Kohler Command PRO EFI PCV680LE User manual

PCV680, PCV680LE, PCV740, PCV740LE
Service Manual
KohlerEngines.com24 690 31 Rev. H 1
2 Safety
3 Maintenance
5 Specifications
13 Tools and Aids
16 Troubleshooting
21 Air Cleaner/Intake
22 Propane Electronic Fuel Injection (EFI) System
52 Lubrication System
54 Electrical System
59 Starter System
63 Disassembly/Inspection and Service
81 Reassembly
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.

Safety
2 24 690 31 Rev. HKohlerEngines.com
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
Explosive Fuel can
cause fires and severe
burns.
If a gaseous odor is
detected, ventilate
area and contact an
authorized service
technician.
Propane is extremely flammable
and is heavier than air and tends
to settle in low areas where a
spark or flame could ignite gas.
Do not start or operate this engine
in a poorly ventilated area where
leaking gas could accumulate and
endanger safety of persons in
area.
To ensure personal safety,
installation and repair of propane
fuel supply systems must be
performed only by qualified
propane system technicians.
Improperly installed and
maintained propane equipment
could cause fuel supply system or
other components to malfunction,
causing gas leaks.
Observe federal, state and local
laws governing propane fuel,
storage, and systems.
WARNING
Rotating Parts can cause
severe injury.
Stay away while engine
is in operation.
Keep hands, feet, hair, and
clothing away from all moving
parts to prevent injury. Never
operate engine with covers,
shrouds, or guards removed.
CAUTION
Failure to utilize or
reassemble debris
screen as designed could
result in debris screen
failure and serious
personal injury.
WARNING
Carbon Monoxide can
cause severe nausea,
fainting or death.
Take precautions
against exposure to
carbon monoxide (CO)
emissions. Only operate
an engine in well
ventilated areas.
Engine exhaust gases contain
poisonous carbon monoxide.
Carbon monoxide is odorless,
colorless, and can cause death if
inhaled.
WARNING
Accidental Starts can
cause severe injury or
death.
Disconnect and ground
spark plug lead(s) before
servicing.
Before working on engine or
equipment, disable engine as
follows: 1) Disconnect spark plug
lead(s). 2) Disconnect negative (–)
battery cable from battery.
WARNING
Hot Parts can cause
severe burns.
Do not touch engine
while operating or just
after stopping.
Never operate engine with heat
shields or guards removed.
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.
CAUTION
Electrical Shock can
cause injury.
Do not touch wires while
engine is running.
CAUTION
Damaging Crankshaft
and Flywheel can cause
personal injury.
Using improper procedures can
lead to broken fragments. Broken
fragments could be thrown from
engine. Always observe and use
precautions and procedures when
installing flywheel.
WARNING
High Pressure Fluids can
puncture skin and cause
severe injury or death.
Do not work on fuel
system without proper
training or safety
equipment.
Fluid puncture injuries are highly
toxic and hazardous. If an injury
occurs, seek immediate medical
attention.

Maintenance
324 690 31 Rev. H KohlerEngines.com
MAINTENANCE INSTRUCTIONS
WARNING
Before working on engine or equipment, disable engine as
follows: 1) Disconnect spark plug lead(s). 2) Disconnect
negative (–) battery cable from battery.
Accidental Starts can cause severe injury or
death.
Disconnect and ground spark plug lead(s)
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 low-profile precleaner (if equipped). Air Cleaner/Intake
Every 100 Hours¹
●Check oil cooler fins, clean as necessary (if equipped). Air Cleaner/Intake
●Change oil. Lubrication System
●Replace low-profile air cleaner element (if equipped). Air Cleaner/Intake
●Remove cooling shrouds and clean cooling areas. Air Cleaner/Intake
Every 150 Hours¹
●Check heavy-duty filter minder. Air Cleaner/Intake
●Inspect heavy-duty air filter paper element and inlet screen area. Air Cleaner/Intake
Every 200 Hours
●Change oil filter. Lubrication System
●Replace unique EFI fuel filters.
Every 300 Hours¹
●Replace heavy-duty air cleaner element and check inner element. Air Cleaner/Intake
Every 300 Hours³ (Not available for PCV680LE, PCV740LE engine models)
●Change oil and filter (KOHLER PRO 10W-50 oil and KOHLER PRO filter only). Lubrication System
Every 500 Hours or Annually¹
●Check all lines (high pressure/vacuum) including fittings for leaks. Fuel System
●Drain vaporizer/regulator of accumulated fuel deposits. Fuel System
●Replace spark plugs and set gap. Electrical System
Every 500 Hours or Annually1,2
●Inspect lock-offassembly for damage/leakage. Fuel System
Every 600 Hours or Annually1
●Replace heavy-duty air cleaner inner element. Air Cleaner/Intake
Every 1500 Hours1,2
●Have vaporizer/regulator tested. Fuel System
1Perform these procedures more frequently under severe, dusty, dirty conditions.
2Must be performed by a Kohler authorized dealer or qualified propane personnel only.
³ Option only if using KOHLER®PRO oil and PRO oil filter.
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).

Maintenance
4 24 690 31 Rev. HKohlerEngines.com
OIL RECOMMENDATIONS
PCV680, PCV740
All-season KOHLER®PRO 10W-50 Synthetic Oil is the
ideal oil for KOHLER engines. It is specifically formulated
to extend the oil and oil filter change interval to 300
Hours when paired with a KOHLER PRO Extended Life
Oil Filter.
300-Hour oil and oil filter change intervals are exclusive
to and only authorized on KOHLER engines that utilize
both the KOHLER PRO 10W-50 Synthetic Oil and
KOHLER PRO Extended Life Oil Filter. Alternative
engine oils and oil filters may be used with KOHLER
engines but require 100-Hour oil and 200-Hour oil filter
change intervals for proper maintenance. Oil must be
API (American Petroleum Institute) service class SJ or
higher. Select viscosity based on air temperature at time
of operation as shown below.
°F -20 020324060
50 80 100
°C -30 -20 -10 0 10 20 30 40
5W-30
10W-30
SAE 30
Kohler PRO 10W-50
PCV680LE, PCV740LE
Only use Full Synthetic ILSAC (International Lubricants
Standardization and Approval Committee) GF-5 or
higher motor oils and API (American Petroleum Institute)
service class SN or higher to meet emissions life of
this engine and protect catalyst muffler. Select viscosity
based on air temperature at time of operation as shown
in table below.
FUEL RECOMMENDATIONS
WARNING
Explosive Fuel can cause fires and severe
burns.
If a gaseous odor is detected, ventilate area
and contact an authorized service technician.
Propane is extremely flammable and is heavier than
air and tends to settle in low areas where a spark or
flame could ignite gas. Do not start or operate this
engine in a poorly ventilated area where leaking gas
could accumulate and endanger safety of persons in
area.
To ensure personal safety, installation and repair of
propane fuel supply systems must be performed only
by qualified propane system technicians. Improperly
installed and maintained propane equipment could
cause fuel supply system or other components to
malfunction, causing gas leaks.
Observe federal, state and local laws governing
propane fuel, storage, and systems.
This engine is certified to operate on commercial
propane with a minimum propane content of 85% (per
GPA STD 2140). If you have any questions, contact your
propane supplier.
This engine requires propane fuel in a
gaseous/vapor
source from a supply tank designed for use with
gaseous/vapor draw.
Propane from an appropriate propane fuel tank (supplied
separately) is required to operate this engine.
STORAGE
If engine will be out of service for 2 months or more
follow procedure below.
1. Change oil while engine is still warm from operation
(NOT required if using KOHLER PRO 10W-50
full-synthetic oil). 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.
2. Disconnect negative (-) battery cable.
3. Separate propane tank from unit and store
separately in an area designated for safe propane
tank storage.
4. Store engine in a clean, dry place.

Specifications
524 690 31 Rev. H KohlerEngines.com
Dimensions in millimeters.
Inch equivalents shown in [ ].
412.98
[16.259]
296.38
[11.668]
269.48
[10.609]
96.02
[3.780]
135.00
[5.315]
AIR FILTER RAIN CAP
REMOVAL
130.00
[5.118]
AIR FILTER
COVER ASSEMBLY
REMOVAL
73.06
[2.877]
SPARK PLUG REMOVAL
52.36 [2.061]
SPARK PLUG
BOOT REMOVAL
22.84 [0.899]
SPARK PLUG BOOT
246.07
[9.688]
SPARK
PLUG
BOOT
REMOVAL
253.53
[9.982]
SPARK
PLUG
REMOVAL
417.98 [16.456]
SAFETY AIR FILTER
ELEMENT REMOVAL
530.30 [20.878]
PRIMARY AIR FILTER
ELEMENT REMOVAL
OIL FILL & DIPSTICK
MOUNTING
HOLE“A” ENGINE
495.66
[19.514]
ENGINE
152.99
[6.023]
45.35
[1.786]
137.09
[5.397]
15.70
[0.618]
OIL FILTER
REMOVAL
81.86
[3.223]
73.23 [2.883]
SPARK PLUG REMOVAL
52.45
[2.065]
SPARK PLUG
BOOT REMOVAL
27.43
[1.080]
SPARK PLUG
BOOT
246.28
[9.696]
SPARK
PLUG
BOOT
REMOVAL
253.53
[9.982]
SPARK
PLUG
REMOVAL
20˚ 20˚
FLYWHEEL SIDE
154.08
[6.066]
92.08
[3.625]
EXHAUST
PORT #1
72.08
[2.838]
EXHAUST
PORT #2
STARTER SIDE
367.38
[14.464]
13.38
[0.527]
40.80
[1.606]
ENGINE MOUNTING
SURFACE
OIL DRAIN PLUG
3/8 N.P.T INCH
405.85
[15.978]
247.85
[9.758]
445.32
[17.532]
OIL COOLER
REGULATOR RECTIFIER
REGULATOR ASSEMBLY
143.17
[5.636]
134.45
[5.293]
50.78
[1.999]
13.72
[0.540]
11.81
[0.465]
26.80
[1.055]
86.30
[3.398]
24.895 ± 0.10 [0.980 ± 0.0039]
Ø 28.56 ± 0.01 [1.125 ± 0.005]
OXYGEN
SENSOR
SPARK
PLUG
ENGINE MOUNTING
SURFACE
OIL FILTER SIDE 7/16-20 UNF 2B IN
97.2
[3.827]
38.1 +0.00 -3.81
[1.500 +0.00 -0.150]
ENGINE MOUNTING SURFACE
PTO END
334.4
[13.164]
94.26
[3.711]
15˚
MOUNTING
HOLE“D”
152.25
[5.994]
104.03
[4.096]
89.80
[3.536]
MOUNTING
HOLE“A”
MOUNTING
HOLE“B”
MOUNTING
HOLE“C”
242.22
[9.536]
48.39
[1.905]
50
[1.969]
EXHAUST
PORT #2
SOLENOID
SHIFT STARTER
45˚ ± 0.135˚
45˚ ± 0.135˚
35˚ ± 0.135˚
35˚ ± 0.135˚
72.84 ± 0.30
[2.868 ± 0.118]
15˚
4X Ø 8.64.7.54 [0.340/0.297 THRU
Ø 254.00 ± 0.3 [10.000] B.C. 2X 89.80
[3.536]
50
[1.969]
EXHAUST
PORT #2
Engine Dimensions

Specifications
6 24 690 31 Rev. HKohlerEngines.com
ENGINE IDENTIFICATION NUMBERS
Kohler engine identification numbers (model, specification and serial) should be referenced for efficient repair,
ordering correct parts, and engine replacement.
Model. . . . . . . . . . . . . . . . . . . . . PCV680
Propane EFI Command Engine
Vertical Shaft
Numerical Designation
Specification . . . . . . . . . . . . . . . PCV680-3001
Serial . . . . . . . . . . . . . . . . . . . . . 4923500328
Year Manufactured Code Factory Code
Code Year
49 2019
50 2020
51 2021
GENERAL SPECIFICATIONS4,7 PCV680, PCV680LE, PCV740, PCV740LE
Bore 83 mm (3.27 in.)
Stroke 69 mm (2.72 in.)
Displacement 747 cc (45.6 cu. in.)
Oil Capacity (refill) 1.6-1.9 L (1.7-2.0 U.S. qt.)
Maximum Angle of Operation
(@ full oil level)525°
TORQUE SPECIFICATIONS4,6 PCV680, PCV680LE, PCV740, PCV740LE
Blower Housing
Into cored aluminum hole or weld nut
M5
M6
Into extruded hole in sheet metal
M5
M6
6.2 N·m (55 in. lb.) into new holes
4.0 N·m (35 in. lb.) into used holes
10.7 N·m (95 in. lb.) into new holes
7.3 N·m (65 in. lb.) into used holes
2.8 N·m (25 in. lb.) into new holes
2.3 N·m (20 in. lb.) into used holes
2.8 N·m (25 in. lb.) into new holes
2.3 N·m (20 in. lb.) into used holes
Connecting Rod
Cap Fastener (torque in increments)
6 mm straight shank
6 mm straight shank gray metallic color
11.6 N·m (103 in. lb.)
13.6 N·m (120 in. lb.)
4 Values are in Metric units. Values in parentheses are English equivalents.
5 Exceeding maximum angle of operation may cause engine damage from insufficient lubrication.
6 Lubricate threads with engine oil prior to assembly.
7 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.

Specifications
724 690 31 Rev. H KohlerEngines.com
TORQUE SPECIFICATIONS4,6 PCV680, PCV680LE, PCV740, PCV740LE
Crankcase
Breather Cover Fastener 11.3 N·m (100 in. lb.) into new holes
7.3 N·m (65 in. lb.) into used holes
Oil Temperature Sensor (into breather cover) 7.3 N·m (65 in. lb.)
Oil Drain Plug 13.6 N·m (10 ft. lb.)
Cylinder Head
Hex Flange Nut (torque in 2 increments) first to 16.9 N·m (150 in. lb.)
finally to 33.9 N·m (300 in. lb.)
Rocker Arm Screw
Black Screw (M6x1.0x34)
Silver Screw (M6x1.0x45)
18.1 N·m (160 in. lb.)
13.6 N·m (120 in. lb.)
Fan/Flywheel
Flywheel Retaining Screw 71.6 N·m (52.8 ft. lb.)
Metal Debris Screen Fastener (to flywheel) 9.9 N·m (88 in. lb.)
Fuel Vaporizer/Regulator/Lock-Off
Regulator to Bracket Nut 19.8 N·m (175 in. lb.)
Regulator Bracket Mounting Screw 11.9 N·m (105 in. lb.)
Lock-OffValve Body Nut 6.5 N·m (57 in. lb.)
Lock-OffValve Body 20 N·m (177 in. lb.)
Fuel Outlet Fitting Mounting Screws 2.9 N·m (26 in. lb.)
Fuel Inlet Fitting 20 N·m (177 in. lb.)
Governor
Lever Nut 7.1 N·m (63 in. lb.)
Ignition
Spark Plug 27 N·m (20 ft. lb.)
Coil Fastener 10.2 N·m (90 in. lb.)
Electronic Control Unit Screw 6.2 N·m (55 in. lb.)
Rectifier-Regulator Ground Strap/Ground Lead Fastener
(into backing plate)
2.8 N·m (25 in. lb.) into new holes
2.3 N·m (20 in. lb.) into used holes
Rectifier-Regulator Ground Lead Fastener to Ground
Lug/Backing Plate
5.6 N·m (50 in. lb.) into new holes
4.0 N·m (35 in. lb.) into used holes
Rectifier-Regulator Fastener 1.4 N·m (12.6 in. lb.)
Crankshaft Position Sensor
Earlier Design Bracket
Crankshaft Position Sensor to Bracket Screw 11.3 N·m (100 in. lb.)
Crankshaft Position Sensor Bracket to Crankcase Screw 8.3 N·m (73 in. lb.)
Crankshaft Position Sensor
Later Design Bracket
Crankshaft Position Sensor to Bracket Screw 6.8 N·m (60 in. lb.)
Crankshaft Position Sensor Bracket to Crankcase Screw 7.3 N·m (65 in. lb.)
4 Values are in Metric units. Values in parentheses are English equivalents.
6 Lubricate threads with engine oil prior to assembly.

Specifications
8 24 690 31 Rev. HKohlerEngines.com
TORQUE SPECIFICATIONS4,6 PCV680, PCV680LE, PCV740, PCV740LE
Intake Manifold
Fastener (torque in 2 increments) first to 7.8 N·m (69 in. lb.)
finally to 10.5 N·m (93 in. lb.)
Manifold Absolute Pressure (MAP) Sensor Fastener
(Engines with Separate MAP and Intake Air Temperature
Sensors)
7.3 N·m (65 in. lb.)
Temperature/Manifold Absolute Pressure (TMAP) Sensor
Fastener (Engines with Combined Sensor)
7.3 N·m (65 in. lb.)
Air Cleaner to Throttle Body Fastener Nut 8.2 N·m (73 in. lb.)
Air Cleaner Mounting Bracket Fastener 5.8 N·m (51 in. lb.)
Fuel Injector Cap Fastener 7.3 N·m (65 in. lb.)
Muffler
Retaining Nut 27.8 N·m (246 in. lb.)
Oxygen Sensor 50.1 N·m (37 ft . lb.)
Main Support Bracket to Muffler Fastener (into weld nut)
PCV680LE & PCV740LE engines 9.9 N·m (88 in. lb.)
Oil Cooler
Oil Cooler/Adapter Nipple 28.5 N·m (21 ft . lb.)
Fastener
Into Blower Housing
Between Oil Cooler Hoses
2.8 N·m (25 in. lb.)
2.3 N·m (20 in. lb.)
Oil Pan
Fastener 25.6 N·m (227 in. lb.)
Speed Control Bracket
Fastener assembled to cylinder heads 10.7 N·m (95 in. lb.) into new holes
7.3 N·m (65 in. lb.) into used holes
Fastener assembled to blower housing 2.8 N·m (25 in. lb.) into new holes
2.3 N·m (20 in. lb.) into used holes
Starter Assembly
Thru Bolt 5.6-9.0 N·m (49-79 in. lb.)
Mounting Screw 16.0 N·m (142 in. lb.)
Brush Holder Mounting Screw 2.5-3.3 N·m (22-29 in. lb.)
Starter Solenoid
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.)
Stator
Mounting Screw 6.2 N·m (55 in. lb.) into new holes
4.0 N·m (35 in. lb.) into used holes
Valve Cover
Fastener 9.0 N·m (80 in. lb.)
4 Values are in Metric units. Values in parentheses are English equivalents.
6 Lubricate threads with engine oil prior to assembly.

Specifications
924 690 31 Rev. H KohlerEngines.com
CLEARANCE
SPECIFICATIONS4PCV680, PCV680LE, PCV740, PCV740LE
Camshaft
End Play (with shim) 0.101/0.406 mm (0.0040/0.0160 in.)
Running Clearance 0.025/0.105 mm (0.001/0.004 in.)
Bore I.D.
New
Max. Wear Limit
20.000/20.025 mm (0.7874/0.7884 in.)
20.038 mm (0.7889 in.)
Bearing Surface O.D.
New
Max. Wear Limit
19.920/19.975 mm (0.7843/0.7864 in.)
19.914 mm (0.7840 in.)
Connecting Rod
Connecting Rod-to-Crankpin
Running Clearance @ 21°C
(70°F)
New
Max. Wear Limit
0.043/0.073 mm (0.0017/0.0029 in.)
0.088 mm (0.0035 in.)
Connecting Rod-to-Crankpin
Side Clearance 0.26/0.63 mm (0.0102/0.0248 in.)
Connecting Rod-to-Piston Pin
Running Clearance @ 21°C
(70°F)
0.015/0.028 mm (0.0006/0.0011 in.)
Piston Pin End I.D. @ 21°C
(70°F)
New
Max. Wear Limit
17.015/17.023 mm (0.6699/0.6702 in.)
17.036 mm (0.6707 in.)
Crankcase
Governor Cross Shaft Bore I.D.
New
Max. Wear Limit
8.025/8.075 mm (0.3159/0.3179 in.)
8.088 mm (0.3184 in.)
Crankshaft
End Play (free) 0.025/0.635 mm (0.001/0.025 in.)
Bore (in crankcase)
New
Max. Wear Limit
40.972/40.997 mm (1.6131/1.6141 in.)
41.011 mm (1.6146 in.)
Bore (in oil pan)
New 40.974/41.000 mm (1.6131/1.6141 in.)
Crankshaft to Sleeve Bearing
(oil pan) Running Clearance
New 0.03/0.12 mm (0.001/0.005 in.)
Crankshaft Bore (oil pan)-to-
Crankshaft Running Clearance
New 0.039/0.087 mm (0.0015/0.0034 in.)
Flywheel End Main Bearing
Journal
O.D. - New
O.D. - Max. Wear Limit
Max. Taper Limit
Max. Out-of-Round Limit
40.913/40.935 mm (1.6107/1.6116 in.)
40.843 mm (1.608 in.)
0.022 mm (0.0009 in.)
0.025 mm (0.0010 in.)
4 Values are in Metric units. Values in parentheses are English equivalents.

Specifications
10 24 690 31 Rev. HKohlerEngines.com
CLEARANCE
SPECIFICATIONS4PCV680, PCV680LE, PCV740, PCV740LE
Crankshaft (continued)
Oil Pan End Main Bearing
Journal
O.D. - New
O.D. - Max. Wear Limit
Max. Taper Limit
Max. Out-of-Round Limit
40.913/40.935 mm (1.6107/1.6116 in.)
40.843 mm (1.608 in.)
0.022 mm (0.0009 in.)
0.025 mm (0.0010 in.)
Connecting Rod Journal
O.D. - New
O.D. - Max. Wear Limit
Max. Taper Limit
Max. Out-of-Round Limit
35.950/35.973 mm (1.4153/1.4163 in.)
35.941 mm (1.415 in.)
0.018 mm (0.0007 in.)
0.025 mm (0.0010 in.)
Crankshaft T.I.R.
PTO End, Crank in Engine
Entire Crank, in V-Blocks
0.279 mm (0.0110 in.)
0.10 mm (0.0039 in.)
Cylinder Bore
Bore I.D.
New 83.006/83.031 mm (3.2680/3.2689 in.)
O.D. - Max. Wear Limit 83.081 mm (3.2709 in.)
Max. Out-of-Round Limit 0.120 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
Max. Wear Limit
7.949/8.000 mm (0.3129/0.3149 in.)
7.936 mm (0.3124 in.)
Governor Gear Shaft -to-
Governor Gear Running
Clearance
0.090/0.160 mm (0.0035/0.0063 in.)
Gear Shaft O.D.
New
Max. Wear Limit
5.990/6.000 mm (0.2358/0.2362 in.)
5.977 mm (0.2353 in.)
Ignition
Spark Plug Gap 0.76 mm (0.030 in.)
Crankshaft Position Sensor Air
Gap (only on earlier design
sensor bracket)
0.2-0.7 mm (0.008-0.027 in.)
Crankshaft Position Sensor
Max. Air Gap (only on later
design sensor bracket)
2.794 mm (0.110 in.)
4 Values are in Metric units. Values in parentheses are English equivalents.

Specifications
1124 690 31 Rev. H KohlerEngines.com
CLEARANCE
SPECIFICATIONS4PCV680, PCV680LE, PCV740, PCV740LE
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
Max. Wear Limit
17.006/17.012 mm (0.6695/0.6698 in.)
17.025 mm (0.6703 in.)
Pin O.D.
New
Max. Wear Limit
16.995/17.000 mm (0.6691/0.6693 in.)
16.994 mm (0.6691 in.)
Top Compression Ring-to-
Groove Side Clearance
0.030/0.070 mm (0.001/0.0026 in.)
Middle Compression Ring-to-
Groove Side Clearance
0.030/0.070 mm (0.001/0.0026 in.)
Oil Control Ring-to-Groove Side
Clearance
0.060/0.190 mm (0.0022/0.0073 in.)
Top Compression Ring End Gap
New Bore 0.189/0.277 mm (0.0074/0.0109 in.)
Used Bore (Max.) 0.531 mm (0.0209 in.)
Center Compression Ring End
Gap
New Bore 1.519/1.797 mm (0.0598/0.0708 in.)
Used Bore (Max.) 2.051 mm (0.0808 in.)
Thrust Face O.D.882.978 mm (3.2668 in.)
Max. Wear Limit 82.833 mm (3.2611 in.)
Piston Thrust Face-to Cylinder
Bore8Running Clearance
New 0.019/0.062 mm (0.0007/0.0024 in.)
Valves and Valve Lifters
Hydraulic Lifter to Crankcase
Running Clearance
0.011/0.048 mm (0.0004/0.0019 in.)
Intake Valve Stem-to-Valve
Guide Running Clearance
0.040/0.078 mm (0.0016/0.0031 in.)
Exhaust Valve Stem-to-Valve
Guide Running Clearance
0.052/0.090 mm (0.0020/0.0035 in.)
Intake Valve Guide I.D.
New
Max. Wear Limit
7.040/7.060 mm (0.2772/0.2780 in.)
7.134 mm (0.2809 in.)
Exhaust Valve Guide I.D.
New
Max. Wear Limit
7.040/7.060 mm (0.2772/0.2780 in.)
7.159 mm (0.2819 in.)
Valve Guide Reamer Size
Standard
0.25 mm O.S.
7.050 mm (0.2776 in.)
7.300 mm (0.2874 in.)
Intake Valve Minimum Lift 8.07 mm (0.3177 in.)
Exhaust Valve Minimum Lift 8.07 mm (0.3177 in.)
Nominal Valve Seat Angle 45°
4 Values are in Metric units. Values in parentheses are English equivalents.
8 Measure 6 mm (0.236 in.) above bottom of piston skirt at right angles to piston pin.

Specifications
12 24 690 31 Rev. HKohlerEngines.com
GENERAL TORQUE VALUES
Metric Fastener Torque Recommendations for Standard Applications
Property Class Noncritical
Fasteners
Into Aluminum
Size 4.8 5.8 8.8 10.9 12.9
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
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) —

Tools and Aids
1324 690 31 Rev. H KohlerEngines.com
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.
NOTE: Not all tools listed are required to service this engine.
SEPARATE TOOL SUPPLIERS
Kohler Tools
Contact your local Kohler source of
supply.
SE Tools
415 Howard St.
Lapeer, MI 48446
Phone [phone]
Toll Free 800-664-2981
Fax [phone]
Design Technology Inc.
768 Burr Oak Drive
Westmont, IL 60559
Phone [phone]
Fax [phone]
TOOLS
Description Source/Part No.
Alcohol Content Tester
For testing alcohol content (%) in reformulated/oxygenated fuels.
Kohler 25 455 11-S
Camshaft Endplay Plate
For checking camshaft endplay.
SE Tools KLR-82405
Camshaft Seal Protector (Aegis)
For protecting seal during camshaft installation.
SE Tools KLR-82417
Dual Gauge Cylinder Leakdown Tester
For checking combustion retention and if cylinder, piston, rings, or valves are worn.
Individual component available:
Adapter 12 mm x 14 mm (Required for leakdown test on XT-6 engines)
Kohler 25 761 46-S
Design Technology Inc.
DTI-731-03
Dealer Tool Kit
Complete kit of Kohler required tools.
Components of 25 761 39-S
Ignition System Tester
Dual Gauge Cylinder Leakdown Test Tool
Oil Pressure Test Kit
Digital Vacuum/Pressure Tester
Kohler 25 761 39-S
Kohler 25 455 01-S
Kohler 25 761 46-S
Kohler 25 761 06-S
Kohler 25 455 22-S
Digital Vacuum/Pressure Tester
For checking crankcase vacuum.
Individual component available:
Rubber Adapter Plug
Kohler 25 455 22-S
Design Technology Inc.
DTI-721-10
EFI Service Kit
For troubleshooting and setting up an EFI engine.
Components of 24 761 01-S
Fuel Pressure Tester
Noid Light
90° Adapter
Code Plug, Red Wire
Code Plug, Blue Wire
Code Plug, Yellow Wire
Can Bus Reset Tool, Green Wire
Shrader Valve Adapter Hose
Wire Probe Set (2 pieces regular wire with clip; 1 piece fused wire)
Hose Removal Tool, Dual Size/End (also sold as individual Kohler tool)
K-Line Adapter Jumper Lead Wiring Harness
Kohler 24 761 01-S
Design Technology Inc.
DTI-019
DTI-021
DTI-023
DTI-027
DTI-029
DTI-028
DTI-030
DTI-037
DTI-031
DTI-033
Kohler 25 176 23-S
KOHLER®Diagnostic System (KDS) Gen 2
For Laptop or Desktop PC.
Components of 25 761 50-S
Engine Communication Module
7 Pin to DB9 Cable
USB Module to PC Cable
7 Pin to 4 Pin Adapter
Kohler 25 761 50-S
Kohler 25 761 47-S
Kohler 25 761 48-S
Kohler 25 761 49-S
Kohler 25 761 53-S
Mobile KDS (Wireless) Module
For mobile Android or iOS EFI diagnostics.
Individual component available:
Wireless Diagnostic System Interface Cable
Kohler 25 761 45-S
Kohler 25 761 44-S

Tools and Aids
14 24 690 31 Rev. HKohlerEngines.com
TOOLS
Description Source/Part No.
Flywheel Puller
For properly removing flywheel from engine.
SE Tools KLR-82408
Flywheel Anchor Bolts, Washers, Nuts Tool
Used with Flywheel Puller for properly removing flywheel from 5400 Series engine.
Kohler 25 086 753-S
Hose Removal Tool, Dual Size/End (also available in EFI Service Kit)
Used to properly remove fuel hose from engine components.
Kohler 25 455 20-S
Ignition System Tester
For testing output on all systems, including CD.
Kohler 25 455 01-S
Inductive Tachometer (Digital)
For checking operating speed (RPM) of an engine.
Design Technology Inc.
DTI-110
Oil Pressure Test Kit
For testing/verifying oil pressure on pressure lubricated engines.
Kohler 25 761 06-S
Rectifier-Regulator Tester (120 volt current)
Rectifier-Regulator Tester (240 volt current)
For testing rectifier-regulators.
Components of 25 761 20-S and 25 761 41-S
CS-PRO Regulator Test Harness
Special Regulator Test Harness with Diode
Kohler 25 761 20-S
Kohler 25 761 41-S
Design Technology Inc.
DTI-031R
DTI-033R
Spark Advance Module (SAM) Tester
For testing SAM (ASAM and DSAM) on engines with SMART-SPARK™.
Kohler 25 761 40-S
Starter Servicing Kit (All Starters)
For removing and reinstalling drive retaining rings and brushes.
Individual component available:
Starter Brush Holding Tool (Solenoid Shift)
SE Tools KLR-82411
SE Tools KLR-82416
Stepper Motor Controller Tool
For testing operation of stepper motor/Digital Linear Actuator (DLA).
Kohler 25 455 21-S
Jumper Lead Tool
For use with Stepper Motor Controller Tool to test rotary stepper motor.
Kohler 25 518 43-S
Triad/OHC Timing Tool Set
For holding cam gears and crankshaft in timed position while installing timing belt.
Kohler 28 761 01-S
Valve Guide Reamer (K and M Series)
For properly sizing valve guides after installation.
Design Technology Inc.
DTI-K828
Valve Guide Reamer O.S. (Command Series)
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.
Kohler 25 455 12-S
Reamer Handle
For hand reaming using Kohler 25 455 12-S reamer.
Design Technology Inc.
DTI-K830
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.
Only oxime-based, oil resistant RTV sealants, such as those listed, are approved
for use. Permatex®the Right Stuff® 1 Minute Gasket™ or Loctite®Nos. 5900®or
5910®are recommended for best sealing characteristics.
Kohler 25 597 07-S
Loctite®5910®
Loctite®Ultra Black 598™
Loctite®Ultra Blue 587™
Loctite®Ultra Copper 5920™
Permatex®the Right Stuff® 1
Minute Gasket™
Spline Drive Lubricant Kohler 25 357 12-S

Tools and Aids
1524 690 31 Rev. H KohlerEngines.com
FLYWHEEL HOLDING TOOL ROCKER ARM/CRANKSHAFT TOOL
A flywheel holding tool can be made out of an old junk
flywheel ring gear and used in place of a strap wrench.
1. Using an abrasive cut-offwheel, cut out a six tooth
segment of ring gear as shown.
2. Grind offany burrs or sharp edges.
3. Invert segment and place it between ignition bosses
on crankcase so tool teeth engage flywheel ring
gear teeth. Bosses will lock tool and flywheel in
position for loosening, tightening, or removing with a
puller.
A spanner wrench to lift rocker arms or turn crankshaft
may be made out of an old junk connecting rod.
1. Find a used connecting rod from a 10 HP or larger
engine. Remove and discard rod cap.
2. Remove studs of a Posi-Lock rod or grind off
aligning steps of a Command rod, so joint surface is
flat.
3. Find a 1 in. long capscrew with correct thread size to
match threads in connecting rod.
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.

Troubleshooting
16 24 690 31 Rev. HKohlerEngines.com
Exhaust System PCV680LE, PCV740LE
NOTE: Overfueling can cause overheating of muffler
and premature failure.
●PCV680LE and PCV740LE engines are designed
with lower emissions with a catalyst in exhaust
system. If run quality, including misfiring, is in
question, shut engine down and obtain service right
away.
Engine Cranks But Will Not Start
●Battery connected backwards.
●Blown fuse.
●Carburetor solenoid malfunction.
●Choke not closing.
●Clogged fuel line or fuel filter.
●Diode in wiring harness failed in open circuit mode.
●DSAI or DSAM malfunction.
●Empty fuel tank.
●Faulty electronic control unit.
●Faulty ignition coil(s).
●Faulty spark plug(s).
●Fuel pump malfunction-vacuum hose clogged or
leaking.
●Fuel shut-offvalve closed.
●Ignition module(s) faulty or improperly gapped.
●Insufficient voltage to electronic control unit.
●Interlock switch is engaged or faulty.
●Key switch or kill switch in OFF position.
●Low oil level.
●Quality of fuel (dirt, water, stale, mixture).
●SMART-SPARKTM malfunction.
●Spark plug lead(s) disconnected.
Engine Starts But Does Not Keep Running
●Faulty carburetor.
●Faulty cylinder head gasket.
●Faulty or misadjusted choke or throttle controls.
●Fuel pump malfunction-vacuum hose clogged or
leaking.
●Intake system leak.
●Loose wires or connections that intermittently ground
ignition kill circuit.
●Quality of fuel (dirt, water, stale, mixture).
●Restricted fuel tank cap vent.
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 EFI engine troubles are listed below and vary by engine specification. Use these to
locate causing factors.
Engine Starts Hard
●Clogged fuel line or fuel filter.
●Engine overheated.
●Faulty ACR mechanism.
●Faulty or misadjusted choke or throttle controls.
●Faulty spark plug(s).
●Flywheel key sheared.
●Fuel pump malfunction-vacuum hose clogged or
leaking.
●Interlock switch is engaged or faulty.
●Loose wires or connections that intermittently ground
ignition kill circuit.
●Low compression.
●Quality of fuel (dirt, water, stale, mixture).
●Weak spark.
Engine Will Not Crank
●Battery is discharged.
●Faulty electric starter or solenoid.
●Faulty key switch or ignition switch.
●Interlock switch is engaged or faulty.
●Loose wires or connections that intermittently ground
ignition kill circuit.
●Pawls not engaging in drive cup.
●Seized internal engine components.
Engine Runs But Misses
●Carburetor adjusted incorrectly.
●Engine overheated.
●Faulty spark plug(s).
●Ignition module(s) faulty or improperly gapped.
●Incorrect crankshaft position sensor air gap.
●Interlock switch is engaged or faulty.
●Loose wires or connections that intermittently ground
ignition kill circuit.
●Quality of fuel (dirt, water, stale, mixture).
●Spark plug lead(s) disconnected.
●Spark plug lead boot loose on plug.
●Spark plug lead loose.
Engine Will Not Idle
●Engine overheated.
●Faulty spark plug(s).
●Idle fuel adjusting needle(s) improperly set.
●Idle speed adjusting screw improperly set.
●Inadequate fuel supply.
●Low compression.
●Quality of fuel (dirt, water, stale, mixture).
●Restricted fuel tank cap vent.

1724 690 31 Rev. H KohlerEngines.com
Troubleshooting
Engine Overheats
●Cooling fan broken.
●Excessive engine load.
●Fan belt failed/off.
●Faulty carburetor.
●High crankcase oil level.
●Lean fuel mixture.
●Low cooling system fluid level.
●Low crankcase oil level.
●Radiator, and/or cooling system components clogged,
restricted, or leaking.
●Water pump belt failed/broken.
●Water pump malfunction.
Engine Knocks
●Excessive engine load.
●Hydraulic lifter malfunction.
●Incorrect oil viscosity/type.
●Internal wear or damage.
●Low crankcase oil level.
●Quality of fuel (dirt, water, stale, mixture).
Engine Loses Power
●Dirty air cleaner element.
●Engine overheated.
●Excessive engine load.
●Restricted exhaust.
●Faulty spark plug(s).
●High crankcase oil level.
●Incorrect governor setting.
●Low battery.
●Low compression.
●Low crankcase oil level.
●Quality of fuel (dirt, water, stale, mixture).
Engine Uses Excessive Amount of Oil
●Loose or improperly torqued fasteners.
●Blown head gasket/overheated.
●Breather reed broken.
●Clogged, broken, or inoperative crankcase breather.
●Crankcase overfilled.
●Incorrect oil viscosity/type.
●Worn cylinder bore.
●Worn or broken piston rings.
●Worn valve stems/valve guides.
Oil Leaks from Oil Seals, Gaskets
●Breather reed broken.
●Clogged, broken, or inoperative crankcase breather.
●Loose or improperly torqued fasteners.
●Piston blow by, or leaky valves.
●Restricted exhaust.
EXTERNAL ENGINE INSPECTION
NOTE: It is good practice to drain oil at a location away
from workbench. Be sure to allow ample time for
complete drainage.
Before cleaning or disassembling engine, make a
thorough inspection of its external appearance and
condition. This inspection can give clues to what
might be found inside engines (and cause) when it is
disassembled.
●Check for buildup of dirt and debris on crankcase,
cooling fins, grass screen, and other external surfaces.
Dirt or debris on these areas can cause overheating.
●Check for obvious fuel and oil leaks, and damaged
components. Excessive oil leakage can indicate a
clogged or inoperative breather, worn or damaged
seals or gaskets, or loose fasteners.
●Check air cleaner cover and base for damage or
indications of improper fit and seal.
●Check air cleaner element. Look for holes, tears,
cracked or damaged sealing surfaces, or other
damage that could allow unfiltered air into engine. A
dirty or clogged element could indicate insufficient or
improper maintenance.
●Check throttle body throat for dirt. Dirt in throat is
further indication that air cleaner was not functioning
properly.
●Check if oil level is within operating range on dipstick.
If it is above, snifffor gasoline odor.
●Check condition of oil. Drain oil into a container; it
should flow freely. Check for metal chips and other
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.

Troubleshooting
18 24 690 31 Rev. HKohlerEngines.com
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
fasteners.
Replace all worn or damaged seals and gaskets. Make
sure all fasteners are tightened securely. Use appropriate
torque valves and sequences when necessary.
Piston blow by or leaky valves (confirm by inspecting
components).
Recondition piston, rings, cylinder bore, valves and
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.
CRANKCASE VACUUM TEST
WARNING
Carbon Monoxide can cause severe nausea,
fainting or death.
Take precautions against exposure to carbon
monoxide
(CO) emissions. Only operate an
engine in well ventilated areas.
Engine exhaust gases contain poisonous carbon
monoxide. Carbon monoxide is odorless, colorless,
and can cause death if inhaled.
To test crankcase vacuum with manometer:
1. Insert rubber stopper into oil fill hole. Be sure pinch
clamp is installed on hose and use tapered adapters
to connect hose between stopper and one
manometer tube. Leave other tube open to
atmosphere. Check that water level in manometer is
at 0 line. Make sure pinch clamp is closed.
2. Start engine and run no-load high speed.
3. Open clamp and note water level in tube.
Level in engine side should be a minimum of 10.2
cm (4 in.) above level in open side.
If level in engine side is less than specified (low/no
vacuum), or level in engine side is lower than level in
open side (pressure), check for conditions in table
below.
4. Close pinch clamp before stopping engine.
To test crankcase vacuum with vacuum/pressure gauge
(inches of water gauge only):
1. Remove dipstick or oil fill plug/cap.
2. Install adapter into oil fill//dipstick tube opening,
upside down over end of a small diameter dipstick
tube, or directly into engine if a tube is not used.
Insert barbed gauge fitting into hole in stopper.
3. Run engine and observe gauge reading.
Analog tester–needle movement to left of 0 is a
vacuum, and movement to right indicates a
pressure.
Digital tester–depress test button on top of tester.
Crankcase vacuum should be a minimum of 10.2 cm
(4 in.) of water. If reading is below specification, or if
pressure is present, check table below for possible
causes and conclusions.
WARNING
Rotating Parts can cause severe injury.
Stay away while engine is in operation.
Keep hands, feet, hair, and clothing away from all
moving parts to prevent injury. Never operate engine
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 (inches of water gauge only).
Complete instructions are provided in kits.

1924 690 31 Rev. H KohlerEngines.com
Troubleshooting
COMPRESSION TEST
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 battery is fully charged, unplug ECU, and throttle is wide open during test.
Compression should be at least 160 psi and should not vary more than 15% between cylinders.
Some models may be 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.
Dual Gauge Test Procedure
1. Run engine until oil temperature reaches and
maintains 150°F (66°C) or more for a minimum of 5
minutes. Ideally, engine should be run under normal
load conditions.
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 from kit 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 engine cannot rotate offTDC in either
direction.
4. Connect an air source (at least 100 PSI) to tool.
5. Turn regulator knob clockwise (increase direction).
Confirm both gauges read approximately the same
air pressure from 0 to 80 PSI. Note any
discrepancies between gauges for leakage
calculation. Release pressure by turning regulator
knob completely counterclockwise before
proceeding.
6. Install adapter hose into spark plug hole of cylinder
being tested. Use 12 mm x 14 mm adapter if
required.
7. Firmly hold engine at TDC. Connect other end of
adapter hose to tool quick connect. Turn regulator
knob clockwise (increase direction) until left gauge
needle reads 20 PSI.
NOTE: When piston is at TDC, little to no holding force
should be required when air pressure is applied
to cylinder. If excess holding force is required,
this indicates piston is not at TDC. Readjust as
necessary before proceeding.
8. Slowly turn regulator knob clockwise until left hand
gauge maintains selected test pressure (see chart
below).
Left Gauge Regulated Pressure Selection
80 PSI
Recommended for engines over 200 cc
or those exhibiting high leakage at 35 PSI setting.
35 PSI
Recommended for single cylinder
walk-behind push mower applications.
9. Compare right gauge reading to Test Pressure Chart
on next page to identify percentage of leakage. Also
refer to Leakdown Test Results chart on next page
for colors, conditions, and action required.
10. For engines exhibiting leakage in yellow or red zone,
repeat test procedure. Operate engine under normal
load conditions prior to test. Confirm piston is at TDC
during test.
NOTE: To prevent damage to gauge assembly, always
turn pressure regulator knob to zero
(counterclockwise) after each test.

Troubleshooting
20 24 690 31 Rev. HKohlerEngines.com
Test Pressure Chart for Dual Gauge Tool
Left Gauge Regulated Pressure
Selection Right Gauge Reading in PSI
80 PSI
Recommended for engines over 200
cc or those exhibiting high leakage at
35 PSI setting.
80 72 64 56 48 40 32 24 16 8 0
35 PSI
Recommended for single cylinder
walk-behind push mower
applications.
35 31.5 28 24.5 21 17.5 14 10.5 7 3.5 0
Percentage of leakage 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Green Zone Yellow Zone Red Zone
Leakdown Test Results
Test Result Condition Action
Gauge reading in low
(green) zone.
Piston rings and cylinder in
good condition.
No further action required.
Gauge reading in
moderate (yellow)
zone.
Air escaping from crankcase
breather and/or dipstick tube.
Some wear present causing leakage from
combustion chamber to crankcase. Repair not
required at this time if breather system is
functioning normally.
Air escaping from exhaust. Exhaust valve leakage present, possibly due to
carbon deposits. Repair not required. Carbon
cleaning could be performed to reduce leakage.
Air escaping from intake. Intake valve leakage present, possibly due to
carbon deposits. Repair not required. Carbon
cleaning could be performed to reduce leakage.
Gauge reading in
high (red) zone.
Confirm consecutive leakdown
test has been performed AFTER
engine has been operated under
normal load conditions.
Air escaping from crankcase
breather and/or dipstick tube.
Excess wear present causing leakage from
combustion chamber to crankcase. Breather
system will not function normally and will fail
crankcase vacuum test if this condition is truly
present. Engine disassembly and analysis
required to determine root cause and
correction.
Air escaping from exhaust. Excess exhaust valve leakage present, possibly
due to carbon deposits and/or valve to seat
sealing issues. Carbon cleaning may reduce
leakage. Valve grind and/or component
replacement may be necessary. Excess oil
consumption and/or excess heat is a suspect
cause and must be resolved to prevent
reoccurrence.
Air escaping from intake. Excess intake valve leakage present, possibly
due to carbon deposits and/or valve to seat
sealing issues. Carbon cleaning may reduce
leakage. Valve grind and/or component
replacement may be necessary. Excess oil
consumption through intake valve and/or
excess heat is a suspect cause and must be
resolved to prevent reoccurrence. Inspect
breather system components and intake valve
stem sealing.