Kohler Aegis 05810334 User manual

1
KOHLER®AEGIS™17,20,23 HP
SERVICE MANUAL
LIQUID-COOLED
VERTICAL CRANKSHAFT

Contents
Section 1. Safety and General Information ............................................................................
Section 2. Special Tools ..........................................................................................................
Section 3. Troubleshooting .....................................................................................................
Section 4. Air Cleaner and Air Intake System ........................................................................
Section 5. Fuel System and Governor....................................................................................
Section 6. Lubrication System ................................................................................................
Section 7. Cooling System ......................................................................................................
Section 8. Electrical System and Components .....................................................................
Section 9. Disassembly ...........................................................................................................
Section 10. Inspection and Reconditioning ...........................................................................
Section 11. Reassembly...........................................................................................................
1
2
3
4
5
6
7
8
9
10
11

1.1
Section 1
Safety and General Information
1
Section 1
Safety and General Information
Safety Precautions
To insure safe operations please read the following statements and understand their meaning.Also
refer to your equipment manufacturer's manual for other important safety information.This manual
contains safety precautions which are explained below. Please read carefully.
WARNING
Warning is used to indicate the presence of a hazard that can cause severe personal injury, death,
or substantial property damage if the warning is ignored.
CAUTION
Caution is used to indicate the presence of a hazard that will or can cause minor personal injury or
property damage if the caution is ignored.
NOTE
Note is used to notify people of installation, operation, or maintenance information that is important
but not hazard-related.
For Your Safety!
These precautions should be followed at all times. Failure to follow these precautions could result in
injury to yourself and others.
LV560, LV625, LV675
Rotating Parts can cause severe
injury.
Stay away while engine is in
operation.
WARNING
Rotating Parts!
Keep hands, feet, hair, and
clothing away from all moving
parts to prevent injury. Never
operate the engine with covers,
shrouds, or guards removed.
Hot Parts can cause severe burns.
Do not touch engine while operating
or just after stopping.
WARNING
Hot Parts!
Engine components can get
extremely hot from operation. To
prevent severe burns, do not
touch these areas while the
engine is running - or immediately
after it is turned off. Never operate
the engine with heat shields or
guards removed.
Accidental Starts can cause
severe injury or death.
Disconnect and ground spark plug
leads before servicing.
WARNING
Accidental Starts!
Disabling engine. Accidental
starting can cause severe injury
or death. Before working on the
engine or equipment, disable the
engine as follows: 1) Disconnect the
spark plug lead(s). 2) Disconnect
negative (-) battery cable from
battery.

1.2
Section 1
Safety and General Information
Carbon Monoxide can cause
severe nausea, fainting or death.
Do not operate engine in closed or
confined area.
WARNING WARNING
Electrical Shock can cause injury.
Do not touch wires while engine is
running.
CAUTION
Hot liquid can cause severe burns.
Do not loosen radiator cap while
engine is operating or warm to the
touch.
WARNING
Explosive Gas can cause fires and
severe acid burns.
Charge battery only in a well
ventilated area. Keep sources of
ignition away.
Lethal Exhaust Gases!
Engine exhaust gases contain
poisonous carbon monoxide.
Carbon monoxide is odorless,
colorless, and can cause death if
inhaled.Avoid inhaling exhaust
fumes, and never run the engine
in a closed building or confined
area.
Hot Liquid!
The liquid coolant can get extremely
hot from operation. Turning the
radiator cap when the engine is hot
can allow steam and scalding liquid
to blow out and burn you severely.
Shut off machine. Only remove
radiator cap when cool enough to
touch with bare hands. Slowly
loosen cap to first stop to relieve
pressure before removing
completely.
Explosive Gas!
Batteries produce explosive
hydrogen gas while being
charged. To prevent a fire or
explosion, charge batteries only in
well ventilated areas. Keep
sparks, open flames, and other
sources of ignition away from the
battery at all times. Keep batteries
out of the reach of children.
Remove all jewelry when servicing
batteries.
Before disconnecting the negative
(-) ground cable, make sure all
switches are OFF. If ON, a spark
will occur at the ground cable
terminal which could cause an
explosion if hydrogen gas or
gasoline vapors are present.
Explosive Fuel can cause fires and
severe burns.
Stop engine before filling fuel tank.
WARNING
Explosive Fuel!
Gasoline is extremely flammable
and its vapors can explode if
ignited. Store gasoline only in
approved containers, in well
ventilated, unoccupied buildings,
away from sparks or flames. Do not
fill the fuel tank while the engine is
hot or running, since spilled fuel
could ignite if it comes in contact
with hot parts or sparks from
ignition. Do not start the engine
near spilled fuel. Never use
gasoline as a cleaning agent.
Cleaning Solvents can cause
severe injury or death.
Use only in well ventilated areas
away from ignition sources.
WARNING
Flammable Solvents!
Carburetor cleaners and solvents
are extremely flammable. Keep
sparks, flames, and other sources
of ignition away from the area.
Follow the cleaner manufacturer’s
warnings and instructions on its
proper and safe use. Never use
gasoline as a cleaning agent.
Electrical Shock!
Never touch electrical wires or
components while the engine is
running. They can be sources of
electrical shock.

1.3
Section 1
Safety and General Information
1
L V 675 S
A. Model No.
Liquid Cooled
Vertical Crankshaft
Displacement/Size (cc)
Version Code
S = Electric Start
Figure 1-2. Explanation of Engine Identification Numbers.
Engine Identification Numbers
When ordering parts, or in any communication
involving an engine, always give the Model,
Specification and Serial Numbers, including letter
suffixes if there are any.
The engine identification numbers appear on a decal,
or decals, affixed to the engine shrouding. See
Figure 1-1.An explanation of these numbers is shown
in Figure 1-2.
Figure 1-1. Engine Identification Decal Location.
B. Spec. No.
Engine Model Code
Code Model
81 LV560
83 LV625
85 LV675
85 1500 Variation of
Basic Engine
30 05810334 Factory Code
C. Serial No.
Year Manufactured Code
Code Year
30 2000
31 2001

1.4
Section 1
Safety and General Information
Oil Recommendations
Using the proper type and weight of oil in the
crankcase is extremely important. So is checking oil
daily and changing oil regularly. Failure to use the
correct oil, or using dirty oil, causes premature engine
wear and failure.
Oil Type
Use high-quality detergent oil of API (American
Petroleum Institute) Service Class SG, SH, SJ or
higher. Select the viscosity based on the air
temperature at the time of operation as shown in the
followingtable.
NOTE: Using other than service class SG, SH, SJ or
higher oil or extending oil change intervals
longer than recommended can cause engine
damage.
Alogo or symbol on oil containers identifies theAPI
service class and SAE viscosity grade. See
Figure 1-3.
*Use of synthetic oil having 5W-20 or 5W-30 rating is
acceptable, up to 4°C (40°F).
**Synthetic oils will provide better starting in extreme cold
below -23°C (-10°F).
Figure 1-3. Oil Container Logo.
Refer to Section 6 - “Lubrication System” for detailed
procedures on checking the oil, changing the oil and
changing the oil filter.
Coolant Recommendations
Use equal parts of ethylene glycol and water only.
Distilled or deionized water is recommended,
especially in areas where the water contains a high
mineral content. Propylene glycol based anti-freeze is
not recommended.
This mixture will provide protection from -37º C
(-34º F) to 108º C (226º F). For protection and use
outside the indicated temperature limits, follow the
anti-freeze manufacturer's instructions on the
container, but do not exceed 70% anti-freeze.
DO NOT use anti-freeze with stop-leak additive(s), or
put any other additives in the cooling system.
Fuel Recommendations
WARNING: Explosive Fuel!
Gasoline is extremely flammable and its vapors can
explode if ignited. Store gasoline only in approved
containers, in well ventilated, unoccupied buildings,
away from sparks or flames. Do not fill the fuel tank
while the engine is hot or running, since spilled fuel
could ignite if it comes in contact with hot parts or
sparks from ignition. Do not start the engine near
spilled fuel. Never use gasoline as a cleaning agent.
General Recommendations
Purchase gasoline in small quantities and store in
clean, approved containers.Acontainer with a capacity
of 2 gallons or less with a pouring spout is
recommended. Such a container is easier to handle
and helps eliminate spillage during refueling.
Do not use gasoline left over from the previous
season, to minimize gum deposits in your fuel system
and to ensure easy starting.
Do not add oil to the gasoline.
Do not overfill the fuel tank. Leave room for the fuel to
expand.
*
**

1.5
Section 1
Safety and General Information
1
Fuel Type
For best results, use only clean, fresh, unleaded
gasoline with a pump sticker octane rating of 87 or
higher. In countries using the Research method, it
should be 90 octane minimum.
Unleaded gasoline is recommended, as it leaves fewer
combustion chamber deposits. Leaded gasoline may
be used in areas where unleaded is not available and
exhaust emissions are not regulated. Be aware,
however, that the cylinder head will require more
frequent service.
Gasoline/Alcohol blends
Gasohol (up to 10% ethyl alcohol, 90% unleaded
gasoline by volume) is approved as a fuel for Kohler
engines. Other gasoline/alcohol blends are not
approved.
Gasoline/Ether blends
Methyl Tertiary Butyl Ether (MTBE) and unleaded
gasoline blends (up to a maximum of 15% MTBE by
volume) are approved as a fuel for Kohler engines.
Other gasoline/ether blends are not approved.
Periodic Maintenance
WARNING: Accidental Starts!
Disabling engine. Accidental starting can cause severe injury or death. Before working on the engine or
equipment, disable the engine as follows: 1) Disconnect the spark plug lead(s). 2) Disconnect negative (-) battery
cable from battery.
Maintenance Schedule
These required maintenance procedures should be performed at the frequency stated in the table.
They should also be included as part of any seasonal tune-up.
1Perform these maintenance procedures more frequently under extremely dusty, dirty conditions.
2Only required for Denso starters. Not necessary on Delco starters. Have a Kohler Engine Service Dealer perform
this service.
Refer to:
Section 5
Section 6
Section 7
Section 4
Section 4
Maintenance RequiredFrequency • Fill fuel tank.
• Check oil level.
• Check coolant level.
• Check air cleaner for dirty1, loose, or damaged parts.
• Check air intake screen, radiator, and cooling areas,
clean as necessary1.
Daily or Before
Starting Engine
Section 4
Section 4
Section 7
Section 5
Section 6
Section 8
• Service precleaner element1.
• Replace air cleaner element1.
• Clean and check cooling areas.
• Replace fuel filter.
Every 25 Hours
Every 100 Hours
Annually or
Every 200 Hours
• Change oil and oil filter (more frequently under severe
conditions).
• Check spark plug condition and gap. Section 8
Section 8
• Have solenoid shift starter disassembled and cleaned2.
• Replace spark plugs.
• Change engine coolant.
Annually or
Every 500 Hours
Every 2 Years or
Every 1000 Hours Section 7

1.6
Section 1
Safety and General Information
Storage
If the engine will be out of service for two months or
more, use the following storage procedure:
1. Clean the exterior surfaces of the radiator and
engine.
2. Change the oil and filter while the engine is still
warm from operation. See “Change Oil and Filter”
in Section 6.
3. The coolant (anti-freeze) mixture should be in
good condition and tested to guard against
freezing in cold temperatures. The recommended
equal parts mixture will normally provide
protection down to temperatures of -37° C
(-34° F). If storage temperatures will fall below
this, the cooling system should be drained.Anote
should then be attached to the equipment and/or
engine as a reminder to refill the cooling system
before starting.
4. The fuel system must be completely emptied, or
the gasoline must be treated with a stabilizer to
prevent deterioration. If you choose to use a
stabilizer, follow the manufacturer’s
recommendations, and add the correct amount
for the capacity of the fuel system. Fill the fuel
tank with clean, fresh gasoline. Run the engine for
2-3 minutes to get stabilized fuel into the
carburetor. Close fuel shut-off valve when unit is
being stored or transported.
To empty the system, run the engine until the tank
and system are empty.
5. Remove the spark plugs.Add one tablespoon of
engine oil into each spark plug hole. Install plugs,
but do not connect the plug leads. Crank the
engine two or three revolutions.
6. Store the engine in a clean, dry place.

1.7
Section 1
Safety and General Information
1
Figure 1-4. Typical Engine Dimensions.
260.6
Cyl. #1
18.2
Oil Fill &
Dipstick
Mounting Hole ‘‘A’’
285.5 Oil Fill
451.0
135.7
140.0
479.3
Over All
434.1
Cyl. #2
Fuel
Pump
Hose
C
L
C
LOil Fill
153.0
Housing
Removal
472.4
155.5
Spark
Plug
93.5
73.5
Exhaust
Port #2
Exhaust
Port #1
Mounting
Surface
40.8
Oil Drain
Mounting Hole ‘‘A’’
Oil Drain Plug
3/8 N.P.T inch
430.6
Oil Fill &
Dipstick
C
L
C
L
199.0
Center of
Gravity
95.8
Center of Gravity
Mounting Hole ‘‘A’’
Mounting Surface
334.5
167.2
2x
89.8
2x
72.8
Coolant Drain Plug
3/8 N.P.T Inch
30º
30º
45º45º
242.2
104.0
89.8
15.7
Oil Filter
Removal
118.3
Oil Filter Mounting Hole ‘‘A’’ø135.0
4x ø9.2 (.36) thru
254.0 (10.00) B.C
Starter Motor
50.0
Exhaust
Port #1
Coolant Drain Plug
3/8 N.P.T Inch
50.0
Exhaust
Port #2
35º35º
Fuel Pump
95.5
139.8
Center of Gravity
86.3
Oil
Filter
Oil Drain Plug
3/8 N.P.T Inch
26.8
Oil Drain Mounting
Surface
13.2
51.2
Oil Filter
Mounting Hole ‘‘A’’
135.5
Spark Plug
ø28.6
C
L
C
L
Dimensions in millimeters.

1.8
Section 1
Safety and General Information
General Specifications1
Power (@ 3600 RPM, corrected to SAE J1995)
LV560............................................................................................. 12.7 kW (17 HP)
LV625............................................................................................. 14.9 kW (20 HP)
LV675............................................................................................. 17.1 kW (23 HP)
Peak Torque
LV560 (@ 2400 RPM) .................................................................... 32.5 N·m (24 ft. lb.)
LV625 (@ 2400 RPM) .................................................................... 41 N·m (30 ft. lb.)
LV675 (@ 2400 RPM) .................................................................... 44 N·m (32 ft. lb.)
Bore LV560.......................................................................................... 73 mm (2.87 in.)
LV625.......................................................................................... 77 mm (3.03 in.)
LV675.......................................................................................... 80 mm (3.14 in.)
Stroke ................................................................................................... 67 mm (2.64 in.)
Displacement
LV560............................................................................................. 561 cc (34.2 cu. in.)
LV625............................................................................................. 624 cc (38.1 cu. in.)
LV675............................................................................................. 674 cc (41.1 cu. in.)
Compression Ratio ............................................................................. 8.2:1 (LV560)
8.5:1 (LV625, LV675)
Dry Weight .......................................................................................... 49.8 kg (110 lb.)
Oil Capacity (with filter)......................................................................... 1.9 L (2.0 U.S. qt.)
Coolant Capacity (equal parts of water and ethylene glycol) ................. 1.4 L (1.5 U.S. qt.)
Angle of Operation - Maximum (at full oil level)All Directions ............... 20°
Lower Blower Housing
M5 Fasteners Torque............................................................................ 4.0 N·m (35 in. lb.)
M6 Fasteners Torque............................................................................ 6.8 N·m (60 in. lb.)
Rectifier Fastener Torque ..................................................................... 4.0 N·m (35 in. lb.)
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.)
Camshaft Bearing Surface O.D.
New................................................................................................ 19.962/19.975 mm (0.7859/0.7864 in.)
Max. Wear Limit ............................................................................. 19.959 mm (0.7858 in.)
1Values are in Metric units. Values in parentheses are English equivalents. Lubricate threads with engine oil prior
to assembly.

1.9
Section 1
Safety and General Information
1
Carburetor and Intake Manifold
Intake Manifold Mounting Fasteners Torque ......................................... 6.2 N·m (55 in. lb.)
Carburetor Mounting Fasteners Torque ................................................ 6.2 N·m (55 in. lb.)
Connecting Rod
Cap Fastener Torque (torque in increments) ........................................ 11.3 N·m (100 in. lb.)
Connecting Rod-to-Crankpin Running Clearance
New................................................................................................ 0.043/0.068 mm (0.0016/0.0026 in.)
Max. Wear Limit............................................................................. 0.083 mm (0.0032 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.)
Breather Cover Fasteners Torque......................................................... 10.7 N·m (95 in. lb.) Into new as-cast hole
7.3 N·m (65 in. lb.) Into used hole
Oil Drain Plugs...................................................................................... 13.6 N·m (120 in. lb.)
Crankshaft
End Play (free)...................................................................................... 0.070/0.590 mm (0.0028/0.0232 in.)
Crankshaft Bore (in crankcase)
New................................................................................................ 40.974/40.987 mm (1.6131/1.6136 in.)
Max. Wear Limit ............................................................................. 41.000 mm (1.6141 in.)
Crankshaft Bore (in oil pan)
New................................................................................................ 40.974/41.000 mm (1.6131/1.6141 in.)
Max. Wear Limit ............................................................................. 41.038 mm (1.6156 in.)
Crankshaft Bore (in oil pan)-to-Crankshaft
Running Clearance - New .............................................................. 0.039/0.087 mm (0.0015/0.0034 in.)
Main Bearing Journals
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.)
Crankshaft Bore (in crankcase)-to-Crankshaft
Running Clearance - New .............................................................. 0.039/0.074 mm (0.0015/0.0029 in.)

1.10
Section 1
Safety and General Information
Crankshaft (Cont'd.)
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.)
Crankshaft T.I.R.
PTO End, Crank in Engine............................................................. 0.15 mm (0.0059 in.)
Entire Crank, in V-Blocks ............................................................... 0.10 mm (0.0039 in.)
Cylinder Bore
Cylinder Bore I.D.
New
LV560.......................................................................................... 73.006/73.031 mm (2.8742/2.8752 in.)
LV625.......................................................................................... 77.000/77.025 mm (3.0315/3.0325 in.)
LV675.......................................................................................... 80.000/80.025 mm (3.1496/3.1506 in.)
Max. Wear Limit
LV560.......................................................................................... 73.070 mm (2.8767 in.)
LV625.......................................................................................... 77.063 mm (3.0340 in.)
LV675.......................................................................................... 80.065 mm (3.1522 in.)
Max. Out-of-Round ........................................................................ 0.12 mm (0.0047 in.)
Max. Taper ..................................................................................... 0.05 mm (0.0020 in.)
Cylinder Head
Cylinder Head Fastener Torque (torque in 2 increments)...................... 16.9, 33.9 N·m (150, 300 in. lb.)
Max. Out-of-Flatness............................................................................ 0.076 mm (0.003 in.)
Rocker Pivot Fastener Torque, if Screw................................................ 11.3 N·m (100 in. lb.)
Rocker Pivot Fastener Torque, if Nut .................................................... 15.8 N·m (140 in. lb.)
Electric Starter
Starter Mounting Fastener Torque ........................................................ 15.3 N·m (135 in. lb.)
Fan/Flywheel
Fan Fastener Torque ............................................................................ 13.6 N·m (120 in. lb.)
Flywheel Retaining ScrewTorque ......................................................... 66.4 N·m (49 ft. lb.)
Governor
Governor Cross Shaft to Crankcase Running Clearance...................... 0.025/0.126 mm (0.0009/0.0049 in.)
Governor 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 O.D.
New................................................................................................ 5.990/6.000 mm (0.2358/0.2362 in.)
Max. Wear Limit............................................................................. 5.977 mm (0.2353 in.)
Governor Gear Shaft-to-Governor Gear Running Clearance ................ 0.090/0.160 mm (0.0035/0.0063 in.)

1.11
Section 1
Safety and General Information
1
Ignition
Spark Plug Type (Champion®or equivalent) ......................................... RC14YC (Kohler Part No. 66 132 01-S)
Spark Plug Gap .................................................................................... 0.76 mm (0.030 in.)
Spark Plug Torque ................................................................................ 24.4-29.8 N·m (18-22 ft. lb.)
Ignition ModuleAir Gap ........................................................................ 0.2/0.3 mm (0.008/0.012 in.)
Ignition Module Fastener Torque .......................................................... 6.2 N·m (55 in. lb.) Into new as-cast hole
3.9 N·m (35 in. lb.) Into used hole
Muffler
Muffler Retaining Nuts Torque .............................................................. 24.4 N·m (216 in. lb.)
Oil Filter/Oil Pan
Oil Filter Torque .................................................................................... 8.1-9.4 N·m (72-84 in. lb.)
Oil Pan Fastener Torque....................................................................... 24.4 N·m (216 in. lb.)
Piston, Piston Rings, and Piston Pin
Piston-to-PistonPin .............................................................................. 0.006/0.018 mm (0.0002/0.0007 in.)
Piston Pin Bore I.D.
New................................................................................................ 17.006/17.013 mm (0.6695/0.6698 in.)
Max. Wear Limit ............................................................................. 17.025 mm (0.6703 in.)
Piston 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
LV560............................................................................................. 0.040/0.096 mm (0.0016/0.0037 in.)
LV625............................................................................................. 0.040/0.086 mm (0.0016/0.0034 in.)
LV675............................................................................................. 0.050/0.096 mm (0.0012/0.0030 in.)
Middle Compression Ring-to-Groove Side Clearance
LV560............................................................................................. 0.030/0.080 mm (0.0012/0.0031 in.)
LV625............................................................................................. 0.040/0.086 mm (0.0016/0.0034 in.)
LV675............................................................................................. 0.030/0.076 mm (0.0012/0.0030 in.)
Oil Control Ring-to-Groove Side Clearance
LV560............................................................................................. 0.046/0.201 mm (0.0018/0.0079 in.)
LV625............................................................................................. 0.046/0.196 mm (0.0018/0.0077 in.)
LV675............................................................................................. 0.046/0.196 mm (0.0018/0.0077 in.)

1.12
Section 1
Safety and General Information
²Measure 6 mm (0.236 in.) above the bottom of the piston skirt at right angles to the piston pin.
Piston, Piston Rings, and Piston Pin (Cont'd.)
Top and Middle Compression Ring End Gap
LV560
New Bore
Top Ring .................................................................................. 0.180/0.380 mm (0.0071/0.0150 in.)
Middle Ring ............................................................................. 0.180/0.440 mm (0.0071/0.0173 in.)
Used Bore (Max.)........................................................................ 0.76 mm (0.029 in.)
LV625
New Bore
Top Ring .................................................................................. 0.180/0.380 mm (0.0071/0.0150 in.)
Middle Ring ............................................................................. 0.250/0.450 mm (0.0098/0.0177 in.)
Used Bore (Max.)........................................................................ 0.77 mm (0.030 in.)
LV675
New Bore
Top Ring .................................................................................. 0.180/0.430 mm (0.0071/0.0169 in.)
Middle Ring ............................................................................. 0.250/0.460 mm (0.0098/0.0181 in.)
Used Bore (Max.)........................................................................ 0.80 mm (0.0315 in.)
Piston Thrust Face O.D.²
LV560
New ............................................................................................ 72.966/72.984 mm (2.8727/2.8734 in.)
Max. Wear Limit.......................................................................... 72.839 mm (2.8677 in.)
LV625
New ............................................................................................ 76.967/76.985 mm (3.0302/3.0309 in.)
Max. Wear Limit.......................................................................... 76.840 mm (3.0252 in.)
LV675
New ............................................................................................ 79.963/79.981 mm (3.1481/3.1488 in.)
Max. Wear Limit.......................................................................... 79.831 mm (3.1430 in.)
Piston Thrust Face-to-Cylinder Bore² Running Clearance
LV560............................................................................................. 0.022/0.065 mm (0.0009/0.0026 in.)
LV625............................................................................................. 0.014/0.057 mm (0.0005/0.0022 in.)
LV675............................................................................................. 0.019/0.062 mm (0.0007/0.0024 in.)
Speed Control
Speed Control BracketAssembly Fastener Torque............................... 10.7 N·m (95 in. lb.) Into new as-cast hole
7.3 N·m (65 in. lb.) Into used hole
Stator
Stator Mounting Screw Torque.............................................................. 6.2 N·m (55 in. lb.)
Throttle/Choke Controls
Governor Control Lever Fastener Torque ............................................. 9.9 N·m (88 in. lb.)
Valve Cover/Rocker Arms
Valve Cover Fastener Torque ............................................................... 6.2 N·m (55 in. lb.)
Valves and Valve Lifters
Hydraulic Valve Lifter to Crankcase Running Clearance....................... 0.0124/0.0501 mm (0.0004/0.0020 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.)

1.13
Section 1
Safety and General Information
1
Valves and Valve Lifters (Cont'd.)
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.)
Intake Valve Stem Diameter
New................................................................................................ 6.982/7.000 mm (0.2749/0.2756 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.)
Exhaust Valve Stem Diameter
New................................................................................................ 6.970/6.988(0.2744/0.2751in.)
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..................................................................... 8.88 mm (0.3496 in.)
Exhaust Valve Minimum Lift.................................................................. 8.88 mm (0.3496 in.)
Nominal Valve SeatAngle..................................................................... 45°
General Torque Values
Metric Fastener Torque Recommendations for Standard Applications
Tightening Torque: N·m (in. lb.) + or - 20%
Property Class
Noncritical
Fasteners
IntoAluminum
Size
M4 1.2 (11) 1.7 (15) 2.9 (26) 4.1 (36) 5.0 (44) 2.0 (18)
M5 2.5 (22) 3.2 (28) 5.8 (51) 8.1 (72) 9.7 (86) 4.0 (35)
M6 4.3 (38) 5.7 (50) 9.9 (88) 14.0 (124) 16.5 (146) 6.8 (60)
M8 10.5 (93) 13.6 (120) 24.4 (216) 33.9 (300) 40.7 (360) 17.0 (150)
Tightening Torque: N·m (ft. lb.) + or -20%
Property Class
Noncritical
Fasteners
IntoAluminum
M10 21.7 (16) 27.1 (20) 47.5 (35) 66.4 (49) 81.4 (60) 33.9 (25)
M12 36.6 (27) 47.5 (35) 82.7 (61) 116.6 (86) 139.7 (103) 61.0 (45)
M14 58.3 (43) 76.4 (55) 131.5 (97) 184.4 (136) 219.7 (162) 94.9 (70)
5.8 8.8 10.9 12.9
4.8 5.8 10.9 12.9
4.8
8.8

1.14
Section 1
Safety and General Information
English Fastener Torque Recommendations for Standard Applications
Grade 2 or 5
Fasteners Into
Aluminum
Size
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) --------- --------- ---------
Size
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) 142.4 (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) ---------
5/8-11 149.2 (110) 244.1 (180) 352.6 (260) ---------
5/8-18 189.8 (140) 311.9 (230) 447.5 (330) ---------
3/4-10 199.3 (150) 332.2 (245) 474.6 (350) ---------
3/4-16 271.2 (200) 440.7 (325) 637.3 (470) ---------
Tightening Torque: N·m (ft. lb.) + or - 20%
Tightening Torque: N·m (in. lb.) + or - 20%
Grade 2 Grade 5 Grade 8
Bolts, Screws, Nuts and Fasteners
Assembled Into Cast Iron or Steel
N·m = in. lb. x 0.113
N·m = ft. lb. x 1.356
in. lb. = N·m x 8.85
ft. lb. = N·m x 0.737
Torque
Conversions

2.1
Section 2
Special Tools
2
LV560, LV625, LV675
Section 2
Special Tools
These quality tools are designed to help you perform specific disassembly, repair, and reassembly procedures.
By using tools designed for the job, you can service engines easier, faster, and safer! In addition, you’ll increase
your service capabilities and customer satisfaction by decreasing engine downtime.
Camshaft End play Plate ................................................................................. KO1031*
Flywheel Puller Kit ........................................................................................... NU3226*
Hose Clamp Pliers........................................................................................... KO1043*
Valve Guide Reamer........................................................................................ KO1026*
Hydraulic Lifter Removal Tool .......................................................................... KO1044*
Rocker Arm Spanner Wrench .......................................................................... (Obtainlocally)
Water Manometer............................................................................................ 25 761 02-S
Vacuum Gauge................................................................................................ 25 761 22-S
Cylinder Leakdown Tester................................................................................ 25 761 05-S
Ignition System Tester ..................................................................................... 24 455 02-S
Starter Ring Tool .............................................................................................. 25 761 18-S
*These items can be ordered through your Kohler distributor or purchased directly from SPX
Corp. by phoning 1-800-533-0492.
Ignition System Tester
Use Kohler Part No. 24 455 02-S to test the CD
ignition modules on theAEGIS™engines.
Cylinder Leakdown Tester
Kohler Part No. 25 761 05-S Cylinder Leakdown Tester
is a valuable alternative to a compression test. By
pressurizing the combustion chamber from an external
air source, this tool can determine if valves or rings are
leaking. Instructions for using this tester are found on
pages 3.3 and 3.4 of this manual.
Figure 2-1. Hose Clamp Pliers.

2.2
Section 2
Special Tools
Special Tools You Can Make
Flywheel Holding Tool
Flywheel removal and reinstallation becomes a ‘‘snap’’
using a handy holding tool you can make out of a
piece of an old ‘‘junk’’ flywheel ring gear as shown in
Figure 2-2. Using an abrasive cut-off wheel, cut out a
six tooth segment of the ring gear as shown. Grind off
any burrs or sharp edges. The segment can be used in
place of a strap wrench. Invert the segment and place
it between the ignition module bosses on the #1
cylinder so that the tool teeth engage the ring gear
teeth on the flywheel. The bosses will ‘‘lock’’the tool
and flywheel in position for loosening, tightening, or
removing with a puller.
Figure 2-2. Flywheel Holding Tool.
RTV Silicone Sealant
RTV (Room Temperature Vulcanizing) silicone sealant
is used as a gasket between the crankcase and oil
pan.
Only oxime-based, oil resistant RTV sealants, such as
those listed below, are approved for use. Loctite®Nos.
5900 and 5910 are recommended for best sealing
characteristics.
Loctite®Ultra Blue 587
Loctite®Ultra Copper
Loctite®Ultra Black 598
Loctite®5900 (Heavy Body)
Loctite®5910
NOTE: Always use fresh sealant. Using outdated
sealant can result in leakage.

3.1
Section 3
Troubleshooting
3
Section 3
Troubleshooting
Troubleshooting Guide
When troubles occur, be sure to check the simple
causes which, at first, may seem too obvious to be
considered. For example, a starting problem could be
caused by an empty fuel tank.
Some common causes of engine troubles are listed
below. Use these to locate the causing factors.
Engine Cranks But Will Not Start
1. Empty fuel tank.
2. Fuel shut-off valve closed.
3. Dirt or water in the fuel system.
4. Clogged fuel line.
5. Spark plug lead(s) disconnected.
6. Key switch or kill switch in “off” position.
7. Faulty spark plugs.
8. Faulty ignition module.
9. Carburetor solenoid malfunction.
10. Diode in wiring harness failed in open circuit
mode.
11. Vacuum fuel pump malfunction, or oil in vacuum
hose.
12. Vacuum hose to fuel pump leaking/cracked.
13. Battery connected backwards.
Engine Starts But Does Not Keep Running
1. Restricted fuel tank cap vent.
2. Dirt or water in the fuel system.
3. Faulty choke or throttle controls.
4. Loose wires or connections that short the kill
terminal of ignition module to ground.
5. Faulty cylinder head gasket.
6. Faultycarburetor.
7. Vacuum fuel pump malfunction, or oil in vacuum
hose.
8. Leaking/cracked vacuum hose to fuel pump.
Engines Starts Hard
1. PTO drive is engaged.
2. Dirt or water in the fuel system.
3. Clogged fuel line.
4. Loose or faulty wires or connections.
5. Faulty choke or throttle controls.
6. Faulty spark plugs.
7. Low compression.
8. Weak spark.
9. Fuel pump malfunction causing lack of fuel.
10. Engine overheated-cooling system problem.
Engine Will Not Crank
1. PTO drive is engaged.
2. Battery is discharged.
3. Safety interlock switch is engaged.
4. Loose or faulty wires or connections.
5. Faulty key switch or ignition switch.
6. Faulty electric starter or solenoid.
7. Seized internal engine components.
Engine Runs But Misses
1. Dirt or water in the fuel system.
2. Spark plug lead disconnected.
3. Loose wires or connections that intermittently
short the kill circuit of ignition system to ground.
4. Engine overheated-cooling system problem.
5. Faulty ignition module.
6. Faulty spark plugs.
7. Carburetor adjusted incorrectly.
8. Faulty interlock switch.
Engine Will Not Idle
1. Restricted fuel tank cap vent.
2. Dirt or water in the fuel system.
3. Faulty spark plugs.
4. Idle speed (RPM) adjusting screw improperly set.
5. Low compression.
6. Stale fuel and/or gum in carburetor.
7. Fuel supply inadequate.
8. Engine overheated-cooling system problem.
Engine Overheats
1. Air intake/grass screen, radiator, or cooling
shrouds clogged.
2. Excessive engine load.
3. Low crankcase oil level.
4. High crankcase oil level.
5. Faultycarburetor.
6. Low coolant level.
LV560, LV625, LV675

3.2
Section 3
Troubleshooting
Engine Overheats (cont'd.)
7. Radiator cap faulty or loose.
8. Lean fuel mixture.
9. Water pump belt failed/off.
10. Water pump malfunction.
Engine Knocks
1. Excessive engine load.
2. Low crankcase oil level.
3. Old or improper fuel.
4. Internal wear or damage.
5. Hydraulic lifter malfunction.
Engine Loses Power
1. Low crankcase oil level.
2. High crankcase oil level.
3. Dirty air cleaner element.
4. Dirt or water in the fuel system.
5. Excessive engine load.
6. Engineoverheated.
7. Faulty spark plugs.
8. Low compression
9. Exhaust restriction.
10. Lowbattery.
Engine Uses Excessive Amount Of Oil
1. Incorrectoilviscosity/type.
2. Clogged or improperly assembled breather.
3. Worn or broken piston rings.
4. Worn cylinder bore.
5. Worn valve stems or valve guides.
6. Crankcase overfilled.
Oil Leaks from Oil Seals, Gaskets
1. Crankcase breather is clogged or inoperative.
2. Loose or improperly torqued fasteners.
3. Piston blowby or leaky valves.
4. Restricted exhaust.
Engine Loses or Uses Coolant
1. Overheating-See ‘‘Engine Overheats’’section.
2. External leakage-from a joint connection, or a
component of the cooling system.
3. Internal leakage-from a head gasket, or cooling
system water jacket (passage) leak.
External Engine Inspection
Before cleaning or disassembling the engine, make a
thorough inspection of its external appearance and
condition. This inspection can give clues to what might
be found inside the engine (and the cause) when it is
disassembled.
•Check for buildup of dirt and debris on the
radiators, crankcase, cooling fins, grass screen,
blower housing and other external surfaces. Dirt
or debris on these areas are causes of higher
operating temperatures and overheating.
•Check for obvious fuel, oil, and coolant leaks, or
damaged components. Excessive oil leakage can
indicate a clogged or improperly assembled
breather, worn or damaged seals and gaskets, or
loose or improperly torqued fasteners. Coolant
leaks can cause higher operating temperatures
andoverheating.
•Check the air cleaner and base for damage or
indications of improper fit and seal.
•Check the air cleaner element. Look for holes,
tears, cracked or damaged sealing surfaces, or
other damage that could allow unfiltered air into
the engine.Also note if the element is dirty or
clogged. These could indicate that the engine has
beenunderserviced.
•Check the carburetor throat for dirt. Dirt in the
throat is further indication that the air cleaner is
not functioning properly.
•Check the oil level. Note if the oil level is within
the operating range on the dipstick, or if it is low
or overfilled.
• Check the coolant level within the reservoir and in
the neck of radiator cap adapter.A low or
improperly filled cooling system can cause
overheating, excessive fuel consumption, and a
lack of power.
•Check the condition of the oil. Drain the oil into a
container - the oil should flow freely. Check the
appearance (color) of the oil, and for metal chips
or foreign particles.Amilky, opaque color denotes
the presence of engine coolant in the crankcase
oil.
Sludge is a natural by-product of combustion; a
small accumulation is normal. Excessive sludge
formation could indicate overrich carburetion,
weak ignition, overextended oil change intervals
or wrong weight or type of oil was used, to name
a few.