting Checklist
M L When engine starts hard, runs rough, or stalls at low
idle speed, check these areas before adjusting or
Idle Fuel Adjusting disassembling carburetor.
A Carburetor Body B Screw 1. Make sure fuel tank is filled with clean, fresh
Idle Fuel Adjusting gasoline.
C D Passage Cover
Spring 2. Make sure fuel tank cap vent is not blocked and is
E Cover Gasket F Cover Retaining Screw operating properly.
Ground Lead 3. Make sure fuel is reaching carburetor. This includes
G Main Jet H checking fuel shut-off valve, fuel tank filter screen,
(Solenoid Only)
I Fuel Bowl Gasket J Float Kit in-line fuel filter, fuel lines and fuel pump for
restrictions or faulty components as necessary.
Bowl Retaining
K Fuel Bowl L 4. Make sure air cleaner base and carburetor are
Screw Gasket
securely fastened to engine using gaskets in good
Bowl Retaining Shut-off Solenoid condition.
M N
Screw Assembly
O Throttle Shaft/Lever P Throttle Plate 5. Make sure air cleaner element (including precleaner
if equipped) is clean and all air cleaner components
Q Choke Shaft R Choke Plate are fastened securely.
S Air Filter T Collar 6. Make sure ignition system, governor system,
U Spring V Ring exhaust system, and throttle and choke controls are
W Choke Lever X Idle Speed Screw operating properly.
Y Idle Speed Spring Z Setscrews
22 KohlerEngines.com 32 690 01 Rev. D
 Fuel System

Troubleshooting-Carburetor Related Causes

Condition Possible Cause Conclusion
Engine starts hard, runs rough, or Low idle fuel mixture (some models)/ Adjust low idle speed tab, then adjust
stalls at idle speed. speed improperly adjusted. low idle fuel needle.
Engine runs rich (indicated by black, Clogged air cleaner. Clean or replace air cleaner.
sooty exhaust smoke, misfiring, loss Choke partially closed during Check choke lever/linkage to ensure
of speed and power, governor operation. choke is operating properly.
hunting, or excessive throttle
opening). Low idle fuel mixture is improperly Adjust low idle fuel needle (some
adjusted. models).
Float level is set too high. Separate carburetor air horn from
carburetor body, adjust float
according to steps outlined in repair
kit installation instructions.
Dirt under fuel inlet needle. Remove needle; clean needle and
seat and blow with compressed air.
Bowl vent or air bleeds plugged. Remove low idle fuel adjusting
needle. 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 Low idle fuel mixture is improperly Adjust low idle fuel needle (some
misfiring, loss of speed and power, adjusted. models).
governor hunting, or excessive Float level is set too low. Separate carburetor air horn from
throttle opening). carburetor body, adjust float
according to steps outlined in repair
kit installation instructions.
Idle holes plugged; dirt in fuel delivery Remove low idle fuel adjusting
channels. needle. Clean main fuel jet and all
passages; blow out with compressed
air.
Fuel leaks from carburetor. Float level set too high. Adjust float according to repair kit
installation instructions.
Dirt under fuel inlet needle. Remove needle; clean needle and
seat and blow with compressed air.
Bowl vents plugged. Blow out with compressed air.
Carburetor bowl gasket leaks. Replace gasket.

32 690 01 Rev. D KohlerEngines.com 23

Fuel System

FUEL SYSTEM Carburetor Adjustments

Fuel Shut-off Solenoid NOTE: Carburetor adjustments should be made only
after engine has warmed up.
Most carburetors are equipped with a fuel shut-off
solenoid. Solenoid is attached to fuel bowl. Solenoid has Carburetor is designed to deliver correct fuel-to-air
a spring-loaded pin that retracts when 12 volts is applied mixture to engine under all operating conditions. Main
to lead, allowing fuel flow to main jet. When current is fuel jet is calibrated at factory and is not adjustable.
removed, pin extends blocking fuel flow. Idle fuel adjusting needles are also set at factory and
normally do not need adjustment.
Below is a simple test, performed with engine off, that
can determine if solenoid is functioning properly: Low Idle Speed (RPM) Adjustment
NOTE: Actual low idle speed depends on application.
1. Shut off fuel and remove solenoid from carburetor. Refer to equipment manufacturer’s
When solenoid is loosened and removed, gas will recommendations. Low idle speed for basic
leak out of carburetor. Have a container ready to engines is 1200 RPM.
catch fuel.
Place throttle control into idle or slow position. Turn low
2. Wipe tip of solenoid with a shop towel or blow with idle speed adjusting screw in or out to obtain allow idle
compressed air to remove any remaining fuel. Take speed of 1200 RPM (± 75 RPM).
solenoid to a location with good ventilation and no
fuel vapors present. You will also need a 12 volt Governed Idle Speed Adjustment (if equipped)
power source that can be switched on and off. 1. Hold governor lever away from carburetor so throttle
lever is against idle speed (RPM) adjustment screw
3. Be sure power source is switched OFF. Connect of carburetor. Start engine and allow to warm up,
positive power source lead to red lead of solenoid. then adjust screw to set approximately 1200 RPM.
Connect negative power source lead to solenoid Check speed using a tachometer. Turn adjustment
body. screw (inner) clockwise (in) to increase or
4. Turn power source ON and observe pin in center of counterclockwise (out) to decrease speed.
solenoid. Pin should retract with power ON and 2. Release governor lever and check that throttle lever
return to its original position with power OFF. Test is in idle position. Turn governed idle adjustment
several times to verify operation. screw to obtain equipment manufacturer’s
recommended idle speed (1500-1800 RPM). Some
Carburetor Circuits engines have a bendable tab that is used to set this
Float speed. A pliers should be used to bend this tab to
Fuel level in bowl is maintained by float and fuel inlet achieve recommended speed. Governed idle speed
needle. Buoyant force of float stops fuel flow when (RPM) is typically 300 RPM (approximate) higher
engine is at rest. When fuel is being consumed, float will than low idle speed.
drop and fuel pressure will push inlet needle away from 3. Move throttle lever to wide-open/full throttle position
seat, allowing more fuel to enter bowl. When demand and hold in this position. Turn high speed screw to
ceases, buoyant force of float will again overcome fuel obtain intended high speed no-load RPM. Governed
pressure, rising to predetermined setting and stop flow. idle speed must be set before making this
Slow and Mid-Range adjustment.
At low speeds engine operates only on slow circuit. As Low Idle Fuel Adjustment
a metered amount of air is drawn through slow air bleed
jets, fuel is drawn through main jet and further metered Optimum Low Idle Fuel Setting
through slow jet. Air and fuel are mixed in body of slow
jet and exit to idle progression (transfer port) chamber. B B
From idle progression chamber, air fuel mixture is C C
metered through idle port passage. At low idle air/fuel
mixture is controlled by setting of idle fuel adjusting
screws. This mixture is then mixed with main body of
air and delivered to engine. As throttle plate opening
increases, greater amounts of air/fuel mixture are drawn
in through fixed and metered idle progression holes. A A
As throttle plate opens further, vacuum signal becomes
great enough at venturi so main circuit begins to work.
Main (high-speed) D E
At high speeds/loads engine operates on main circuit.
As a metered amount of air is drawn through air jet, A Rich B Lean
fuel is drawn through main jet. Air and fuel are mixed
in main nozzles then enters main body of airflow where C Midpoint D Left Side
further mixing of fuel and air occurs. This mixture is then E Right Side
delivered to combustion chamber. Carburetor has a fixed
main circuit; no adjustment is possible. NOTE: Engines will have fixed low idle or limiter caps
on idle fuel adjusting needles. Step 2 can only
be performed within limits allowed by cap. Do
not attempt to remove limiter caps.

24 KohlerEngines.com 32 690 01 Rev. D

 Fuel System

1. Place throttle control into idle or slow position. Adjust 2. Clean exterior surfaces of dirt or foreign material
low idle speed to 1200 RPM. Follow Low Idle Speed before disassembling carburetor. Remove bowl
(RPM) Adjustment. retaining screws, or solenoid assembly on most
2. Low idle fuel needle(s) setting: place throttle into idle single cylinder engines, and carefully separate fuel
or slow position. bowl from carburetor. Do not damage fuel bowl
O-rings. Transfer any remaining fuel into an
a. Turn 1 low idle fuel adjusting needle out approved container. Save all parts. Fuel can also be
(counterclockwise) from preliminary setting until drained prior to bowl removal by loosening/removing
engine speed decreases (rich). Note position of bowl drain screw.
needle. Now turn adjusting needle in (clockwise).
Engine speed may increase, then it will decrease 3. Remove float pin (some carburetors may have a
as needle is turned in (lean). Note position of screw which requires removal), and inlet needle.
needle. Set adjusting needle midway between Seat for inlet needle is not serviceable and should
rich and lean settings. not be removed.
b. Repeat procedure on other low idle adjustment 4. Clean carburetor bowl and inlet seat areas as
needle (two-barrel carburetor only). required.
3. Recheck/adjust Low Idle Speed (RPM) to specified 5. Carefully remove main jets from carburetor. For
setting. two-barrel carburetors, note and mark jets by
location for proper reassembly. Main jets may be
High Speed (RPM) Adjustment size/side specific. After main jets are removed, on
1. With engine running, move throttle control to fast. some carburetors, main nozzles can be removed
2. Turn inner adjustment screw outward to decrease, or through bottom of main towers. Note orientation/
inward to increase RPM speed. Courage singles direction of nozzles. End with 2 raised shoulders
require loosening screws on speed control bracket should be out/down adjacent to main jets. Save
and sliding towards carburetor to lower and away parts for cleaning and reuse.
from carburetor to increase speed. 6. Position of slow jet varies and is removable only on
some styles of carburetors. See correct illustration
Carburetor Servicing for corresponding style of carburetor showing
location. (On two-barrel carburetors, slow jets may
WARNING be sized to specific side. Mark or tag jets for proper
reassembly. Note small O-ring on bottom of each
jet.) Save parts for cleaning and reuse unless a jet
Accidental Starts can cause severe injury or kit is also being installed. Clean slow jets using
death. compressed air. Do not use wire or carburetor
Disconnect and ground spark plug lead(s) cleaner.
before servicing. Carburetor is now disassembled for appropriate cleaning
and installation of parts in overhaul kit. See instructions
provided with repair kits for more detailed information.
Before working on engine or equipment, disable
engine as follows: 1) Disconnect spark plug lead(s). 2) High Altitude Operation
Disconnect negative (–) battery cable from battery.
Engines may require a high altitude carburetor kit to
NOTE: Main and slow jets are fixed and size specific ensure correct engine operation at altitudes above
and can be removed if required. Fixed jets for 1219 meters (4000 ft.). To obtain high altitude kit
high altitudes are available. information or to find a Kohler authorized dealer visit
KohlerEngines.com or call1-800-544-2444 (U.S. and
● Inspect carburetor body for cracks, holes, and other Canada).
wear or damage.
● Inspect float for cracks, holes, and missing or This engine should be operated in its original
damaged float tabs. Check float hinge and shaft for configuration below 1219 meters (4000 ft.) as damage
wear or damage. may occur if high altitude carburetor kit is installed and
● Inspect fuel inlet needle and seat for wear or damage. operated below 1219 meters (4000 ft.).
● Inspect spring loaded choke plate to make sure it
moves freely on shaft.
1. Perform removal procedures for appropriate air
cleaner and carburetor outlined in Disassembly.

32 690 01 Rev. D KohlerEngines.com 25

Fuel System

UNITIZED THROTTLE AND CHOKE CONTROL

Some engines are equipped with a unitized throttle and choke control. This assembly controls choke and engine
speed with a single lever. Engines with a unitized throttle and choke control will have either a left side pull or a right
side pull.

Governor/Throttle Control Connections

A C
H E

H
F

K M
A

E E

B G

D C
F B C

A Left Side Pull B Cable Clamp C Speed Control Lever D Speed Setting Lever
E Choke Lever F Right Side Pull G Contact Point H Choke Control Cable
Dual Control High Speed High Speed Adjusting
I Throttle Control Cable J Lever Stop Screw (Do K L Choke Linkage
Screw
Not Remove)
High Speed Control
M Lever

26 KohlerEngines.com 32 690 01 Rev. D

 Fuel System

Throttle Cable Adjustment

NOTE: Choke is placed ON by moving throttle control
slightly past fast position. If throttle control does
not have a designated choke ON position, be
sure to leave sufficient throttle control travel past
fast position. This will enable choke to be placed
ON.
1. Loosen control cable clamp.
2. Place throttle control lever of equipment into fast or
high speed position.
3. Pull on outer shield of throttle control cable until
speed control lever rotates and makes contact with
choke lever. Tighten cable clamp securely.
Starting an Engine Equipped with Unitized Throttle
and Choke Control
NOTE: Do not crank engine continuously for more than
10 seconds at a time. If engine does not start,
allow a 60 second cool down period between
starting attempts. Failure to follow these
guidelines can burn out starter motor.
NOTE: If engine develops sufficient speed to disengage
starter but does not keep running (a false start),
engine rotation must be allowed to come to a
complete stop before attempting to restart
engine. If starter is engaged while flywheel is
rotating, starter pinion and flywheel ring gear
may clash, resulting in damage to starter.
1. For a Cold or Warm Engine – Place throttle/choke
control into fast/choke ON position. This will also
place choke into ON position.
2. Make sure equipment is in neutral.
3. Activate starter switch. Release switch as soon as
engine starts.
If starter does not turn engine over, shut starter off
immediately. Do not make further attempts to start
engine until condition is corrected. Do not jump start
using another battery. See your Kohler authorized dealer
for trouble analysis.
4. For Operation – After engine starts, move throttle/
choke control from fast/choke ON position and set
desired engine operating speed (between slow and
fast position).

32 690 01 Rev. D KohlerEngines.com 27

Governor System

GOVERNOR
Governed speed setting is determined by position of throttle control. It can be variable or constant, depending on
engine application.
Governor is designed to hold engine speed constant under changing load conditions. Most engines are equipped with
a centrifugal flyweight mechanical governor. Governor gear/flyweight mechanism of mechanical governor is mounted
inside oil pan and is driven off gear on camshaft.
Governor Components

I
B F
H
J

K
D
L A

Inside Engine
G
C

A Throttle Lever B Throttle Linkage C Nut D Governor Lever

E Governor Spring F Choke Linkage G Cross Shaft H Flyweight
Locking Tab Thrust
I Regulating Pin J Governor Gear K L Shaft
Washer

This governor design works as follows: Governor Adjustments

● Centrifugal force acting on rotating governor gear NOTE: Do not tamper with governor setting. Overspeed
assembly causes flyweights to move outward as is hazardous and could cause personal injury.
speed increases. Governor spring tension moves
them inward as speed decreases. Initial Adjustment Procedure
● As flyweights move outward, they cause regulating pin Make this adjustment whenever governor arm is
to move outward. loosened or removed from cross shaft. Adjust as follows:
● Regulating pin contacts tab on cross shaft causing 1. Make sure throttle linkage is connected to governor
shaft to rotate. arm and throttle lever on carburetor.
● One end of cross shaft protrudes through crankcase.
Rotating action of cross shaft is transmitted to throttle 2. Loosen nut holding governor lever to cross shaft.
lever of carburetor through external throttle linkage. 3. Move governor lever toward carburetor as far as it
● When engine is at rest, and throttle is in fast position, will go (wide open throttle) and hold in this position.
tension of governor spring holds throttle plate open.
When engine is operating, governor gear assembly is 4. Insert a long thin rod or tool into hole on cross shaft
rotating. Force applied by regulating pin against cross and rotate shaft clockwise (viewed from end) as far
shaft tends to close throttle plate. Governor spring as it will turn, then torque nut to 6.8 N·m (60 in. lb.).
tension and force applied by regulating pin balance
each other during operation, to maintain engine
speed.
● When load is applied and engine speed and governor
gear speed decreases, governor spring tension moves
governor arm to open throttle plate wider. This allows
more fuel into engine, increasing engine speed. As
speed reaches governed setting, governor spring
tension and force applied by regulating pin will again
offset each other to hold a steady engine speed.

28 KohlerEngines.com 32 690 01 Rev. D

 Lubrication System

This engine uses a combination pressure/splash lubrication system, delivering oil under pressure to crankshaft,
connecting rod and main bearing surfaces. Other component areas are splash lubricated.
A high-efficiency gerotor oil pump maintains high oil flow and oil pressure, even at low speeds and high operating
temperatures. A pressure relief valve limits maximum pressure of system. Oil pan must be removed to service oil
pickup and oil pump.
Lubrication Components

B C
A Oil Fill/Dipstick B Oil Drain Plug C Oil Filter
OIL RECOMMENDATIONS CHANGE OIL AND FILTER
Refer to Maintenance. Change oil while engine is warm.
1. Clean area around oil fill cap/dipstick. Remove drain
CHECK OIL LEVEL plug and oil fill cap/dipstick. Allow oil to drain
NOTE: To prevent extensive engine wear or damage, completely.
never run engine with oil level below or above 2. Clean area around oil filter. Place a container under
operating range indicator on dipstick. filter to catch any oil and remove filter. Wipe off
Ensure engine is cool. Clean oil fill/dipstick areas of any mounting surface. Reinstall drain plug. Torque to
debris. 13.6 N·m (10 ft. lb.).
1. Remove dipstick; wipe oil off. 3. Place new filter in shallow pan with open end up. Fill
a. Push-in cap: reinsert dipstick into tube; press with new oil until oil reaches bottom of threads. Allow
completely down. 2 minutes for oil to be absorbed by filter material.
or 4. Apply a thin film of clean oil to rubber gasket on new
filter.
b. Threaded cap: reinsert dipstick into tube and
thread on completely. 5. Refer to instructions on oil filter for proper
installation.
2. Remove dipstick; check oil level. Level should be at
top of indicator on dipstick. 6. Fill crankcase with new oil. Level should be at top of
indicator on dipstick.
3. If oil is low on indicator, add oil up to top of indicator
mark. 7. Reinstall oil fill cap/dipstick and tighten securely.
4. Reinstall and secure dipstick. 8. Start engine; check for oil leaks. Stop engine; correct
leaks. Recheck oil level.
9. Dispose of used oil and filter in accordance with
local ordinances.

32 690 01 Rev. D KohlerEngines.com 29

Lubrication System

OIL SENTRY™ (if equipped) Installation

NOTE: Make sure oil level is checked before each use, 1. Apply pipe sealant with Teflon® (Loctite® PST® 592™
and is maintained up to FULL or F mark on Thread Sealant or equivalent) to threads of switch.
dipstick. This includes engines equipped with
Oil Sentry™. 2. Install switch into tapped hole in oil filter adapter.
This switch is designed to prevent engine from starting in 3. Torque switch to 4.5 N·m (40 in. lb.).
a low oil or no oil condition. Oil Sentry™ may not shut
down a running engine before damage occurs. In some Testing
applications this switch may activate a warning signal. Compressed air, a pressure regulator, pressure gauge,
Read your equipment manuals for more information. and a continuity tester are required to test switch.
Oil Sentry™ pressure switch is installed in oil filter 1. Connect continuity tester across blade terminal and
adapter. Pressure switch is designed to break contact as metal case of switch. With 0 psi pressure applied to
oil pressure increases above 3-5 psi, and make contact switch, tester should indicate continuity (switch
as oil pressure decreases below 3-5 psi. closed).
On stationary or unattended applications (pumps, 2. Gradually increase pressure to switch. As pressure
generators, etc.), pressure switch can be used to ground increases through range of 2-5 psi tester should
ignition module to stop engine. On vehicular applications indicate a change to no continuity (switch open).
(lawn tractors, mowers, etc.) pressure switch can only be Switch should remain open as pressure is increased
used to activate a low oil warning light or signal. to 90 psi maximum.
3. Gradually decrease pressure through range of 2-5
psi. Tester should indicate a change to continuity
(switch closed) down to 0 psi.
4. Replace switch if it does not operate as specified.

30 KohlerEngines.com 32 690 01 Rev. D

 Electrical System

SPARK PLUGS Inspection

CAUTION Inspect each spark plug as it is removed from cylinder
head. Deposits on tip are an indication of general
Electrical Shock can cause injury. condition of piston rings, valves, and carburetor.
Do not touch wires while engine is running. Normal and fouled plugs are shown in following photos:
Normal
Spark Plug Component and Details

A
B

Plug taken from an engine operating under normal

conditions will have light tan or gray colored deposits. If
center electrode is not worn, plug can be set to proper
gap and reused.
Worn

C D

A Wire Gauge B Spark Plug

C Ground Electrode D Gap
NOTE: Do not clean spark plug in a machine using
abrasive grit. Some grit could remain in spark
plug and enter engine causing extensive wear
and damage.
Engine misfire or starting problems are often caused On a worn plug, center electrode will be rounded and
by a spark plug that has improper gap or is in poor gap will be greater than specified gap. Replace a worn
condition. spark plug immediately.
Engine is equipped with following spark plugs: Wet Fouled
Gap 0.76 mm (0.03 in.)
Thread Size 14 mm
Reach 19.1 mm (3/4 in.)
Hex Size 15.9 mm (5/8 in.)
Refer to Maintenance for Repairs/Service Parts.
Service
Clean out spark plug recess. Remove plug and replace.
1. Check gap using wire feeler gauge. Adjust gap to
0.76 mm (0.03 in.).
A wet plug is caused by excess fuel or oil in combustion
2. Install plug into cylinder head. chamber. Excess fuel could be caused by a restricted air
3. Torque plug to 27 N·m (20 ft. lb.). cleaner, a carburetor problem, or operating engine with
too much choke. Oil in combustion chamber is usually
caused by a restricted air cleaner, a breather problem,
worn piston rings, or valve guides.

32 690 01 Rev. D KohlerEngines.com 31

Electrical System

Carbon Fouled ELECTRONIC IGNITION SYSTEMS

There are 3 different types of ignition systems used on
these engines. All systems use an ignition module which
energizes spark plug. Difference in system is in way
ignition timing is triggered.
All ignition systems are designed to be trouble free for
life of engine. Other than periodically checking/replacing
spark plugs, no maintenance or timing adjustments
are necessary or possible. Mechanical systems do
occasionally fail or break down. Refer to Troubleshooting
to determine root of a reported problem.
Reported ignition problems are most often due to poor
Soft, sooty, black deposits indicate incomplete connections. Before beginning test procedure, check
combustion caused by a restricted air cleaner, over rich all external wiring. Be certain all ignition-related wires
carburetion, weak ignition, or poor compression. are connected, including spark plug leads. Be certain all
terminal connections fit snugly. Make sure ignition switch
Overheated is in run position.

Chalky, white deposits indicate very high combustion

temperatures. This condition is usually accompanied
by excessive gap erosion. Lean carburetor settings,
an intake air leak, or incorrect spark timing are normal
causes for high combustion temperatures.
BATTERY
A 12-volt battery with 400 cold cranking amps (cca) is
generally recommended for starting in all conditions. A
smaller capacity battery is often sufficient if an
application is started only in warmer temperatures. Refer
to following table for minimum capacities based on
anticipated ambient temperatures. Actual cold cranking
requirement depends on engine size, application, and
starting temperatures. Cranking requirements increase
as temperatures decrease and battery capacity shrinks.
Refer to equipment's operating instructions for specific
battery requirements.
Battery Size Recommendations
Temperature Battery Required
Above 32°F (0°C) 200 cca minimum
0°F to 32°F (-18°C to 0°C) 250 cca minimum
-5°F to 0°F (-21°C to -18°C) 300 cca minimum
-10°F (-23°C) or below 400 cca minimum
If battery charge is insufficient to turn over engine,
recharge battery.
Battery Maintenance
Regular maintenance is necessary to prolong battery
life.
Battery Test
To test battery, follow manufacturer's instructions.

32 KohlerEngines.com 32 690 01 Rev. D

 Electrical System

Fixed Ignition System

This system uses a capacitive discharge (CD) coil. Ignition timing and spark remains constant regardless of engine
speed. Timing of spark is controlled by location of flywheel magnet group as referenced to engine TDC. A typical fixed
ignition system consists of:
● 1 magnet assembly which is permanently affixed to flywheel.
● 2 electronic capacitive-discharge ignition modules which mount on engine crankcase.
● 1 kill switch (or key switch) which grounds modules to stop engine.
● 2 spark plugs.

Wiring Diagram-Electronic CD Fixed Ignition Timing System Diagram

AF AC AG
AB Q AF
AC
Z
S D G
T AB D AE
AA
Q AD
S M
Y
N

X
R
Q
O
W
L

K
P

J
V
U
A I H
H
G
B

E
F
C D

Solenoid Shift Inertia Driver

A Starter Solenoid Tang B C D Green
Starter Assembly Starter Assembly
E F White
Violet (Charging) Oil SentryTM (Optional) G Spark Plug(s) H (AC Charging Leads)
Rectifier-Regulator Flywheel Stator
I J Rectifier-Regulator K L Ignition Module(s)
Connector Assembly
M Intake Manifold Screw N Ground O Carburetor P White (Ignition Kill)
Q Red R Solenoid Lead S Orange T Connector
Relay Cranking
U Blue V Starter Solenoid Stud W Relay Stud X (Customer Supplied)
Violet (shown)
Y Battery Negative Z Battery AA Battery Positive AB or Orange
Orange (shown)
AC White AD AE Blue (shown) or Red AF Polarity Rib
or Red
Solenoid Shift Starter
AG Assembly (Optional)

32 690 01 Rev. D KohlerEngines.com 33

Electrical System

Digital Spark Advance Ignition (DSAI) Ignition System

This system uses a digital microprocessor which is located in ignition modules. Ignition timing varies depending upon
engine speed with this system. There are 2 inductive-style ignition modules that control ignition timing based on
engine RPM. A typical DSAI application consists of:
● 1 magnet assembly, which is permanently affixed to flywheel.
● 2 inductive, 12-volt ignition modules, which mount on engine crankcase.
● 1 12-volt battery, which supplies current to ignition modules.
● 1 kill switch (or key switch) which grounds spark advance module to stop engine.
● 2 spark plugs.

Wiring Diagram-Digital Spark Advance Ignition (DSAI) System

AB AD Q
J
AC L
K
F
P
J
AE O

AF N M B N

W
Y
J
B
B
H
D
X I

Z F
E G G

C S
AA V N V N

A J
R
U U
B P B
T
A Oil SentryTM (Optional) B Green C Violet (Charging) D Rectifier-Regulator
Rectifier-Regulator White
E F Spark Plug(s) G H Ignition Module(s)
Connector (AC Charging Leads)
Flywheel Stator
I J Red K Ground L Intake Manifold Screw
Assembly
M Carburetor N White O Solenoid Lead P Orange
Solenoid Shift Starter
Q Connector R Red (shown) or Blue S T Orange (shown) or Red
Assembly (Optional)
Violet (shown) or To Starter Solenoid Inertia Drive Starter
U V Polarity Rib W X
Orange Tang Assembly
Solenoid Shift Starter
Y Starter Solenoid Stud Z Starter Solenoid Tang AA AB Battery Positive
Assembly (Optional)
Relay Cranking
AC Battery Negative AD Battery AE Relay Stud AF (Customer Supplied)

34 KohlerEngines.com 32 690 01 Rev. D

 Electrical System

Digital Spark Advance Module (DSAM) Ignition System

DSAM, previously known as Smart-Spark™, equipped engines utilize an electronic capacitive discharge ignition
system with electronic spark advance. A typical application consists of following components:
● 1 magnet assembly which is permanently affixed to flywheel.
● 2 electronic capacitive discharge ignition modules which mount on engine crankcase.
● 1 spark advance module which mounts to engine shrouding.
● 1 12-volt battery which supplies current to spark advance module.
● 1 kill switch (or key switch) which grounds spark advance module to stop engine.
● 2 spark plugs.

Wiring Diagram-Digital Spark Advance Module (DSAM) Ignition System

U

Q
AF AE O J
AG N
T
M
K F
R
Q B I
AH
AD P
AI
AC K
AJ
S L H

F G G
AK
B E

AM C AA Y AA Y
AL
A V
W Q

Z AB
B B
X T
A Oil Sentry™ (Optional) B Green C Violet (Charging) D Rectifier-Regulator
Rectifier-Regulator White Flywheel Stator
E F Spark Plug(s) G H
Connector (AC Charging Leads) Assembly
I Ignition Module(s) J Yellow (Trigger) K Brown L Pink (Trigger)
M DSAM N Ground O Intake Manifold Screw P Carburetor
Q Red R Solenoid Lead S Red (DSAM Power) T Orange
Solenoid Shift Starter
U Connector V W Red or Blue (shown) X Orange or Red (shown)
Assembly (Optional)
Violet or Orange Violet (shown)
Y White Z AA Polarity Rib AB
(shown) or Orange
White
AC Blue AD AE Battery AF Battery Positive
(Ignition Kill)
Relay Cranking
AG Battery Negative AH Relay Stud AI AJ Starter Solenoid Stud
(Customer Supplied )
Solenoid Shift Starter Inertia Drive Starter
AK Starter Solenoid Tang AL AM
Assembly (Optional) Assembly

32 690 01 Rev. D KohlerEngines.com 35

Electrical System

Electronic Ignition Systems Tests

NOTE: Ignition tester must be used to test ignition on these engines. Use of any other tester can result in inaccurate
findings. Battery on unit must be fully charged and properly connected before performing tests (a battery that
is hooked up or charged backward will crank engine but it won’t have spark). Be certain drive is in neutral and
all external loads are disconnected.
Test Ignition Systems
NOTE: If engine starts or runs during testing, you may need to ground kill lead to shut it down. Because you have
interrupted kill circuit, it may not stop using switch.
Isolate and verify trouble is within engine.
1. Locate connectors where wiring harnesses from engine and equipment are joined. Separate connectors and
remove white kill lead from engine connector. Rejoin connectors and position or insulate kill lead terminal so it
cannot touch ground. Try to start engine to verify whether reported problem is still present.
Condition Possible Cause Conclusion
Problem goes away. Electrical System Check key switch, wires, connections,
safety interlocks, etc.
Problem persists. Ignition or Electrical System Leave kill lead isolated until all testing
is completed.
Identify white kill lead of engine
wiring harness connector. Establish
a connection to a known good
ground location. Engine should kill
completely. If not or only one cylinder
is affected, test ignition modules and
white kill lead connection for affected
module (DSAI and DSAM only).

Test for Spark

NOTE: If 2 testers are available, testing can be performed simultaneously for both cylinders. However, if only 1 tester
is available, 2 individual tests must be performed. Side not being tested must have spark plug lead connected
or grounded. Do not crank engine or perform tests with 1 spark plug lead disconnected and not grounded, or
permanent system damage may occur.
1. With engine stopped, disconnect 1 spark plug lead. Connect spark plug lead to post terminal of spark tester and
attach tester clip to a good engine ground.
2. Crank engine over, establishing a minimum of 550-600 RPM, and observe tester(s) for spark.
3. Repeat spark test on opposite cylinder if cylinders are being tested individually.
Condition Possible Cause Conclusion
One side is not firing. Wiring and Connections Check all wiring, connections, and
terminals on that side. If wiring is
okay, replace ignition module and
retest for spark.
Tester shows spark but engine Spark Plug(s) Try new spark plug(s).
misses or won’t run on that cylinder.
Neither side is firing. Ignition Switch Recheck position of ignition switch
and check for shorted kill lead.
Both cylinders have good spark but Spark Plug(s) Install new spark plug(s) and retest
engine runs poorly or existing plug engine performance.
condition is questionable. If problem persists, check for timing
advance (DSAI and DSAM only).
1 cylinder has good spark and other Ignition Test ignition modules and
cylinder has no or intermittent spark. connections (DSAI and DSAM only).
Spark on both cylinders but power is Timing Advance Check for timing advance (DSAI and
suspect. DSAM only).

36 KohlerEngines.com 32 690 01 Rev. D

 Electrical System

Test Timing Advance (DSAI and DSAM only)

1. Make a line near edge of flywheel screen with a marking pen, chalk, or narrow tape.
2. Connect an automotive timing light to cylinder that had good spark.
3. Run engine at idle and use timing light beam to locate line on screen. Draw a line on blower housing next to line
on screen. Accelerate to full throttle and watch for movement of line on screen relative to line on blower housing.
If both cylinders had good spark, repeat test on other cylinder.
Condition Possible Cause Conclusion
Line on screen did not move away Ignition Test ignition modules and
from line on blower housing during connections.
acceleration.
Lines made on blower housing not
90° apart.

Test Ignition Modules and Connections (DSAI only)

1. Remove blower housing from engine. Inspect wiring for any damage, cuts, bad crimps, loose terminals, or broken
wires. Check that connections are oriented properly on terminals of modules.
2. Disconnect leads from ignition module(s) and clean all of terminals (male and female) with aerosol electrical
contact cleaner to remove any old dielectric compound, dark residue, dirt, or contamination. Disconnect spark
plug leads from spark plugs.
3. Using a multi-meter, check that a proper ground is established between ground (black) lead of DSAI module
(closest to spark plug lead) and a known good ground location on engine.
4. Turn key switch to ON position and check for 12 volts at center/power (red) lead terminal of DSAI module. Use
same ground location for multi-meter as in checking for timing advance.
Condition Possible Cause Conclusion
All tests are OK but module has no Ignition Module Replace affected module.
spark or fails to advance.
Any test is BAD. Ignition Module or Connections Determine cause and fix as required;
retest.

Test Ignition Modules and Connections (DSAM only) Ignition Module Resistance Table
NOTE: Resistance values apply only to modules that
have been on a running engine. New service 24 584 36-S Digital 24 584 36-S
modules may have higher resistance until they (2-1/16 in. High) Ohmmeter (2-1/16 in. High)
have been run.
4 2 1
1. Remove blower housing from engine. Inspect wiring From No. 590
for any damage, cuts, bad crimps, loose terminals, 1 to 4 to 616 ohms
or broken wires.
From No. 183
2. Disconnect leads from ignition module(s) and clean 2 to 4 to 208 ohms
all of terminals (male and female) with aerosol 3
electrical contact cleaner to remove any old From No. 8000 to 40,000
dielectric compound, dark residue, dirt, or 3 to 4 ohms
contamination. Disconnect spark plug leads from
spark plugs.
3. Remove one of mounting screws from each ignition module. Look in mounting hole with a flashlight and use a
small round wire brush to remove any loose rust from laminations inside mounting hole.
4. Use a digital ohmmeter to check resistance values of ignition modules and compare them to table. When testing
resistance to laminations, touch probe to laminations inside screw hole, as some laminations have a rust
preventative coating on surface which could alter resistance reading.
Condition Possible Cause Conclusion
All resistance values are within --- Test DSAM.
ranges specified in table.
At least 1 resistance value is not Ignition Module Ignition module is faulty and should
within ranges specified in table. be replaced.

32 690 01 Rev. D KohlerEngines.com 37

Electrical System

5. Check and/or adjust ignition module air gap(s). An air gap of 0.28/0.33 mm (0.011/0.013 in.) must be maintained
under all three legs of ignition module(s). Checking/adjusting should be performed with parts at room
temperature.
Condition Possible Cause Conclusion
Module was not loosened or Ignition Module Air Gap Check that specified air gap is
replaced. present under all three legs. If gap is
correct, reinstall second mounting
screw removed earlier and recheck
gap after tightening.
Module was loosened or replaced. Ignition Module Adjust ignition module air gap.

a. Adjust ignition module air gap.

1. Turn flywheel magnet away from module position.
2. Attach module to mounting legs, pull it away from flywheel, and tighten screws to hold it temporarily.
3. Rotate flywheel so magnet is centered under module.
4. Position a 0.30 mm (0.012 in.) feeler gauge between magnet and all three legs of module. Ignition module
air gap is critical to proper system performance. Do not attempt to set it with a business card or folded
microfiche card. Use feeler gauge specified.
5. Loosen mounting screws, allow magnet to pull module down against feeler gauge, and retighten mounting
screws.
6. Rotate flywheel to remove feeler gauge, position magnet back under module, and recheck that specified
gap, minimum of 0.28 mm (0.011 in.), exists under each leg of module. When you are certain gap is
correct, torque module mounting screws to 4.0 N·m (35 in. lb.). Repeat these 6 steps to set other ignition
module.
6. Reattach lead wires to ignition module(s), noting if resistance is felt, indicating a snug fit between male and
female terminals. If any connections do not feel snug, disconnect lead, lightly pinch female terminal with a pliers,
and recheck fit.
7. When integrity of all connections has been verified, retest for spark.
Condition Possible Cause Conclusion
Strong, steady spark is now present DSAM Go to Test DSAM and perform step 4.
on both sides.
Still a spark problem. DSAM Fully test DSAM.

38 KohlerEngines.com 32 690 01 Rev. D

 Electrical System

Test DSAM
1. Trace red power source lead from DSAM to harness connection. Separate connector and connect red lead of a
DC voltmeter to harness terminal. Trace ground lead (green) from SAM to grounding screw. Connect black
voltmeter lead to eyelet terminal of ground lead or ground screw/bolt. Check voltage with key switch in both
START and RUN positions. A minimum of 7.25 volts must be present.
a. If correct voltage is not measured, connect black voltmeter lead directly to negative (-) post of battery and test
voltage again in both key positions. If correct voltage is now indicated, check ground circuit connections. If
ground screw/bolt or any other fasteners in ground circuit are black (oxide-coated), replace them with zinc
plated (silver colored) fasteners.
b. If correct voltage is still not indicated, check harness connector terminal for a good connection and crimp to
lead. Then trace power source circuit back through harness, key switch, etc., looking for any poor connections,
or faulty circuits.
Condition Possible Cause Conclusion
Incorrect voltage is measured. Voltage Connect black voltmeter lead directly
to negative (-) post of battery and test
voltage again in both key positions.
If correct voltage is still not indicated,
check harness connector terminal for
a good connection and crimp to lead.
Then trace power source circuit back
through harness, key switch, etc.,
looking for any poor connections, or
faulty circuits.
Correct voltage is measured. Voltage Check ground circuit connections.
If ground screw/bolt or any other
fasteners in ground circuit are black
(oxide-coated), replace them with zinc
plated (silver colored) fasteners.

2. Disconnect all of DSAM leads, isolating it from engine. Test DSAM with tester 25 761 40-S, using instructions
following, or use TT-5152 provided with tester. If DSAM tests bad, replace it.
3. Reattach DSAM leads, verifying a snug fit at ignition module terminals. If any connections do not feel snug,
disconnect lead, lightly pinch female terminal with a pliers, and recheck fit.
4. Seal base of ignition module connections with GE/Novaguard G661 or Fel-Pro Lubri-Sel dielectric compound.
Beads should overlap between two connections to form a solid bridge of compound. Do not put any compound
inside connectors.
5. Test for spark to be sure system is working, before you reinstall blower housing. If there is still a spark problem on
one side, replace that ignition module and recheck spark.

32 690 01 Rev. D KohlerEngines.com 39

Electrical System

To test DSAM using spark advance module (SAM) 3. Depress tester button repeatedly until correct test
tester: number appears on display. After a few seconds,
NOTE: DSAM must be at room temperature when test number will flash three times and test will begin.
tested. Disconnect all of DSAM leads, isolating it A reverse numerical sequence will be displayed,
from main wiring harness and ignition module(s). starting with a 6 and progressing down to 1, followed
Testing may be performed with module mounted by a P (pass) or F (fail), indicating condition of part.
or loose. 4. If you get a negative (-) sign instead of numerical
NOTE: Do not allow alligator clip leads to touch each sequence, and/or an F at end of test cycle, recheck
other. all connections, check condition of tester battery and
repeat test. If you get negative (-) or F sign again in
1. Connect tester to DSAM as follows: retest replace DSAM.
Attach: Allow 15-20 seconds for tester to clear and reset itself
● Yellow tester lead to long yellow module lead. between tests or if test is interrupted before completion
● Brown tester lead to long brown module lead. of test cycle. Otherwise, a false reading may be
● Red tester lead to red module lead. displayed in form of a (-) or a faint (8).
● Black tester lead to green or black module ground Tester is powered by a 9-volt battery. Most SAM’s are
lead with eyelet terminal. designed to operate down to a minimum of 7.25 volts.
● Pink tester lead to short yellow or pink module If tester battery drops below that level, incorrect test
lead. readings will result. Tester battery should be checked
● Brown tester lead with black band or terminal to periodically by connecting a DC voltmeter between red
short brown module lead. and green lead wires, with tester connected to a DSAM.
Start appropriate test sequence. While test is running
2. Check DSAM part number, stamped on end of tester monitor voltage reading on voltmeter. If voltage drops
housing, noting last two digits. Using those numbers, below 7.5 at any time during cycle, 9-volt tester battery
refer to table below or tester faceplate to determine must be replaced. Use an extended life (alkaline) battery.
test number to be used. To replace battery, remove outer set of screws on
faceplate and carefully lift panel from body. Unplug
DSAM connector and pull battery (with mounting tape) off back
--- 24 584 31 --- ---
Part No. of tester. Attach connector to new battery and mount
Test battery to case with double-backed tape. Reinstall
1 2 3 4 faceplate and secure with four screws.
No.
DSAM --- --- --- ---
Part No.
Test 5 6 7 8
No.

40 KohlerEngines.com 32 690 01 Rev. D

 Electrical System

BATTERY CHARGING SYSTEM

NOTE: Observe following guidelines to avoid damage to electrical system and components:
● Make sure battery polarity is correct. A negative (-) ground system is used.
● Disconnect rectifier-regulator plug and/or wiring harness plug before doing any electric welding on equipment
powered by engine. Disconnect all other electrical accessories in common ground with engine.
● Prevent stator (AC) leads from touching or shorting while engine is running. This could damage stator.

Most engines are equipped with a 15 amp regulated charging system. Some have a 25 amp regulated charging
system.
15/25 Amp Regulated Charging System
Stator
Stator is mounted on crankcase behind flywheel. Follow procedures in Disassembly and Reassembly if stator
replacement is necessary.
Rectifier-Regulator
NOTE: When installing rectifier-regulator, take note of terminal positions and install plug correctly.
NOTE: Disconnect all electrical connections attached to rectifier-regulator. Testing may be performed with rectifier-
regulator mounted or loose. Repeat applicable test procedure 2 or 3 times to determine condition of part.
Rectifier-regulator is mounted on backing shroud assembly. To replace it, disconnect plug, remove mounting screws,
and ground lead.
Testing rectifier-regulator may be performed as follows, using appropriate rectifier-regulator tester.
To test 25 amp rectifier-regulators: To test 15 amp rectifier-regulators:
1. Connect single lead adapter in between B+ (center) 1. Connect tester ground lead (with spring clamp) to
terminal of rectifier-regulator being tested and body of rectifier-regulator being tested.
squared single end of tandem adapter lead. 2. Connect tester red lead to B+ terminal of rectifier-
2. Connect tester ground lead (with spring clamp) to regulator and 2 black tester leads to 2 AC terminals.
body of rectifier-regulator. 3. Plug tester into proper AC outlet/power for tester
3. Connect red lead and 1 black lead to terminals on being used. Turn on power switch. POWER light
open end of tandem adapter lead (connections are should be illuminated and 1 of 4 status lights may be
not location specific). on as well. This does not represent condition of part.
4. Connect remaining black lead from tester to 1 outer 4. Press TEST button until a click is heard and then
AC terminal on rectifier-regulator. release. Momentarily 1 of 4 status lights will
5. Plug tester into proper AC outlet/power for tester illuminate indicating condition of part.
being used. Turn on power switch. POWER light
should be illuminated and 1 of 4 status lights may be
on as well. This does not represent condition of part.
6. Press TEST button until a click is heard and then
release. Momentarily 1 of 4 lights will illuminate
indicating partial condition of part.

Condition Conclusion
25 amp 15 amp
OK (green) light comes on and stays steady. Disconnect tester black lead Part is good and may be used.
attached to 1 AC terminal and
reconnect it to other AC terminal.
Repeat test. If OK (green) light
comes on again, part is good
and may be used.
NOTE: A flashing LOW light can also occur as Rectifier-regulator is faulty and should not be used.
a result of an inadequate ground lead
connection. Make certain connection
location is clean and clamp is secure.
Other lights come on.

32 690 01 Rev. D KohlerEngines.com 41

Electrical System

15/25 Amp Battery Charging Systems

NOTE: Always zero ohmmeter on each scale before testing to ensure accurate readings. Voltage tests should be
made with engine running at 3600 RPM with no load. Battery must be good and fully charged.
When problems occur in keeping battery charged or battery charges at high rate, charging system or battery might be
causing problems.
To test charging system for no charge to battery: To test charging system for battery continuously charging
1. Insert an ammeter in B+ lead from rectifier-regulator. at high rate:
With engine running at 3600 RPM and B+ (at 1. With engine running at 3600 RPM, measure voltage
terminal on rectifier-regulator) to ground using a DC from B+ lead to ground using a DC voltmeter.
voltmeter.
If voltage is 13.8 volts or more, place a minimum Condition Conclusion
load of 5 amps (turn on lights if 60 watts or more, or Voltage is 14.7 volts or Charging system is OK.
place a 2.5 ohm, 100 watt resistor across battery less. Battery is unable to hold
terminals) on battery to reduce voltage. Observe charge; service or replace.
ammeter. Voltage is more than 14.7 Faulty rectifier-regulator;
volts. replace.
Condition Conclusion
Charge rate increases Charging system is OK
when load is applied. and battery was fully
charged.
Charge rate does not Test stator and rectifier-
increase when load is regulator (steps 2 and 3).
applied.

2. Remove connector from rectifier-regulator. With

engine running at 3600 RPM, measure AC voltage
across stator leads using an AC voltmeter.
Condition Conclusion
Voltage is 28 volts or Stator is OK. Rectifier-
more. regulator is faulty; replace.
Voltage is less than 28 Stator is faulty; replace.
volts. Test stator further using an
ohmmeter (steps 3 and 4).

3. With engine stopped, measure resistance across

stator leads using an ohmmeter.
Condition Conclusion
Resistance is 0.064/0.2 Stator is OK.
ohms.
Resistance is 0 ohms. Stator is shorted; replace.
Resistance is infinity Stator is open; replace.
ohms.

4. With engine stopped, measure resistance from each

stator lead to ground using an ohmmeter.
Condition Conclusion
Resistance is infinity ohms Stator is OK (not shorted
(no continuity). to ground).
Resistance (or continuity) Stator leads are shorted to
measured. ground; replace.

42 KohlerEngines.com 32 690 01 Rev. D

 Starter System

NOTE: Do not crank engine continuously for more than 10 seconds. Allow a 60 second cool-down period between
starting attempts. Failure to follow these guidelines can burn out starter motor.
NOTE: If engine develops sufficient speed to disengage starter but does not keep running (a false start), engine
rotation must be allowed to come to a complete stop before attempting to restart engine. If starter is engaged
while flywheel is rotating, starter pinion and flywheel ring gear may clash and damage starter.
NOTE: If starter does not crank engine, shut off starter immediately. Do not make further attempts to start engine until
condition is corrected.
NOTE: Do not drop starter or strike starter frame. Doing so can damage starter.
Engines in this series use inertia drive or solenoid shift starters.
Troubleshooting-Starting Difficulties
Condition Possible Cause Conclusion
Starter does not energize. Battery Check specific gravity of battery. If low, recharge or replace
battery as necessary.
Wiring Clean corroded connections and tighten loose connections.
Replace wires in poor condition and with frayed or broken
insulation.
Starter Switch By-pass switch or solenoid with a jumper wire. If starter cranks
or Solenoid normally, replace faulty components. Remove and perform
individual solenoid test procedure.
Starter energizes but turns Battery Check specific gravity of battery. If low, recharge or replace
slowly. battery as necessary.
Brushes Check for excessively dirty or worn brushes and commutator.
Clean using a coarse cloth (not emery cloth).
Replace brushes if excessively or unevenly worn.
Transmission Make sure clutch or transmission is disengaged or placed
or in neutral. This is especially important on equipment with
Engine hydrostatic drive. Transmission must be exactly in neutral to
prevent resistance which could keep engine from starting.
Check for seized engine components such as bearings,
connecting rod, and piston.

32 690 01 Rev. D KohlerEngines.com 43

Starter System

INERTIA DRIVE ELECTRIC STARTERS Drive Service

Inertia Drive Electric Starter Components If drive pinion is worn, or has chipped or broken teeth, it
must be replaced.
J
1. Rubber dust cover has a molded lip on inside that
I snaps over a lip on front of drive pinion. Turn drive
pinion clockwise until it reaches fully extended
H position. While holding it in extended position, grasp
tip of dust cover with a pliers or vise grip and pull it
G free from pinion.
2. Grasp spring retainer with a pliers and push it toward
starter, compressing anti-drift spring to expose
F retaining ring.
E 3. Remove retaining ring from armature shaft using
either a retaining ring pliers or snap ring removal
D tool, as described in Steps 4, and 5. Do not reuse
old retainer.
4. Holding spring retainer in retracted position,
assemble inner halves of removal tool around
armature shaft with retaining ring in inner groove.
Slide collar over inner halves to hold them in
position.
5. Thread center screw into removal tool until you feel
resistance. Use a wrench (1-1/8" or adjustable) to
hold base of removal tool. Use another wrench or
socket (1/2" or 13 mm) to turn center screw
C clockwise. Resistance against center screw will tell
you when retaining ring has popped out of groove in
armature shaft.
6. Remove drive components from armature shaft,
paying attention to sequence. If splines are dirty,
clean them with solvent.
7. Splines should have a light film of lubricant.
Lubricate as necessary with Kohler starter drive
B lubricant. Reinstall or replace drive components,
assembling them in reverse order they were
removed.
Retaining Ring Installation
1. Position retaining ring in groove in one of inner
halves. Assemble other half over top and slide on
outer collar.
A 2. Be certain drive components are installed in correct
sequence onto armature shaft.
Commutator End Cap B 3. Slip tool over end of armature shaft, so retaining ring
A Frame inside is resting on end of shaft. Hold tool with one
with Brushes
hand, exerting slight pressure toward starter. Tap top
C Armature D Drive End Cap of tool with a hammer until you feel retaining ring
E Drive Nut (Collar) F Drive Pinion snap into groove. Disassemble and remove tool.
G Anti-Drift Spring H Spring Retainer 4. Squeeze retaining ring with a pliers to compress it
I Retaining Ring J Dust Cover into groove.
When power is applied to starter, armature rotates. As 5. Assemble inner halves with larger cavity around
armature rotates, drive pinion moves out on drive shaft spring retainer. Slide collar over them and thread
splines and into mesh with flywheel ring gear. When center screw in until resistance is felt.
pinion reaches end of drive shaft, it rotates flywheel and 6. Hold base of tool with a 1-1/8" wrench and turn
cranks engine. center screw clockwise with a 1/2" or 13 mm wrench
When engine starts, flywheel rotates faster than starter to draw spring retainer up around retaining ring. Stop
armature and drive pinion. This moves drive pinion out turning when resistance increases. Disassemble and
of mesh with ring gear and into retracted position. When remove tool.
power is removed from starter, armature stops rotating 7. Reinstall dust cover.
and drive pinion is held in retracted position by anti-drift
spring.
44 KohlerEngines.com 32 690 01 Rev. D
 Starter System

Starter Disassembly SOLENOID SHIFT STARTERS

1. Remove drive components following instructions for Solenoid Shift Starter Components
servicing drive.
2. Remove thru bolts. H I
3. Remove commutator end cap containing brush
holder, brushes, brush springs and thrust washer J
(cup).
G
4. Remove drive end cap. K
5. Remove armature from inside starter frame. F
L
End Cap/Brush Replacement E
Brushes are contained in a plastic carrier housing, D M
attached to end cap. Replacement brushes in brush
holder come preassembled, attached to end cap with N
commutator end thrust washer (cup) holding brushes in C
retracted position. When installation is performed, end O
of armature shaft will push thrust washer (cup) back into
final position allowing brushes to contact commutator.
Do not remove protective tape and shipping strip holding
washer (cup) until part is ready to be installed.
P
Commutator Service
Clean commutator with a coarse, lint free cloth. Do not
use emery cloth. B Q
If commutator is badly worn or grooved, turn it down on
a lathe or replace starter. R
Starter Reassembly
S
1. Insert armature into starter frame. Make sure
magnets are closer to drive shaft end of armature.
Magnets will hold armature inside frame. A T
2. Install drive end cap over drive shaft and align with
cutout starter frame. U
3. Installing new brushes: carefully remove tape
holding thrust washer (cup) in place against brushes. A Tube B Washer
Do not allow thrust washer (cup) to move out of this C Armature D Drive
position. Align terminal stud block with notch in
starter frame and start brush holder/end cap E Stop F Retaining Ring
assembly onto end of armature. G Collar H Drive End Cap
4. Pull out thin shipping strip from behind thrust washer I Screw J Plunger
(cup), and slide brush holder/end cap into position. K Spring L Lever
5. Install thru bolts and torque to 4.5-5.7 N·m M Plate N Plug
(40-50 in. lb.). O Solenoid P Frame and Field
6. Lubricate drive shaft with Kohler starter drive Q Brush Holder R Nut
lubricant. Install drive components following
instructions for servicing starter drive. Commutator End
S T Screw
Plate
U Bolt
When power is applied to starter electric solenoid moves
drive pinion out onto drive shaft and into mesh with
flywheel ring gear. When pinion reaches end of drive
shaft it rotates flywheel and cranks engine.
When engine starts and start switch is released, starter
solenoid is deactivated, drive lever moves back, and
drive pinion moves out of mesh with ring gear into
retracted position.

32 690 01 Rev. D KohlerEngines.com 45

Starter System

Starter Disassembly Armature

Components and Details
NOTE: Do not reuse old retainer.
NOTE: Do not soak armature or use solvent when A
cleaning. Wipe clean using a soft cloth, or use
compressed air.
1. Remove hex nut and disconnect positive (+) brush
lead/bracket from solenoid terminal.
2. Remove head screws securing solenoid to starter.
B
3. Unhook plunger pin from drive lever. Remove gasket
from recess in housing. A Commutator O.D. B Mica Insulation
4. Remove thru (larger) bolts.
5. Remove commutator end plate assembly, containing
brush holder, brushes, springs, and locking caps.
Remove thrust washer from inside commutator end.
C
6. Remove frame from armature and drive end cap.
7. Remove drive lever pivot bushing and backing plate
(if equipped) from end cap.
8. Take out drive lever and pull armature out of drive
end cap. E
D
9. Remove thrust washer from armature shaft.
10. Push stop collar down to expose retaining ring.
C Insulation Check D Armature Coil
11. Remove retainer from armature shaft. Save stop E Continuity Check
collar.
12. Remove drive pinion assembly from armature. 1. Clean and inspect commutator (outer surface). Mica
13. Clean parts as required. insulation must be lower than commutator bars
(undercut) to ensure proper operation of
Inspection commutator.
Drive Pinion 2. Use an ohmmeter set to Rx1 scale. Touch probes
Check and inspect following areas: between 2 different segments of commutator, and
check for continuity. Test all segments. Continuity
● Pinion teeth for abnormal wear or damage. must exist between all or armature is bad.
● Surface between pinion and clutch mechanism for
nicks or irregularities which could cause seal damage. 3. Check for continuity between armature coil
● Check drive clutch by holding clutch housing and segments and commutator segments. There should
rotating pinion. Pinion should rotate in only 1 direction. be no continuity. If continuity exists between any 2
armature is bad.
Brushes and Springs
Detail 4. Check armature windings/insulation for shorting.
Shift Fork
Check that shift fork is complete, and pivot and contact
areas are not excessively worn, cracked, or broken.

A Brush Replacement
4 brushes and springs are serviced as a set. Use a new
Kohler brush and spring kit if replacement is necessary.
1. Perform steps 1-5 in Starter Disassembly.
2. Remove screws securing brush holder assembly to
end cap (plate). Note orientation for reassembly later.
Discard old brush holder assembly.
3. Clean component parts as required.
A Wear Limit Length New brushes and springs come preassembled in a
brush holder with a protective sleeve that will also
Inspect both springs and brushes for wear, fatigue, or serve as an installation tool.
damage. Measure length of each brush. Minimum length
for each brush is 7.6 mm (0.300 in.). Replace brushes if 4. Perform steps 10-13 in Starter Reassembly
they are worn, undersize, or condition is questionable. sequence. If starter has been disassembled,
installation must be done after armature, drive lever,
and frame are installed.

46 KohlerEngines.com 32 690 01 Rev. D

 Starter System

Starter Reassembly 10. Starter reassembly when replacing brushes/brush

holder assembly:
NOTE: Always use a new retainer. Do not reuse old
retainers that have been removed. a. Hold starter assembly vertically on end housing,
and carefully position assembled brush holder
NOTE: Correctly installed, center pivot section of drive assembly, with supplied protective tube, against
lever will be flush or below machined surface of end of commutator/armature. Mounting screw
housing. holes in metal clips must be up/out. Slide brush
1. Apply drive lubricant to armature shaft splines. Install holder assembly down into place around
drive pinion onto armature shaft. commutator, and install positive (+) brush lead
grommet in cutout of frame. Protective tube may
2. Install and assemble stop collar/retainer assembly. be saved and used for future servicing.
a. Install stop collar down onto armature shaft with Starter reassembly when not replacing brushes/
counter bore (recess) up. brush holder assembly:
b. Install a new retainer in larger (rear) groove of a. Carefully unhook retaining caps from brush
armature shaft. Squeeze with a pliers to assemblies. Do not lose springs.
compress it in groove.
b. Position brushes back in their slots so they are
c. Slide stop collar up and lock it into place, so flush with I.D. of brush holder assembly. Insert
recess surrounds retainer in groove. If necessary, brush installation tool (with extension), or use
rotate pinion outward on armature splines against tube described above from a prior brush
retainer to help seat collar around retainer. installation, through brush holder assembly, so
3. Install offset thrust (stop) washer so smaller offset of holes in metal mounting clips are up/out.
washer faces retainer/collar. c. Install brush springs and snap on retainer caps.
4. Apply a small amount of oil to bearing in drive end d. Hold starter assembly vertically on end housing,
cap, and install armature with drive pinion. and carefully place tool (with extension) and
5. Lubricate fork end and center pivot of drive lever assembled original brush holder assembly onto
with drive lubricant. Position fork end into space end of armature shaft. Slide brush holder
between captured washer and rear of pinion. assembly down into place around commutator,
install positive (+) brush lead grommet in cutout
6. Slide armature into drive end cap and at same time of frame.
seat drive lever into housing.
11. Install end cap onto armature and frame, aligning
7. Install rubber grommet into matching recess of drive thin raised rib in end cap with corresponding slot in
end cap. Molded recesses in grommet should be grommet of positive (+) brush lead.
out, matching and aligned with those in end cap.
12. Install thru bolts and brush holder mounting screws.
8. Install frame, with small notch forward, onto Torque bolts to 5.6-9.0 N·m (49-79 in. lb.) and brush
armature and drive end cap. Align notch with holder mounting screws to 2.5-3.3 N·m
corresponding section in rubber grommet. Install (22-29 in. lb.).
drain tube in rear cutout, if it was removed
previously. 13. Hook plunger behind upper end of drive lever and
install spring into solenoid. Insert mounting screws
9. Install flat thrust washer onto commutator end of through holes in drive end cap. Use these to hold
armature shaft. solenoid gasket in position, then mount solenoid.
Torque screws to 4.0-6.0 N·m (35-53 in. lb.).
14. Connect positive (+) brush lead/bracket to solenoid
and secure with nut. Torque nut to 8-11 N·m
(71-97 in. lb.). Do not overtighten.

32 690 01 Rev. D KohlerEngines.com 47

Starter System

Solenoid Tests
NOTE: DO NOT leave 12 volt test leads connected to solenoid for any time over what is necessary for performing
each of individual tests. Internal damage to solenoid may occur.
Disconnect all leads from solenoid including positive brush lead attached to lower stud terminal. Remove mounting
hardware and separate solenoid from starter for testing.
To test solenoid pull-in coil/plunger: To test solenoid hold-in coil:
Actuation Function
1. Use a 12 volt power supply and 2 test leads. 1. Connect a 12 volt test lead to flat spade S/start
2. Connect 1 lead to flat spade S/start terminal on terminal on solenoid and other lead to body or
solenoid. Momentarily connect other lead to lower mounting surface of solenoid.
large post terminal. 2. Manually push plunger IN and check if coil holds
When connection is made solenoid should energize plunger retracted. Do not allow test leads to remain
(audible click) and plunger retract. Repeat test connected to solenoid for a prolonged period of time.
several times. Continuity
Continuity 1. Use an ohmmeter set to audible or Rx2K scale, and
1. Use an ohmmeter set to audible or Rx2K scale, and connect 2 ohmmeter leads to 2 large post terminals.
connect 2 ohmmeter leads to 2 large post terminals. 2. Perform preceding solenoid hold-in coil function test
2. Perform solenoid pull-in coil/plunger actuation test and check for continuity. Meter should indicate
and check for continuity. Ohmmeter should indicate continuity. Repeat test several times.
continuity. Repeat test several times.

Condition Conclusion
Solenoid fails to activate. Replace solenoid.
No continuity is indicated.
Plunger fails to stay retracted.

48 KohlerEngines.com 32 690 01 Rev. D

 Emission Compliant Systems

EVAPORATIVE EMISSION COMPLIANT SYSTEM

Carbon Canister System

D
A

Roll Over Valve

A Fuel Tank Cap B Fuel Tank C D Carbon Canister
(ROV)
Canister Breather
E F To Carburetor
Filter
For engine to be Tier III compliant, it may be fitted with a Kohler supplied canister vapor recovery system, or a system
developed and installed by Original Equipment Manufacturer (OEM). Details on Kohler system are included below.
Operation Maintenance
Fuel vapors travel from fuel tank through tubing to On Kohler-supplied canisters, breather filter can be
carbon canister. On intake stroke of engine fuel vapors removed and cleaned with hot soapy water, dried and
are drawn in through a port in carburetor and burned reinstalled. Do not oil breather screen. This is done
with fuel charge. periodically or if system operation is suspect. Carbon
canister is sealed and requires no maintenance.
In some applications or installations, OEM will have
installed a different canister or fuel vapor recovery
system. See OEM equipment documentation for service
or maintenance information.

32 690 01 Rev. D KohlerEngines.com 49

Emission Compliant Systems

SECONDARY EMISSION COMPLIANT SYSTEM

Twin Secondary Air Induction System

A
C

D
C

Hose To Exhaust Secondary Air

A B Inlet Screen C D Hose To Carburetor
Manifold Valve Assembly
Hose To Exhaust
E Manifold

Single Secondary Air Induction System

G
F

Secondary Air Hose To Exhaust

F G H Hose To Carburetor I Inlet Screen
Valve Assembly Manifold
For engine to be Tier III compliant, it may be fitted with a secondary air induction system (SAI).
Operation Maintenance
Intake pulse of engine activates secondary air valve. Air inlet screen in secondary air valve can be removed,
Air is drawn through an inlet screen of secondary air cleaned, and reinstalled. If inspection of system reveals
valve. Air is then drawn into exhaust manifold and any damage or decomposition of hoses, secondary air
muffler where it mixes with any unburned hydrocarbons, valve, or exhaust system, parts should be replaced.
which then burn in heat of muffler. A hose is connected
between a carburetor port and a diaphragm chamber
in secondary air valve. Carburetor vacuum moves
diaphragm to close valve when air induction is not
required, primary idle.

50 KohlerEngines.com 32 690 01 Rev. D

 Emission Compliant Systems

Remove Inlet Screen

Inlet Components

A
B

A Secondary Air Valve Assembly B Barb C Inlet Screen

1. Remove inlet screen from secondary air valve assembly by grasping inlet screen at base and gently pulling away
from valve assembly.
2. Use a soft brush to remove debris from screen.
3. Run water through inlet screen in reverse direction.
4. To reinstall, push inlet screen onto barb of secondary air valve assembly. An audible click will be heard when inlet
screen is properly reinstalled.

32 690 01 Rev. D KohlerEngines.com 51

Disassembly/Inspection and Service

WARNING
Accidental Starts can cause severe injury or Before working on engine or equipment, disable engine as
death. follows: 1) Disconnect spark plug lead(s). 2) Disconnect
negative (–) battery cable from battery.
Disconnect and ground spark plug lead(s)
before servicing.
External Engine Components

E
B
F
C
E
W
G
H
E D
V

I
U

T
J
S
X R

K
L
M N
L

O
P

Air Cleaner
A Fixed Guard B C Debris Screen D Blower Housing
Access Door
E Hose Clamp F Fuel Pump G Hose Clip H Fuel Line
I Fuel Filter J Oil Filter K Nipple L O-Ring
Oil Feed Tube Oil Feed Tube
M N O Outer Baffle P Electric Starter
(Oil Pump Outlet) (Filter to Pan)
Q Inner Baffle R Ignition Module S Intake Manifold T Carburetor
U Gasket V Air Cleaner Base W Air Cleaner X Rectifier-Regulator

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 Disassembly/Inspection and Service

Clean all parts thoroughly as engine is disassembled. Remove Blower Housing and Outer Baffles
Only clean parts can be accurately inspected
and gauged for wear or damage. There are many 1. Remove screws securing blower housing.
commercially available cleaners that will quickly remove 2. Remove blower housing from engine.
grease, oil and grime from engine parts. When such a
cleaner is used, follow manufacturer’s instructions and 3. Remove M6 mounting screw on bottom of each
safety precautions carefully. outer baffle into cylinder, and M5 screws going into
backing plate and cylinder head flange. One screw
Make sure all traces of cleaner are removed before may also secure lift strap on 1 side.
engine is reassembled and placed into operation. Even
small amounts of these cleaners can quickly break down Remove Throttle Controls
lubricating properties of engine oil.
Disconnect Spark Plug Leads Control Bracket Components
NOTE: Pull on boot only, to prevent damage to spark
plug lead. A
1. Disconnect leads from spark plugs.
B
2. Shut off fuel supply.
Drain Oil From Crankcase and Remove Oil Filter
1. Remove oil fill cap/dipstick and oil drain plug. C
F
2. Allow ample time for oil to drain from crankcase and
oil filter. E
3. Remove and appropriately discard oil filter.
4. Use an allen wrench to loosen adapter nipple. Note
locating pin of adapter and corresponding notch in
pad of oil pan. Remove nipple, washer (plastic D
adapters only), and oil filter adapter.
C
5. Remove oil pump outlet tube assembly and oil feed
tube (if not removed with nipple).
Remove Muffler
Remove exhaust system and attaching hardware from G
engine
C
Remove Fuel Pump (if equipped)
D
WARNING A Choke Linkage B Throttle Linkage
Explosive Fuel can cause fires and severe C Governor Lever D Governor Spring
burns.
E Cross Shaft F Control Bracket
Do not fill fuel tank while engine is hot or
running. G Dampener Spring
Gasoline is extremely flammable and its vapors can 1. Remove screws securing throttle control bracket to
explode if ignited. Store gasoline only in approved cylinder heads.
containers, in well ventilated, unoccupied buildings,
away from sparks or flames. Spilled fuel could ignite 2. Disconnect choke linkage from choke actuator lever.
if it comes in contact with hot parts or sparks from Unhook governor spring, and dampener spring from
ignition. Never use gasoline as a cleaning agent. governor lever. Note hole locations for reassembly.

1. Disconnect pulse (vacuum) hose and outlet fuel line Remove External Governor Controls
from fuel pump. Loosen nut and remove governor lever from cross shaft.
2. Remove mounting screws, unhook outlet hose from Leave lever attached to throttle linkage.
blower housing clip, and remove fuel pump from
blower housing.

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Disassembly/Inspection and Service

Remove Air Cleaner and Carburetor Remove Electric Starter Motor

1. Disconnect leads from starter.
WARNING
2. Remove screws and starter.
Explosive Fuel can cause fires and severe
burns. 3. Pull out oil fill tube with lifting strap from crankcase.
Do not fill fuel tank while engine is hot or Remove Inner Baffles
running.
Remove mounting screws securing inner baffles to
Gasoline is extremely flammable and its vapors can crankcase. Note position of any lifting bracket(s).
explode if ignited. Store gasoline only in approved Remove inner baffles.
containers, in well ventilated, unoccupied buildings,
away from sparks or flames. Spilled fuel could ignite Remove Ignition Modules
if it comes in contact with hot parts or sparks from 1. Rotate flywheel so magnet is away from modules.
ignition. Never use gasoline as a cleaning agent.
2. Disconnect lead(s) from each ignition module. Fixed
1. Remove carburetor/air cleaner base mounting nuts Timing Models and DSAI Models have 1 lead per
and disconnect breather hose. Remove air cleaner module and DSAM or Smart-Spark™ (variable
base and gasket. timing) ignition modules have 2 leads per module.
2. Unhook retainer and remove air cleaner element and 3. Remove mounting screws and ignition modules.
precleaner (if equipped) from air cleaner base for Note position of ignition modules.
servicing.
Remove Intake Manifold and Rectifier-Regulator
3. Disconnect ground lead and fuel shut-off solenoid
lead (if equipped). 1. Remove screws securing intake manifold to cylinder
heads. Note which screws hold wiring clamp(s).
4. Remove carburetor, throttle linkage and governor
lever as an assembly. 2. Remove intake manifold and O-rings. Leave wiring
harness attached to manifold.
5. Remove carburetor gasket.
3. Remove screws securing rectifier-regulator to
6. If necessary, carburetor, throttle linkage and backing plate and disconnect plug.
governor lever can be separated. Reattach bushings
to linkage following separation to avoid losing them. 4. Use tip of a small screwdriver or similar small flat
tool to bend locking tang, then remove B+ (center
lead) from terminal plug. This will allow intake
manifold to be removed with wiring harness intact.

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Cylinder Head Components

M
E A
C
D
F I
G H
J

L
N
O

A Gasket B Valve C Cylinder Head D Spring Cap

E Valve Stem Seal F Valve Spring G Valve Spring Retainer H Valve Spring Keeper
I Stud J Spark Plug K Guide Plate L Push Rod
M Rocker Arm N Rocker Arm Pivots O Adjusters P O-Ring
Q Valve Cover

Remove Spark Plugs 3. Sealing surface of stamped steel valve covers must
be checked for flatness prior to reinstallation. Hold
Remove spark plug from each cylinder head. valve cover down firmly against a flat, level surface
or piece of glass, and check around entire perimeter
Remove Valve Covers and Cylinder Heads that a 0.012 in. (0.30 mm) feeler gauge cannot be
Plastic Valve Covers with O-Rings inserted anywhere. If gauge goes in anywhere,
Remove screws securing each valve cover. Most valve cover needs to be replaced.
covers have screw hole spacers molded in place.
Remove valve covers and O-rings. Remove Cylinder Heads
Stamped Steel Valve Covers with RTV Sealant NOTE: Exhaust side is located on output shaft side of
NOTE: Valve cover is sealed to cylinder head using engine, while intake side is located on fan side
RTV silicone sealant. When removing valve of engine. Cylinder head number is embossed
cover, use care not to damage gasket surfaces on outside of each cylinder head.
of cover and cylinder head. To break RTV seal, 1. Loosen rocker arm pivot screws, or inner setscrews
hold a block of wood against 1 flat face of valve (T25 TORX) based on design, and back off rocker
cover. Strike wood firmly with a mallet. If seal arm adjusting nuts.
doesn't break loose after 1 or 2 attempts, repeat
procedure on other side. 2. Mark location of push rods as either intake or
exhaust and cylinder 1 or 2. Push rods should
1. Remove screws, or Torx screws securing each valve always be installed in same positions.
cover.
3. Remove screws securing each cylinder head.
2. Using a brass wire brush and gasket remover or Discard screws once removed. Do not reuse.
similar solvent, clean old RTV from surface of
cylinder head and valve cover. 4. Remove cylinder head and head gasket.

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Disassemble Cylinder Heads 3. Once valve spring is compressed, remove following

items.
NOTE: On engines with valve stem seals on intake
valves; use a new seal whenever valve is ● Valve spring keepers.
removed or if seal is deteriorated or damaged. ● Valve spring retainers.
Never reuse an old seal. ● Valve springs.
● Valve spring caps.
1. Remove adjusters, pivots, rocker arms, studs, and ● Intake and exhaust valves (mark position).
guide plate with adjusters from cylinder head. ● Valve stem seal (intake valve some models).
2. Compress valve springs using a valve spring 4. Repeat above procedure for other cylinder head. Do
compressor. not interchange parts from 1 cylinder head to
another.
Inspection and Service
Valve Details
Exhaust Insert

F B F
E C A E

G D G

H H

Exhaust Valve A Intake Valve

B

Intake Insert
Dimension Intake Exhaust
A Seat Angle 89° 89°
B Insert O.D. 36.987/37.013 mm (1.4562/1.4572 in.) 32.987/33.013 mm (1.2987/1.2997 in.)
C Guide Depth 4 mm (0.1575 in.) 6.5 mm (0.2559 in.)
D Guide I.D. 7.038/7.058 mm (0.2771/0.2779 in.) 7.038/7.058 mm (0.2771/0.2779 in.)
E Valve Head Diameter 33.37/33.63 mm (1.3138/1.3240 in.) 29.37/29.63 mm (1.1563/1.1665 in.)
F Valve Face Angle 45° 45°
G Valve Margin (Min.) 1.5 mm (0.0591 in.) 1.5 mm (0.0591 in.)
H Valve Stem Diameter 6.982/7.000 mm (0.2749/0.2756 in.) 6.970/6.988 mm (0.2744/0.2751 in.)
After cleaning, check flatness of cylinder head and corresponding top surface of crankcase, using a surface plate or
piece of glass and feeler gauge. Maximum allowable out of flatness is 0.076 mm (0.003 in.).
Carefully inspect valve mechanism parts. Inspect valve springs and related hardware for excessive wear or distortion.
Check valves and valve seat area or inserts for evidence of deep pitting, cracks, or distortion. Check clearance of
valve stems in guides. See valve details and specifications.
Hard starting, or loss of power accompanied by high fuel consumption may be symptoms of faulty valves. Although
these symptoms could also be attributed to worn rings, remove and check valves first. After removal, clean valve
heads, faces, and stems with a power wire brush. Then, carefully inspect each valve for defects such as warped
head, excessive corrosion, or worn stem end. Replace valves found to be in bad condition.

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Valve Guides Flywheel/Ignition/Breather Components

If a valve guide is worn beyond specifications, it will not
guide valve in a straight line. This may result in burnt A
valve faces or seats, loss of compression, and excessive
oil consumption.
To check valve guide-to-valve stem clearance, B
thoroughly clean valve guide and, using a split-ball
gauge, measure inside diameter of guide. Then, using
an outside micrometer, measure diameter of valve stem
at several points on stem where it moves in valve guide.
Use largest stem diameter to calculate clearance by
subtracting stem diameter from guide diameter. If intake C
clearance exceeds 0.038/0.076 mm (0.0015/0.003
in.) or exhaust clearance exceeds 0.050/0.088 mm D
(0.0020/0.0035 in.), determine whether valve stem or E
guide is responsible for excessive clearance.
Maximum (I.D.) wear on intake valve guide is 7.134 mm
(0.2809 in.) while 7.159 mm (0.2819 in.) is maximum
allowed on exhaust guide. Guides are not removable but F
can be reamed 0.25 mm (0.010 in.) oversize. Valves with
0.25 mm oversize stems must then be used.
If guides are within limits but valve stems are worn
beyond limits, install new valves.
Valve Seat Inserts G
Hardened steel alloy intake and exhaust valve seat
inserts are press-fitted into cylinder head. Inserts are
not replaceable but can be reconditioned if not too badly
pitted or distorted. If cracked or badly warped, cylinder
head should be replaced. H
Recondition valve seat inserts following instructions
provided with valve seat cutter being used. Final cut
should be made with an 89° cutter as specified for
valve seat angle. Cutting proper 45° valve face angle,
as specified, and proper valve seat angle (44.5°, half of I
full 89° angle), will achieve desired 0.5° (1.0° full cut) J
interference angle where maximum pressure occurs on K
outside diameters of valve face and seat. L
Lapping Valves
Reground or new valves must be lapped in, to provide
fit. Use a hand valve grinder with suction cup for M
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 SAE 10 oil to prevent rusting.
Intake Valve Stem Seal
Some engines use valve stem seals on intake valves.
Always use a new seal when valves are removed
from cylinder head. Seals should also be replaced if N
deteriorated or damaged in any way. Never reuse an old
seal. A Flywheel Screw B Fan
C Washer D Fan Mounting Plate
E Magnet F Flywheel
G Stator H Backing Plate
I Outer Breather Cover J Stud
K Retainer L Breather Reed
M Ignition Module N Woodruff Key

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Disassembly/Inspection and Service

Remove Debris Screen, Fan, and Flywheel Crankshaft/Governor Gear/Oil Pump Components
NOTE: Always use a flywheel strap wrench or flywheel
holding tool (see Tools and Aids) to hold flywheel
when loosening or tightening flywheel and fan
retaining fasteners. Do not use any type of bar
or wedge between fins of cooling fan, as fins
could become cracked or damaged. A
NOTE: Always use a puller to remove flywheel from
crankshaft. Do not strike crankshaft or flywheel,
as these parts could become cracked or
damaged. Striking puller or crankshaft can
cause crank gear to move, affecting crankshaft
endplay.
1. Unsnap debris screen from cooling fan.
1 2
2. Remove retaining screw, washer, and fan mounting
plate, securing fan and flywheel to crankshaft. B
3. Carefully lift cooling fan to disengage 2 drive pins
and remove it from flywheel.
4. Remove flywheel from crankshaft using a puller. R
5. Remove woodruff key. C
Flywheel Inspection
Inspect flywheel for cracks, and flywheel keyway for P
damage. Replace flywheel if it is cracked. Replace
flywheel, crankshaft, and key if flywheel key is sheared D
Q O
or keyway is damaged.
Inspect ring gear for cracks or damage. Kohler does M
not provide ring gears as a serviceable part. Replace E
flywheel if ring gear is damaged. F

Remove Backing Plate and Stator N

G
1. Remove mounting screws and backing plate from S
H
crankcase. L
2. Remove screws and stator. Note routing of stator
leads. I

Remove Outer Breather Assembly

1. RTV sealant is used between outer breather cover
and crankcase. Remove nut and sealing (flat)
washer securing breather cover to crankcase.
Carefully pry under small tab of cover flange to
separate and remove. Do not bend or distort cover. J
2. Unscrew and remove mounting stud, retainer and K
breather reed. Governor Cross
A B Crankshaft
Shaft
C Valve Tappets D Camshaft
E Regulating Pin F Shaft
Locking Tab Thrust
G Governor Gear H Washer
I Oil Pan J Drain Plug
Oil Feed Tube
K Oil Seal L (Filter to Pan)
M Oil Pump N Gerotor Gears
Oil Feed Tube
O P O-Rings
(Oil Pump Outlet)
Q Oil Sentry™ R Oil Pump Torque
S Retaining Ring

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Remove Oil Pan Assembly 3. Carefully inspect governor gear shaft and replace it
only if it is damaged. After removing damaged shaft,
1. Remove screws securing oil pan to crankcase. press or lightly tap replacement shaft into oil pan to
2. Locate splitting tab cast into perimeter of oil pan. depth shown.
Insert drive end of a 1/2” breaker bar between Reassembly
splitting tab and crankcase and turn it to break RTV 1. Install locking tab thrust washer on governor gear
seal. Do not pry on sealing surfaces as this can shaft with tab down.
cause leaks.
2. Position regulating pin within governor gear/
Inspection flyweights assembly and slide both onto governor
Inspect oil seal in oil pan and remove it if it is worn shaft until assembly locks into place.
or damaged. New oil seal is installed after oil pan is
assembled to crankcase. See Reassembly, Oil Seal in Oil Pump Assembly
Oil Pan.
Oil pump is mounted inside oil pan. If service is required,
Inspect main bearing surface for wear or damage (refer continue with Disassembly, Inspection, and Reassembly.
to Specifications). Replace oil pan assembly if required.
Disassembly
Governor Assembly NOTE: Relief valve is sealed as part oil pump housing
and not serviceable. Replace oil pump if relief
Governor gear assembly is located inside oil pan. If valve condition or function is questionable in any
service is required, continue following steps. way.
Inspection 1. Remove screws.
Inspect governor gear teeth. Replace gear if it is worn,
chipped, or if any teeth are missing. Inspect governor 2. Lift oil pump assembly from oil pan.
weights. They should move freely in governor gear. 3. Outer gerotor gear is typically held captive in oil
Disassembly pump housing. If gear becomes separated, see step
1 under Reassembly for proper reinstallation.
Governor Shaft Component and Details
Inspection
C Inspect oil pump housing, gear, and rotors for nicks,
burrs, wear, or any visible damage. Check oil pickup
screen for damage or restriction. If any parts are worn or
damaged, replace oil pump assembly. Disassembly of oil
pump is not recommended. If retaining ring of main shaft
B is removed for any reason, a new retaining ring should
be used. Do not install a used ring.
A
Reassembly
1. Lubricate outer gerotor gear with oil. If outer gear
was separated from oil pump housing examine outer
edges. On gerotor gears: 1 edge contains small
molding marks or dots, which must be matched to
those on inner gear. If dots are not visible on inner
gear, install outer gear with dots down or in. If dots
are visible, outer gear should be installed with dots
up or out. Not matching molding dots will result in
reduced pump output efficiency.
2. Install oil pump inserting center shaft into
corresponding recess in oil pan. Secure oil pump by
torquing screws in indicated sequence to 11.2 N·m
(100 in. lb.) in new, as-cast holes, or 7.3 N·m
34.0 mm (1.3386 in.) (65 in. lb.) into used holes.
A B 19.40 mm (0.7638 in.)
33.5 mm (1.3189 in.) a. Start fastener 1 into hole, apply only minimal
C Gear Shaft torque to position pump.
b. Torque fastener 2 to full value.
NOTE: Governor gear is held onto shaft by small
molded tabs in gear. When gear is removed from c. Torque fastener 1 to full value.
shaft, these tabs are destroyed and gear must d. After torquing, rotate gear and check for freedom
be replaced. Therefore, remove gear only if of movement. Make sure there is no binding. If
absolutely necessary. binding occurs, loosen screws, reposition pump,
Governor gear must be replaced once it is removed from retorque screws and recheck movement.
oil pan.
1. Use 2 small screwdrivers and carefully pry upward to
remove regulating pin and governor gear assembly.
2. Remove locking tab thrust washer located under
governor assembly.

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Remove Camshaft and Valve Tappets Connecting Rods/Piston/Breather Components

1. Position crankcase so flywheel side is down.
Remove camshaft and shim.
2. Remove valve tappets from crankcase and mark
them by their location, as either intake or exhaust
and cylinder 1 or 2. Tappets should always be J B
reinstalled in same position.
A C
Camshaft Inspection and Service
Check lobes of camshaft for wear or damage. See
Specifications for minimum lift specifications. Inspect D
cam gear for badly worn, chipped or missing teeth. B
Replacement of camshaft will be necessary if any of
these conditions exist.
Valve Tappets Inspection
Check base surface of valve tappet(s) for wear or
damage. Replace tappet(s) if condition is questionable F E
in any way. Corresponding camshaft lobe(s) should also
be checked for wear or damage. Whenever tappets are
replaced, apply a liberal coating of Kohler lubricant to
base of each new tappet before it is installed. G

Remove Governor Cross Shaft H

Governor Cross Shaft Oil Seal Details
I
A B

A Piston Ring Set B Piston Pin Retainer

C Piston D Piston Pin
Connecting Rod
E Connecting Rod F End Cap
Breather Cover
G Breather Filter H Gasket
Inner Breather
I J Oil Seal
Cover
Remove Connecting Rods with Pistons and Rings
NOTE: If a carbon ridge is present at top of either
Governor Cross cylinder bore, use a ridge reamer tool to remove
A 2.0 mm (0.0787 in.) B Shaft Seal it before attempting to remove piston.
1. Remove retainer and washer from governor cross NOTE: Cylinders are numbered on crankcase. Use
shaft. numbers to mark each end cap, connecting rod
2. Remove cross shaft with small inner washer through and piston for reassembly. Do not mix end caps
inside of crankcase. and connecting rods.
3. Remove governor shaft seal from crankcase. 1. Remove screws securing closest connecting rod end
cap. Remove end cap.
If governor cross shaft seal is damaged and/or leaks,
replace it using following procedure. 2. Carefully remove connecting rod and piston
assembly from cylinder bore.
Remove oil seal from crankcase and replace it with a
new one. Install new seal to depth shown. 3. Repeat above procedure for other connecting rod
and piston assembly.

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Connecting Rods A piston pin is included as part of piston assembly – if

pin boss in piston or pin are worn or damaged, a new
Offset, stepped-cap connecting rods are used in all piston assembly is required.
these engines.
Ring failure is usually indicated by excessive oil
Inspection and Service consumption and blue exhaust smoke. When rings fail,
Check bearing area (big end) for excessive wear, score oil is allowed to enter combustion chamber where it is
marks, running and side clearances (See Specifications). burned along with fuel. High oil consumption can also
Replace rod and cap if scored or excessively worn. occur when piston ring end gap is incorrect because
Service replacement connecting rods are available in ring cannot properly conform to cylinder wall under this
STD size and 0.25 mm (0.010 in.) undersize. Undersized condition. Oil control is also lost when ring gaps are not
rods, 0.25 mm (0.010 in.), have an identification marking staggered during installation.
on lower end of rod shank. Always refer to appropriate When cylinder temperatures get too high, lacquer and
parts information to ensure correct replacements are varnish collect on pistons causing rings to stick, which
used. results in rapid wear. A worn ring usually takes on a
shiny or bright appearance.
Piston and Rings
Scratches on rings and pistons are caused by abrasive
Inspection material such as carbon, dirt, or pieces of hard metal.
Piston and Rings Components and Details
Detonation damage occurs when a portion of fuel charge
A ignites spontaneously from heat and pressure shortly
after ignition. This creates 2 flame fronts, which meet
and explode to create extreme hammering pressures on
a specific area of piston. Detonation generally occurs
B from using low octane fuels.
Pre-ignition or ignition of fuel charge before timed spark
can cause damage similar to detonation. Pre-ignition
C damage is often more severe than detonation damage.
Pre-ignition is caused by a hot spot in combustion
chamber such as glowing carbon deposits, blocked
cooling fins, an improperly seated valve, or wrong spark
plug(s).
D Replacement pistons are available in STD bore size,
and 0.25 mm (0.010 in.) oversize. Replacement pistons
E include new piston ring sets and new piston pins.
Replacement ring sets are also available separately for
STD, and 0.25 mm (0.010 in.) oversize pistons. Always
F use new piston rings when installing pistons. Never use
old rings.
Some important points to remember when servicing
G piston rings:
1. Cylinder bore must be de-glazed before service ring
I sets are used.
2. If cylinder bore does not need re-boring and if old
H piston is within wear limits and free of score or scuff
marks, old piston may be reused.
A Piston Ring B End Gap
3. Remove old rings and clean up grooves. Never
C Identification Mark D Piston reuse old rings.
Top Compression Center 4. Before installing new rings on piston, place top 2
E F
Ring Compression Ring rings, each in turn, in its running area in cylinder
G Rails H Expander bore and check end gap. Top and center
compression ring end gap clearance is 0.25/0.56
Oil Control Ring mm (0.0100/0.0224 in.) for a new bore, or 0.94 mm
I (3 Piece) (0.037 in.) for a used bore.
Scuffing and scoring of pistons and cylinder walls occurs 5. After installing new compression (top and middle)
when internal engine temperatures approach welding rings on piston, make sure top compression ring-to-
point of piston. Temperatures high enough to do this are groove side clearance is 0.025/0.048 mm
created by friction, which is usually attributed to improper (0.0010/0.0019 in.) and middle compression ring-to-
lubrication and/or overheating of engine. groove side clearance 0.015/0.037 mm
Normally, very little wear takes place in piston boss- (0.0006/0.0015 in.). If side clearance is greater than
piston pin area. If original piston and connecting rod can specified, a new piston must be used.
be reused after new rings are installed, original pin can
also be reused but new piston pin retainers are required.

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Disassembly/Inspection and Service

Install New Piston Rings Remove Flywheel and PTO End Oil Seals
NOTE: Rings must be installed correctly. Ring
installation instructions are usually included with Remove oil seals from crankcase and oil pan.
new ring sets. Follow instructions carefully. Use
a piston ring expander to install rings. Install Crankcase
bottom (oil control) ring first and top Inspection and Service
compression ring last. Check all gasket surfaces to make sure they are free of
To install new piston rings, proceed as follows: gasket fragments. Gasket surfaces must also be free of
deep scratches or nicks.
1. Oil control ring (bottom groove): Install expander and
then rails. Make sure ends of expander are not Check cylinder bore for scoring. In severe cases,
overlapped. unburned fuel can cause scuffing and scoring of cylinder
wall. It washes necessary lubricating oils off piston and
2. Middle compression ring (center groove): Install cylinder wall. As raw fuel seeps down cylinder wall,
center ring using a piston ring expander tool. Make piston rings make metal to metal contact with wall.
sure identification mark is up or colored dye stripe (if Scoring of cylinder wall can also be caused by localized
contained) is to left of end gap. hot spots resulting from blocked cooling fins or from
3. Top compression ring (top groove): Install top ring inadequate or contaminated lubrication.
using a piston ring expander tool. Make sure If cylinder bore is badly scored, excessively worn,
identification mark is up or colored dye stripe (if tapered, or out-of-round, resizing is necessary. Use an
contained) is left of end gap. inside micrometer to determine amount of wear (refer
to Specifications). A 0.25 mm (0.010 in.) oversize piston
Remove Crankshaft is available if resizing is selected. Initially, resize using
Carefully pull crankshaft from crankcase. a boring bar, then use these following procedures for
honing cylinder.
Inspection and Service
Inspect gear teeth of crankshaft. If teeth are badly worn, Honing
chipped, or some are missing, replacement of crankshaft Details
will be necessary.
Inspect crankshaft bearing surfaces for scoring,
grooving, etc. Measure running clearance between A
crankshaft journals and their respective bearing bores.
Use an inside micrometer or telescoping gauge to
measure inside diameter of both bearing bores in vertical
and horizontal planes. Use an outside micrometer to
measure outside diameter of crankshaft main bearing
journals. Subtract journal diameters from their respective
bore diameters to get running clearances. Check results
against values in Specifications. If running clearances
are within specification, and there is no evidence of
scoring, grooving, etc., no further reconditioning is
necessary. If bearing surfaces are worn or damaged,
crankcase and/or oil pan will need to be replaced.
Inspect crankshaft keyways. If worn or chipped,
replacement of crankshaft will be necessary.
Inspect crankpin for score marks or metallic pickup. A 23°-33° Crosshatch
Slight score marks can be cleaned with crocus cloth
soaked in oil. If wear limits are exceeded, as stated in NOTE: Kohler pistons are custom-machined to exacting
Specifications, it will be necessary to replace crankshaft. tolerances. When over-sizing a cylinder, it
should be machined exactly 0.25 mm (0.010 in.)
Remove Inner Breather Assembly over new diameter (refer to Specifications).
Oversize Kohler replacement piston will then fit
Breather system is designed to control amount of oil correctly.
in head area and still maintain necessary vacuum in
crankcase. While most commercially available cylinder hones can
be used with either portable drills or drill presses, use
When pistons move downward, crankcase gases are of a low speed drill press is preferred as it facilitates
pushed past reed through mesh filter into intake system. more accurate alignment of bore in relation to crankshaft
Upward travel of pistons closes reed and creates a crossbore. Honing is best accomplished at a drill speed
low vacuum in lower crankcase. Any oil separated out of about 250 RPM and 60 strokes per minute. After
through filter drains back into crankcase. installing coarse stones in hone, proceed as follows:
1. Remove screw securing inner breather cover and
gasket to crankcase.
2. Carefully remove cover, gasket, and breather filter.
Make sure drain back hole is not plugged or
restricted.

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1. Lower hone into bore and after centering, adjust so Measuring Piston-to-Bore Clearance
stones are in contact with cylinder wall. Use of a Piston Detail
commercial cutting-cooling agent is recommended.
2. With lower edge of each stone positioned even with
lowest edge of bore, start drill and honing process.
Move hone up and down while resizing to prevent A
formation of cutting ridges. Check size frequently.
3. When bore is within 0.064 mm (0.0025 in.) of
desired size, remove coarse stones and replace
them with burnishing stones. Continue with
burnishing stones until bore is within 0.013 mm
(0.0005 in.) of desired size and then use finish A 6 mm (0.24 in.)
stones (220-280 grit) and polish bore to its final size.
A crosshatch should be observed if honing is done NOTE: Do not use a feeler gauge to measure piston-to-
correctly. Crosshatch should intersect at bore clearance, it will yield inaccurate
approximately 23°-33° off horizontal. Too flat an measurements. Always use a micrometer.
angle could cause rings to skip and wear Before installing piston into cylinder bore, it is necessary
excessively, and too steep an angle will result in high that clearance be accurately checked. This step is
oil consumption. often overlooked, and if clearances are not within
4. After resizing, check bore for roundness, taper, and specifications, engine failure will usually result.
size. Use an inside micrometer, telescoping gauge, Use following procedure to accurately measure piston-
or bore gauge to take measurements. These to-bore clearance:
measurements should be taken at 3 locations in 1. Use a micrometer and measure diameter of piston
cylinder – at top, middle, and bottom. Two 6 mm (0.24 in.) above bottom of piston skirt and
measurements should be taken (perpendicular to perpendicular to piston pin.
each other) at 3 locations.
2. Use an inside micrometer, telescoping gauge, or
Clean Cylinder Bore After Honing bore gauge and measure cylinder bore.
Proper cleaning of cylinder walls following boring and/ Measurement approximately 63.5 mm (2.5 in.) below
or honing is very critical to a successful overhaul. top of bore and perpendicular to piston pin.
Machining grit left in cylinder bore can destroy an engine
in less than 1 hour of operation after a rebuild. 3. Piston-to-bore clearance is difference between bore
diameter and piston diameter (step 2 minus step 1).
Final cleaning operation should always be a thorough
scrubbing with a brush and hot, soapy water. Use a
strong detergent capable of breaking down machining
oil while maintaining a good level of suds. If suds break
down during cleaning, discard dirty water and start again
with more hot water and detergent. Following scrubbing,
rinse cylinder with very hot, clear water, dry it completely,
and apply a light coating of engine oil to prevent rusting.

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Reassembly

NOTE: Make sure engine is assembled using all Install Flywheel End Oil Seal
specified torque values, tightening sequences,
and clearances. Failure to observe specifications 1. Make sure seal bore of crankcase is clean and free
could cause severe engine wear or damage. of any nicks or burrs.
Always use new gaskets. 2. Apply a light coat of engine oil to outside diameter of
Make sure all traces of any cleaner are removed before oil seal.
engine is assembled and placed into operation. Even 3. Install oil seal into crankcase using a seal driver.
small amounts of these cleaners can quickly break down Make sure oil seal is installed straight and true in
lubricating properties of engine oil. bore and tool bottoms against crankcase.
Check oil pan, crankcase, cylinder heads, and valve
covers to be certain all old sealing material has been Install Breather Filter and Inner Cover
removed. Use gasket remover, lacquer thinner, or paint NOTE: Make sure drainback hole in gasket and cover is
remover to remove any remaining traces. Clean surfaces aligned and open after cover is secured. Check
with isopropyl alcohol, acetone, lacquer thinner, or using a piece of wire or similar tool.
electrical contact cleaner.
1. Install breather filter between 2 ribs inside inner
Connecting Rods/Piston/Breather Components breather chamber.
2. Make sure sealing surfaces are clean and free of
nicks or damage. Install a new breather cover gasket
and breather cover onto chamber.
3. Secure breather cover with M6 screw. Torque screw
J B to 10.7 N·m (95 in. lb.) into a new, cored hole, or
7.3 N·m (65 in. lb.) into a used hole.
A C
Install Governor Cross Shaft
D 1. Lubricate governor cross shaft bearing surfaces in
B crankcase with engine oil.
2. Slide lower washer onto governor cross shaft and
install cross shaft from inside of crankcase.
3. Install nylon washer onto governor cross shaft, then
F E start push-on retaining ring. Hold cross shaft up in
position, place a 0.50 mm (0.020 in.) feeler gauge on
top of nylon washer, and push retaining ring down
shaft to secure. Remove feeler gauge, which will
G have established proper endplay.

A Piston Ring Set B Piston Pin Retainer

C Piston D Piston Pin
Connecting Rod
E Connecting Rod F End Cap
Breather Cover
G Breather Filter H Gasket
Inner Breather
I J Oil Seal
Cover

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 Reassembly

Crankshaft/Governor Gear/Oil Pump Components Install Crankshaft

1. Lubricate flywheel side main bearing surface and
lips of oil seal in crankcase with clean engine oil.
2. Carefully slide flywheel end of crankshaft through
main bearing in crankcase.
A Install Connecting Rods with Pistons and Rings
Piston and Connecting Rod Details

1 2

B
B

C
A
P
A Side 1 B Side 2
D
Q O NOTE: Cylinders are numbered on crankcase. Make
sure to install piston, connecting rod, and end
M E cap into its appropriate cylinder bore as
previously marked during disassembly. Do not
F mix end caps and connecting rods.
G NOTE: Proper orientation of piston/connecting rod
N assemblies inside engine is extremely important.
H Improper orientation can cause extensive wear
L or damage. Be certain pistons and connecting
rods are assembled exactly as shown.
I
NOTE: Align chamfer of connecting rod with chamfer of
its mating end cap. When installed, flat faces of
connecting rods should face each other. Faces
with raised rib should be toward outside.
1. Stagger piston rings in grooves until end gaps are
120° apart. Oil ring rails should also be staggered.
J 2. Lubricate cylinder bore, piston, and piston rings with
K engine oil. Compress rings using a piston ring
compressor.
Governor Cross 3. Lubricate crankshaft journals and connecting rod
A B Crankshaft
Shaft bearing surfaces with engine oil.
C Valve Tappets D Camshaft 4. Make sure FLY stamping on piston is facing toward
flywheel side of engine. Use a hammer with a rubber
E Regulating Pin F Shaft or wood grip and gently tap piston into cylinder. Be
Locking Tab Thrust careful oil ring rails do not spring free between
G Governor Gear H bottom of ring compressor and top of cylinder.
Washer
I Oil Pan J Drain Plug 5. Install inner rod cap to connecting rod using screws.
Torque screws in increments to 11.3 N·m
Oil Feed Tube (100 in. lb.). Illustrated instructions are provided in
K Oil Seal L (Filter to Pan) service rod package.
M Oil Pump N Gerotor Gears 6. Repeat above procedure for other connecting rod
Oil Feed Tube and piston assembly.
O P O-Rings
(Oil Pump Outlet)
Q Oil Sentry™ R Oil Pump Torque

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Reassembly

Install Valve Tappets and Camshaft Install Oil Seal in Oil Pan
NOTE: Exhaust valve tappets are located on output Oil Seal Component and Detail
shaft side of engine, while intake valve tappets
are located on fan side of engine. Cylinder
number is embossed on outside of each cylinder A
on crankcase. Valve tappets should always be
installed in same position as before disassembly.
1. Apply camshaft lubricant to contact surface of valve
tappets. Note mark or tag identifying tappets and B
install them in their appropriate crankcase locations.
A small amount of grease applied to stems will hold
valve tappets up until camshaft is installed.
2. Liberally apply camshaft lubricant to lobes of
camshaft. Lubricate camshaft bearing surfaces of
crankcase and camshaft with engine oil.
3. Position timing mark of crankshaft gear at 12 o’clock
position.
4. Turn governor cross shaft clockwise until lower end A 6.5 mm (0.255 in.) B Oil Seal
(blade) is laying against bottom of cylinder. Make
sure cross shaft remains in this position while 1. Check to make sure there are no nicks or burrs in
installing camshaft. crankshaft bore of oil pan.
5. Slide camshaft into bearing surface of crankcase, 2. Apply a light coat of engine oil to outside diameter of
positioning timing mark of camshaft gear at 6 o’clock oil seal.
position. Make sure camshaft gear and crankshaft
gear mesh with both timing marks aligned. 3. Drive oil seal into oil pan using a seal driver. Make
sure oil seal is installed straight and true in bore, to
Determining Camshaft End Play depth shown.
1. If a camshaft shim was used, install shim removed
during disassembly onto camshaft. Install Oil Feed Tubes and Filter Adapter
2. Position camshaft endplay checking tool on
camshaft. Oil Filter Adapter Components
3. Apply pressure on endplay tool (pushing camshaft B
toward crankshaft). Use a feeler gauge to measure
camshaft endplay between shim (if used) and
endplay tool. Camshaft endplay should be
0.076/0.127 mm (0.003/0.005 in.).
4. If camshaft endplay is not within specified range,
remove endplay tool and shim accordingly. Shims
are color-coded by thickness and listed below.
White: 0.69215/0.73025 mm (0.02725/0.02875 in.) A
Blue: 0.74295/0.78105 mm (0.02925/0.03075 in.)
A Oil Filter Adapter B O-Ring
Red: 0.79375/0.83185 mm (0.03125/0.03275 in.)
Yellow: 0.84455/0.88265 mm (0.03325/0.03475 in.) 1. Lubricate new O-rings with clean oil and install into
groove on ends of oil pump oil feed tube.
Green: 0.89535/0.99345 mm (0.03525/0.03675 in.)
2. Install oil feed tube with O-rings. Push in until seated
Gray: 0.94615/0.98425 mm (0.03725/0.03875 in.) into outlet of oil pump. Make sure inner O-ring is not
Black: 0.99695/1.03505 mm (0.03925/0.04075 in.) unseated or damaged when installing.
5. Reinstall endplay tool and recheck end play. 3. Slide oil feed tube through oil pan and into hole for
main bearing. A small amount of grease applied to
Oil Pump Assembly outside, forward end of tube will hold tube in position
until adapter is installed.
Oil pump is mounted inside oil pan. If service
was required and oil pump was removed, refer to 4. Apply a small amount of grease and install a new
Disassembly/Inspection and Service procedure. O-ring into groove of adapter for oil filter.
5. Position adapter, aligning locating pin with
Governor Assembly corresponding recess in oil pan. Install flat washer
Governor assembly is located inside oil pan. If service (plastic adapters only) onto adapter nipple, then
was required and governor was removed, refer to insert through adapter, surrounding oil feed tube and
Disassembly/Inspection and Service procedure. finger tighten. Tighten nipple and torque to 33.9 N·m
(300 in. lb.). Do not overtighten.

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 Reassembly

Install Oil Pan Assembly Flywheel/Ignition/Breather Components

Sealant Pattern A

C
D
E

Fastener Torque Sequence

1
3
10 G

5
8
H
7

6
I
9 4 J
2
K
L
RTV sealant is used as a gasket between oil pan
and crankcase. Refer to Tools and Aids for a listing of
approved sealants. Always use fresh sealant. Using M
outdated sealant can result in leakage.
1. Be sure sealing surfaces have been cleaned and
prepared as described at beginning of Reassembly.
2. Check to make sure there are no nicks or burrs on
sealing surfaces of oil pan or crankcase.
3. Apply a 1.5 mm (1/16 in.) bead of black RTV sealant
to sealing surface of oil pan. See sealant pattern. Oil
pan must be installed within 5 minutes of sealant
being applied for proper sealing to occur.
4. Make sure end of governor cross shaft is lying N
against bottom of cylinder inside crankcase.
5. Install oil pan to crankcase. Carefully seat camshaft A Flywheel Screw B Fan
with shim and crankshaft into their mating bearings.
Rotate crankshaft to help engage oil pump and C Washer D Fan Mounting Plate
governor gear meshes. E Magnet F Flywheel
6. Install 10 screws securing oil pan to crankcase. G Stator H Backing Plate
Torque fasteners in sequence shown to 24.4 N·m
(216 in. lb). On some engines 1 of 10 mounting Outer Breather
I J Stud
screws is plated. Plated screw is typically installed in Cover
hole location 6 as shown. K Retainer L Breather Reed
M Ignition Module N Woodruff Key

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Reassembly

Install Breather Reed and Outer Cover Install Flywheel and Fan
Breather Cover Sealant CAUTION
Damaging Crankshaft and Flywheel can
cause personal injury.

Using improper procedures can lead to broken

A fragments. Broken fragments could be thrown from
engine. Always observe and use precautions and
procedures when installing flywheel.
NOTE: Before installing flywheel, make sure crankshaft
taper and flywheel hub are clean, dry, and
completely free of lubricants. Presence of
lubricants can cause flywheel to be overstressed
and damaged when screw is torqued to
A Sealant Bead specifications.
NOTE: RTV sealant should be allowed to cure a NOTE: Make sure flywheel key is installed properly in
minimum of 1 hour before engine is started. keyway. Flywheel can become cracked or
damaged if key is not installed properly.
1. Install breather reed, followed by retainer over
passage hole and mounting hole in crankcase. Hold 1. Install woodruff key into keyway of crankshaft. Make
in position and secure with mounting stud. Torque sure key is properly seated and parallel with shaft
stud to 6.2 N·m (55 in. lb.) into a new, cored hole, or taper.
4.0 N·m (35 in. lb.) into a used hole. 2. Install flywheel onto crankshaft being careful not to
2. Invert breather housing (cover) and apply a 1.5 mm shift woodruff key.
(1/16 in.) bead of RTV sealant to perimeter flange of 3. Install fan onto flywheel, so locating pins fit into
outer housing (cover) as shown. Use Loctite® 5900 corresponding recesses.
or 5910.
4. Install fan mounting plate onto fan, aligning 4
3. Immediately install housing over mounting stud and cutouts, followed by heavy flat washer and screw.
onto crankcase. Do not allow RTV sealant to come
in contact with breather reed, or reed sealing 5. Use a flywheel strap wrench or holding tool to hold
surface. flywheel. Torque screw securing flywheel to
crankshaft to 74.5 N·m (55 ft. lb.).
4. Secure with a new sealing washer and M5 nut.
Torque nut to 1.3 N·m (12 in. lb.). Check that a Install Ignition Modules
complete seal has occurred by RTV sealant being
squeezed out around entire flange perimeter. 1. Rotate flywheel to position magnet away from
ignition module bosses.
5. Attach breather hose to housing if disconnected
earlier. Make sure cover is between formed lips of 2. DSAI or DSAM ignition system ignition modules are
breather hose. Position hose so opposite end is installed in similar ways with tabs out.
away from crankshaft. Fixed ignition system ignition modules are installed
with spark plug lead from module always away from
Install Stator and Backing Plate cylinder. On cylinder 1, single kill tab should be up/
1. Apply pipe sealant with Teflon® (Loctite® PST® 592TM towards you. On cylinder 2, single kill tab should be
or equivalent) to stator mounting holes. down/away from you.
2. Position stator aligning mounting holes so leads are 3. Install each ignition module to crankcase bosses
at bottom, toward crankcase. with screws. Slide modules up as far away from
flywheel as possible and snug screws to hold them
3. Install and torque screws to 6.2 N·m (55 in. lb.). in position.
4. Route stator leads in crankcase recess, then install 4. Rotate flywheel to position magnet directly under 1
backing plate. Secure with screws. Torque screws in ignition module.
a crisscross pattern to 7.3 N·m (65 in. lb.).

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 Reassembly

5. Insert a 0.30 mm (0.012 in.) flat feeler gauge 8. Rotate flywheel back and forth checking for
between magnet and ignition module. Loosen clearance between magnet and ignition modules.
screws enough to allow magnet to pull module Make sure magnet does not strike modules. Check
against feeler gauge. gap with a feeler gauge and readjust if necessary.
6. Torque screws to 4.0-6.2 N·m (35-55 in. lb.). Final air gap 0.280/0.330 mm (0.011/0.013 in.).
7. Repeat Steps 4 through 6 for other ignition module.

Cylinder Head Components

M
E A
C
D
F I
G H
J

L
N
O

R
P

A Gasket B Valve C Cylinder Head D Spring Cap

E Valve Stem Seal F Valve Spring G Valve Spring Retainer H Valve Spring Keeper
I Stud J Spark Plug K Guide Plate L Push Rod
M Rocker Arm N Rocker Arm Pivots O Adjuster P O-Ring
Q Valve Cover R Torque Sequence

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Reassembly

Assemble and Install Cylinder Heads Adjust Valve Clearance

Valve Stem Seals Adjusters Retaining Push Rods
Some engines use a valve stem seal on intake valves.
If engine being serviced used a valve stem seal, use B
a new seal whenever valve is removed, or if seal is
deteriorated or damaged. Never reuse an old seal.
A
Assemble Cylinder Heads
Prior to installation, lubricate all components with engine
oil, paying particular attention to lip of valve stem seal,
valve stems, and valve guides. Install following items in
order listed below using a valve spring compressor.
● Intake and exhaust valves.
● Valve spring caps. E
● Valve springs. C
● Valve spring retainers.
● Valve spring keepers.

Install Cylinder Heads

NOTE: Match numbers embossed on cylinder heads D
and crankcase.
NOTE: When installing cylinder heads, new screws
should always be used. New screws are
supplied in gasket sets.
A Adjustment Screw B End Adjustment Style
NOTE: Push rods should always be installed in same
position as before disassembly. C Adjuster D Center Pivot
Adjustment Style
1. Check to make sure there are no nicks or burrs on
sealing surfaces of cylinder head or crankcase. E Nut
Make sure dowel locating pins are in lower 2 cylinder 1. Turn adjusters in rocker arms or pivots down
bolt holes on each side. (clockwise) only enough to capture push rods in
2. Install a new cylinder head gasket (with printing up) recesses.
on each side. 2. Rotate crankshaft to establish TDC on compression
3. Install each cylinder head and start 4 new screws. stroke for cylinder 1.
4. Torque screws in 2 stages; first to 22.6 N·m Check for:
(200 in. lb.), then finally to 41.8 N·m (370 in. lb.), a. Compression will be felt through spark plug hole.
following sequence.
b. Keyway of crankshaft will be aligned with cylinder
Install Rocker Arms 1.
1. Loosen locking nut and back off adjusters for rocker
arms. If adjusters for rocker arms were removed, c. No rocker arm/push rod movement if crankshaft
reinstall them into threaded end of arm is rotated slightly back and forth. If they are
approximately 3 threads and thread locking nut onto moving, rotate crankshaft 1 full revolution.
adjuster from underside. Screw adjuster flush with 3. Insert a 0.127 mm (0.005 in.) feeler gauge between
bottom of nut as an initial setting. Do not tighten end of 1 valve and rocker arm. Turn adjuster or
locking nut at this time, final adjustment will be made adjustment nut (based on design), until a slight drag
later. is felt. Hold in this position and tighten locking nut or
2. Apply grease to contact surfaces of adjusters, rocker setscrew securely. Torque setscrew to 7.9 N·m
arms and rocker arm pivots. Install rocker arms and (70 in. lb.). After tightening recheck adjustment.
rocker arm pivots onto appropriate cylinder head, Proper valve clearance is 0.101/0.152 mm
and start screws. (0.004/0.006 in.).
3. Hold rocker arms in aligned position and torque 4. Repeat procedure for other valve on side 1.
screws to 11.3 N·m (100 in. lb.). 5. Viewed from PTO end, rotate crankshaft 270° (3/4
4. Note mark or tag identifying push rod as either turn) counterclockwise and align crankshaft keyway
intake or exhaust and cylinder 1 or 2. Check each with cylinder 2, which now puts cylinder at TDC on
push rod is straight and not bent. Dip ends of push compression stroke.
rods in engine oil and install in their original 6. Repeat steps 3-4 for setting valve clearance on side
positions, making sure each push rod ball seats in its 2.
tappet socket.
7. Rotate crankshaft to check for free operation of
valve train. Check for clearance between valve
spring coils at full lift, or bending of push rod(s) can
occur. Minimum allowable clearance is 0.25 mm
(0.010 in.).

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 Reassembly

Check Assembly Stamped Steel Valve Cover Torque Sequence

Rotate crankshaft a minimum of 2 revolutions to check
longblock assembly and overall proper operation.
Install Valve Covers 1&5 3
Plastic valve covers contain integral bolt hole spacers
molded in place. Sealing of plastic valve covers is
accomplished using a yellow colored O-ring. In stamped
steel valve covers sealing is accomplished using RTV
sealant.
Plastic Valve Covers
Plastic Valve Cover Torque Sequence

1&5 3
4 2

NOTE: Always use fresh sealant. Using outdated

sealant can result in leakage. Refer to Tools and
Aids for information on sealant dispenser.
NOTE: To ensure proper adhesion of sealant to both
sealing surfaces, perform step 3 immediately (5
minutes maximum) after application of RTV.
RTV silicone sealant is used as a gasket between valve
4 cover and cylinder head. Refer to Tools and Aids for a
2 listing of approved sealants.
1. Prepare sealing surfaces of cylinder heads and
1. Make sure sealing surfaces of valve covers and valve covers. Flatness of sealing surface must be
cylinder heads are clean and free of any nicks or checked prior to reinstallation. See Disassembly.
burrs.
2. Apply a 1.5 mm (1/16 in.) bead of sealant to valve
2. Install a new O-ring in groove of each cover. Do Not cover as shown.
use gaskets or RTV sealant.
3. Position covers on cylinder heads. If a pulse style
3. Position covers on cylinder heads. If a pulse style fuel pump is used valve cover with pulse fitting hole
fuel pump is used, valve cover with pulse fitting hole must be installed on side 2. Install screws in each
must be installed on side 2. Install screws in each cover and finger tighten.
cover and finger tighten.
4. Torque valve cover fasteners to 6.2 N·m (55 in. lb.),
4. Torque valve cover fasteners to 6.2 N·m (55 in. lb.), using sequence shown.
using sequence shown.
Stamped Steel Valve Covers Install Spark Plugs
Stamped Steel Valve Cover RTV Sealant 1. Check gap using wire feeler gauge. Adjust gap to
0.76 mm (0.03 in.).
2. Install plug into cylinder head.
3. Torque plug to 27 N·m (20 ft. lb.).

A
A RTV Sealant

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Reassembly

External Engine Components

E
B
F
C
E
W
G
H
E D
V

I
U

T
J
S
X R

K
L
M N
L

O
P

Air Cleaner
A Fixed Guard B C Debris Screen D Blower Housing
Access Door
E Hose Clamp F Fuel Pump G Hose Clip H Fuel Line
I Fuel Filter J Oil Filter K Nipple L O-Ring
Oil Feed Tube Oil Feed Tube
M N O Outer Baffle P Electric Starter
(Oil Pump Outlet) (Filter to Pan)
Q Inner Baffle R Ignition Module S Intake Manifold T Carburetor
U Gasket V Air Cleaner Base W Air Cleaner X Rectifier-Regulator

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 Reassembly

Install Intake Manifold Install Carburetor

Torque Sequence
WARNING
3 4 Explosive Fuel can cause fires and severe
burns.
Do not fill fuel tank while engine is hot or
1 2 running.
Gasoline is extremely flammable and its vapors can
NOTE: If wires were disconnected from ignition modules explode if ignited. Store gasoline only in approved
on engines with DSAM, reattach leads and seal containers, in well ventilated, unoccupied buildings,
base of terminal connectors with GE/Novaguard away from sparks or flames. Spilled fuel could ignite
G661 or equivalent dielectric compound. Beads if it comes in contact with hot parts or sparks from
should overlap between terminals to form a solid ignition. Never use gasoline as a cleaning agent.
bridge of compound. Do not put any compound
inside terminals. 1. Install a new carburetor gasket. Make sure all holes
align and are open.
1. Install intake manifold using new O-rings, with wiring
harness attached, onto cylinder heads. Slide any 2. Install carburetor, throttle linkage and governor lever
wiring harness clips onto appropriate bolts before as an assembly.
installing. Ground lead for fuel solenoid (if equipped) 3. If carburetor is equipped with a fuel solenoid,
should be attached to inner screw on side 2. Using connect red (power) lead. Attach eyelet terminal of
sequence shown, torque screws in 2 increments, ground lead to inner top carburetor cover mounting
first to 7.4 N·m (66 in. lb.), then to 9.9 N·m screw.
(88 in. lb.).
2. Connect kill lead to tab terminal on standard ignition Install External Governor Controls
modules.
Control Bracket Components
Install Rectifier-Regulator (if equipped)
1. Install B+ terminal/lead into center position of A
rectifier-regulator plug so it locks in place, and
connect plug to rectifier-regulator. B
2. Attach rectifier-regulator to opening in backing plate
from underside, and secure with mounting screws.
Torque screws to 4.0 N·m (35 in. lb.)
C
F
Install Inner and Outer Cylinder Baffles
1. Attach outer cylinder baffles and secure with M6 E
screw (lower cylinder location), and M5 screw into
backing plate. Tighten screws as listed following step
2.
2. Attach inner baffles including any lifting straps to D
cylinder head flanges and to 2 crankcase mounting
bosses. Lift strap should be outside outer baffle. C
Secure with M5 screws. Remaining lower inner
baffle mounting screws will be installed later.
Torque baffle mounting screws:
M5 screws: 6.2 N·m (55 in. lb.) into a new cored
hole, or 4.0 N·m (35 in. lb.) into a used hole. G
M6 screws: 10.7 N·m (95 in. lb.) into a new cored C
hole, or 7.3 N·m (65 in. lb.) into a used hole. D
3. Install spark advance module (DSAM) if equipped,
onto outer cylinder baffle. A Choke Linkage B Throttle Linkage
C Governor Lever D Governor Spring
E Cross Shaft F Control Bracket
G Dampener Spring

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Reassembly

Throttle and Choke Components RPM Chart

High Idle Governor Lever Governor Spring
A B RPM Hole No. Color Code
K 2900 1 Black
3300 1 Orange
J C
1. Connect choke linkage to choke actuator lever on
I main control bracket assembly.
H D
2. Install main control bracket to cylinder heads using
E screws. Two lower screws should also secure inner
G baffles. Torque screws to 10.7 N·m (95 in. lb.) into
F new holes, or 7.3 N·m (65 in. lb.) into used holes.
A Screw B Choke Lever 3. Connect governed idle spring to governor lever and
Throttle Actuator main control bracket. Connect governor spring from
C Throttle Lever D Lever throttle control bracket to appropriate hole in
E Control Bracket F Choke Return Spring governor lever, as indicated in applicable chart. Note
hole positions are counted from pivot point of
G Lock Nut M5x0.8 H Shoulder Washer governor lever.
I Flat Washer J Nylon Washer
K Wave Washer Install Electric Starter Motor and Oil Fill/Dipstick
Tube
1. Install governor lever onto governor cross shaft if
disconnected previously. 1. Install starter motor, lift bracket, and oil fill/dipstick
tube (if not separated from bracket), using screws.
2. Make sure throttle linkage is connected to governor Position lift bracket to also secure dipstick tube.
lever and throttle lever on carburetor. Connect choke
linkage to carburetor choke lever. 2. Torque screws to 15.3 N·m (135 in. lb.).
3. Attach fuel line to carburetor and secure with a 3. On models with a solenoid shift starter, connect
clamp. leads to solenoid.
4. Install a new air cleaner base gasket and air cleaner 4. If separated earlier, install dipstick tube and align
base onto mounting studs. Torque nuts to mounting hole with threaded hole in lift bracket.
6.2-7.3 N·m (55-65 in. lb.). Secure with M5 screw. Torque screw to 4.0 N·m
(35 in. lb.).
5. Connect breather hose to air cleaner base and
secure with clamp. 5. Install oil fill cap/dipstick.
6. Move governor lever toward carburetor as far as it Install Debris Screen
will go (wide-open throttle), and hold in position.
Snap screen onto fan.
7. Insert a nail or similar tool into hole on cross shaft
and rotate shaft counterclockwise as far as will turn, Install Blower Housing
then torque nut to 6.8 N·m (60 in. lb.).
NOTE: Do not completely tighten screws until all are
Install Air Cleaner Element installed to allow shifting for hole alignment.
Install air cleaner element (with precleaner if equipped), 1. Install blower housing with access door onto engine.
onto air cleaner base. Secure with latch. Start all mounting screws. Two HI-LO thread screws
are installed in front securing blower housing to air
Install Throttle and Choke Controls cleaner base. Make sure wire harness and spark
plug leads exit out through appropriate openings in
Governor Lever Hole Position shrouding. Attach any fuel line clamps used.
E 2. Torque screws as follows:
D M5 Blower Housing Screws: 6.2 N·m (55 in. lb.) in a
C new hole, or 4.0 N·m (35 in. lb.) in a used hole.
B M4 HI-LO Screws: 2.8 N·m (25 in. lb.).
A

A Governor Lever B Hole 1

C Hole 2 D Hole 3
E Hole 4

74 KohlerEngines.com 32 690 01 Rev. D

 Reassembly

Install Fuel Pump Install Muffler

1. Install muffler and attaching hardware to muffler
WARNING bracket. Torque screws to 9.9 N·m (88 in. lb.).
Explosive Fuel can cause fires and severe 2. Install M8 nuts or 5/16-18 head capscrews (based
burns. on head design), to secure muffler. Torque nuts to
Do not fill fuel tank while engine is hot or 24.4 N·m (216 in. lb.), or capscrews to 16.9 N·m
running. (150 in. lb.).
Gasoline is extremely flammable and its vapors can Install Oil Filter and Fill Crankcase with Oil
explode if ignited. Store gasoline only in approved
containers, in well ventilated, unoccupied buildings, NOTE: Make sure oil drain plug is installed and torqued
away from sparks or flames. Spilled fuel could ignite to specification to prevent oil leakage.
if it comes in contact with hot parts or sparks from 1. Install oil drain plug. Torque plug to 13.6 N·m
ignition. Never use gasoline as a cleaning agent. (10 ft. lb.).
Fuel Pump Components 2. Place new filter in shallow pan with open end up. Fill
with new oil until oil reaches bottom of threads. Allow
2 minutes for oil to be absorbed by filter material.
3. Apply a thin film of clean oil to rubber gasket on new
filter.
G
4. Refer to instructions on oil filter for proper
installation.
5. Fill crankcase with new oil. Level should be at top of
F indicator on dipstick.
E 6. Reinstall oil fill cap/dipstick and tighten securely.
C D
A Connect Spark Plug Leads
B
Connect leads to spark plugs.
A Blower Housing Clip B Outlet Fuel Line
Prepare Engine for Operation
C Pulse Hose D Inlet Fuel Line
Engine is now completely reassembled. Before starting
E Fuel Line Clamp F Fuel Filter or operating engine, be sure to do following.
G Fuel Pump 1. Make sure all hardware is tightened securely.
NOTE: If a new fuel pump is being installed, make sure 2. Make sure oil drain plug, Oil SentryTM pressure
orientation of new pump is consistent with switch, and a new oil filter are installed.
removed pump. Internal damage may occur if 3. Adjust carburetor idle fuel needle, or idle speed
installed incorrectly. adjusting screw as necessary.
1. Connect pulse hose to valve cover. Valve cover
should be situated between 2 formed lips on pulse Testing Engine
hose. It is recommended engine be operated on a stand or
2. Attach pulse hose to fuel pump and secure with a bench prior to installation in piece of equipment.
clamp. Mount fuel pump to blower housing with 1. Run engine at idle for 2-3 minutes, then 5-6 minutes
screws. Torque screws to 2.3 N·m (20 in. lb.). more between idle and midrange. Adjust carburetor
3. Connect inlet and outlet fuel lines to pump. Route mixture setting as necessary.
inlet fuel line through fuel line clamp (if used) as 2. Adjust idle speed screw and high-speed stop as
shown, and seat outlet hose in blower housing clip. necessary. Make sure maximum engine speed does
not exceed 3750 RPM (no load).

32 690 01 Rev. D KohlerEngines.com 75

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76 KohlerEngines.com 32 690 01 Rev. D