Kohler Courage SV470 User manual

S
ERVICE
M
E
ANUAL
M
M
V
ERTI
C
A
L
C
RANK
S
HAF
T
C
O
URA
GE
S
V47
0-
S
V
620

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

1.1
Section 1
Safety and General Information
1
Section 1
Safety and General Information
Safety Precautions
To ensure safe operation 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.
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
ȱȱĞȱǯ
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
Ğȱȱȱȱěǯȱȱȱ
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 (-)
Ĵ¢ȱȱȱĴ¢ǯ

1.2
Section 1
Safety and General Information
Carbon Monoxide can cause
severe nausea, fainting or death.
Avoid inhaling exhaust fumes, and
never run the engine in a closed
ȱȱęȱǯ
WARNING
Electrical Shock can cause injury.
Do not touch wires while engine is
running.
CAUTION
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
ȱȱȱȱȱȱęȱ
area.
Explosive Gas!
Ĵȱȱ¡ȱ¢ȱ
gas while being charged. To prevent a
ęȱȱ¡ǰȱȱĴȱ¢ȱ
in well ventilated areas. Keep
ǰȱȱĚǰȱȱȱȱ
ȱȱ¢ȱȱȱĴ¢ȱȱȱ
ǯȱȱĴȱȱȱȱȱ
of children. Remove all jewelry when
ȱĴǯ
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.
Electrical Shock!
Never touch electrical wires or
components while the engine is
running. They can be sources of
electrical shock.
¡ȱȱȱȱęȱ
and severe burns.
ȱȱęȱȱȱȱȱȱ
engine is hot or running.
WARNING
Explosive Fuel!
ȱȱ¡¢ȱĚȱȱ
its vapors can explode if ignited. Store
gasoline only in approved containers,
in well ventilated, unoccupied
ǰȱ¢ȱȱȱȱĚǯȱ
ȱȱęȱȱȱȱȱȱ
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
¡¢ȱĚǯȱȱǰȱ
Ěǰȱȱȱȱȱȱ
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.
WARNING
¡ȱȱȱȱęȱȱ
severe acid burns.
ȱĴ¢ȱ¢ȱȱȱȱ
ventilated area. Keep sources of
ignition away.

1.3
Section 1
Safety and General Information
1
A. Model No.
Courage Vertical Shaft Engine
Numerical Designation
Version Code
S = Electric Start
First spec
written in this
model series
B. Spec. No.
Engine Model
Model
SV470
SV480
SV530
SV540
SV590
SV600
SV610
SV620
C. Serial No.
Year Manufactured Code
Code Year
32 2002
33 2003
34 2004
35 2005
36 2006
37 2007
38 2008
Factory Code
3205810334
(QJLQH,GHQWL¿FDWLRQ1XPEHUV
When ordering parts, or in any communication
involving an engine, always give the Model,
ęǰȱȱȱ of the engine.
ȱȱęȱȱȱȱȱȱ
Ĝ¡ȱȱȱȱǯȱȱȱŗȬŗǯȱȱ
¡ȱȱȱȱȱȱȱȱŗȬŘǯ
)LJXUH([SODQDWLRQRI(QJLQH,GHQWL¿FDWLRQ1XPEHUV
SV540-0001
)LJXUH(QJLQH,GHQWL¿FDWLRQ'HFDO/RFDWLRQ
,GHQWL¿FDWLRQ'HFDO
SV 540 S

1.4
Section 1
Safety and General Information
Oil Recommendations
Using the proper type and weight of oil in the
crankcase is extremely important, as is checking oil
¢ȱȱȱȱ¢ǯȱȱȱȱȱ
correct oil or using dirty oil causes premature engine
wear and failure.
Oil Type
Use high-quality detergent oil of ȱǻȱ
ȱǼȱȱȱȱȱ. Select
the viscosity based on the air temperature at the time
of operation as shown below.
NOTE: Using other than service class SJ or higher
oil or extending oil change intervals longer
than recommended can cause engine
damage.
NOTE: Synthetic oils meeting the listed
ęȱ¢ȱȱȱȱȱȱ
performed at the recommended intervals.
However to allow piston rings to properly
seat, a new or rebuilt engine should be
operated for at least 50 hours using standard
petroleum based oil before switching to
synthetic oil.
ȱȱȱ¢ȱȱȱȱęȱȱȱ
ȱȱȱȱ¢ȱǯȱȱȱŗȬŚǯȱ
Fuel Recommendations
WARNING: Explosive Fuel!
ȱȱ¡¢ȱĚȱȱȱȱȱ¡ȱ
if ignited. Store gasoline only in approved containers, in
well ventilated, unoccupied buildings, away from sparks
ȱĚǯȱȱȱęȱȱȱȱȱȱȱȱȱ
or running, since spilled fuel could ignite if it comes in
contact with hot parts or sparks from ignition. Do not
start the engine near spilled fuel. Never use gasoline as a
cleaning agent.
General Recommendations
Purchase gasoline in small quantities and store
in clean, approved containers. A container with a
¢ȱȱŘȱȱȱȱȱȱȱȱȱ
recommended. Such a container is easier to handle
and helps eliminate spillage during refueling.
ȱȱȱȱĞȱȱȱȱȱ
season, to minimize gum deposits in your fuel system
and to ensure easy starting.
Do not add oil to the gasoline.
ȱȱęȱȱȱǯȱȱȱȱȱȱ
to expand.
Fuel Type
ȱȱǰȱȱ¢ȱǰȱǰȱȱ
gasoline with a pump sticker octane rating of 87 or
ǯȱȱȱȱȱȱǰȱȱ
should be 90 octane minimum.
Unleaded gasoline is recommended, as it leaves less
ȱȱǯȱȱȱ¢ȱ
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
ȱǻȱȱŗŖƖȱ¢ȱǰȱşŖƖȱȱ
gasoline by volume) is approved as a fuel for Kohler
ǯȱȱȦȱȱȱŘŖȱ
and E85 are not to be used and not approved. Any
failures resulting from use of these fuels will not be
warranted.
Gasoline/Ether Blends
Methyl Tertiary Butyl Ether (MTBE) and unleaded
ȱȱǻȱȱ¡ȱȱŗśƖȱȱ¢ȱ
volume) are approved as a fuel for Kohler engines.
Other gasoline/ether blends are not approved.
Figure 1-3. Oil Container Logo.
ȱȱȱŜȱȬȱȱ¢ȱȱȱȱ
ǰȱȱǰȱȱȱęȱȱǯ
SAE
10W-30
A
P
I
S
E
R
V
I
C
E
S
J
5W-20, 5W-30
RECOMMENDED SAE VISCOSITY GRADES
10W-30
Kohler 10W-30
°F -20 0 20 32 40 60 80 100
°C -30 -20 -10 0 10 20 30 40
TEMPERATURE RANGE EXPECTED BEFORE NEXT OIL CHANGE
* Use of synthetic oil having 5W-20 or 5W-30 rating is acceptable,
up to 4°C (40°F)
** Synthetic oils will provide better starting in extreme cold below
-23°C (-10°F)
** *

1.5
Section 1
Safety and General Information
1
Periodic Maintenance
WARNING: Accidental Starts!
Disabling engine. Accidental starting can cause severe injury or death. Before working on the engine or equipment,
ȱȱȱȱDZȱŗǼȱȱȱȱȱǻǼǯȱŘǼȱȱȱǻȬǼȱĴ¢ȱȱȱĴ¢ǯ
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.
Storage
ȱȱȱȱȱȱȱȱȱȱȱȱ
more, use the following storage procedure:
ȱ ŗǯȱ ȱȱ¡ȱȱȱȱǯ
ȱ Řǯȱ ȱȱȱȱȱęȱȱȱȱȱ
still warm from operation. See Change Oil and
ȱȱȱȱŜǯ
3. The fuel system must be completely emptied,
or the gasoline must be treated with a stabilizer
ȱȱǯȱȱ¢ȱȱȱ
use a stabilizer, follow the manufacturer’s
recommendations, and add the correct amount
ȱȱ¢ȱȱȱȱ¢ǯȱȱȱȱ
ȱȱǰȱȱǯȱȱȱȱ
ȱŘȬřȱȱȱȱ£ȱȱȱȱ
carburetor.
To empty the system, run the engine until the
tank and system are empty.
ȱ Śǯȱ ȱȱȱȱȱȱȱȱǰȱ
ȱȱȱ¢ȱȱȱǯȱȱ
the spark plug. The spark plug is most accessible
when the blower housing is removed for
cleaning.
Add one tablespoon of engine oil into the spark
ȱǯȱȱȱǰȱȱȱȱȱ
the plug lead. Crank the engine two or three
revolutions. Connect the plug lead.
ȱȱśǯȱ ȱȱȱǰȱȱȱ
previously, and torque the blower housing screws
to ŝǯśȱȉȱǻŜśȱǯȱǯǼ.
ȱ Ŝǯȱ ȱȱȱȱȱǰȱ¢ȱǯ
¹Perform these maintenance procedures more frequently under extremely dusty, dirty conditions.
²Have a Kohler Engine Service Dealer perform this service.
Daily or Before
Starting Engine
Maintenance RequiredFrequency
ȱ Ȋȱ ȱȱǯ
• Check oil level.
• Check air cleaner for dirty¹, loose, or damaged parts.
• Check air intake and cooling areas, clean as necessary¹.
Every 2 Months
or 25 Hours
• Service precleaner element¹ (if equipped).
• Service air cleaner element¹ (if not equipped with precleaner).
ȱ Ȋȱ ȱȱȱŵȱǻȱȱȱǼǯ
ȱ Ȋȱ ȱȱȱęȱǻȱȱ¢ȱǰȱȱŗǯŚǰȱȱȱȱ
temperatures).
ȱ Ȋȱ ȱȱȱȱȱȱǯ
• Check that all fasteners are in place and components are properly secured.
ȱ Ȋȱ ȱȱęǯ
• Have bendix starter drive serviced².
• Have valve lash checked/adjustedŘ.
Every 200 Hours
Annually or
Every 100 Hours
Every 500 Hours ȱ Ȋȱ ȱȱǯ
• Check spark plug condition and gap.
Every 2 Years or
200 Hours

1.6
Section 1
Safety and General Information
Figure 1-4. Typical Engine Dimensions.
VALVE COVER VIEW
Dimensions in millimeters. Inch equivalents shown in ().

1.7
Section 1
Safety and General Information
1
*HQHUDO6SHFL¿FDWLRQVï
ȱǻȓȱřŜŖŖȱǰȱ¡ȱ¢ȱȱȱȬȱȱȱȱŗşŚŖǼ
ȱ ŚŝŖȱ ............................................................................................................. ŗŗǯŘȱȱǻŗśȱǼ
ŚŞŖȱ ............................................................................................................. ŗŗǯşȱȱǻŗŜȱǼ
śřŖȱ ............................................................................................................. ŗŘǯŝȱȱǻŗŝȱǼ
ȱ śŚŖ .............................................................................................................. ŗřǯŚȱȱǻŗŞȱǼ
ȱ śşŖȱ ............................................................................................................. ŗŚǯŗȱȱǻŗşȱǼ
ȱ ŜŖŖ .............................................................................................................. ŗŚǯşȱȱǻŘŖȱǼ
ȱ ŜŗŖ .............................................................................................................. ŗśǯŝȱȱǻŘŗȱǼ
ȱ ŜŘŖ .............................................................................................................. ŗŜǯŚȱȱǻŘŘȱǼ
Bore
ȱ ŚŝŖǰȱŚŞŖȱǻ¢ȱȱ¢Ǽ .............................................................ŞŚȱȱǻřǯřŖȱǯǼ
ȱ ŚŝŖǰȱŚŞŖǰȱśřŖǰȱśŚŖ ........................................................................89 mm (3.50 in.)
ȱ śşŖǰȱŜŖŖǰȱŜŗŖǰȱŜŘŖ ........................................................................şŚȱȱǻřǯŝŖȱǯǼ
Stroke......................................................................................................................ŞŜȱȱǻřǯřŞȱǯǼ
Displacement
ȱ ŚŝŖǰȱŚŞŖȱǻ¢ȱȱ¢Ǽ .............................................................ŚŝŝȱȱǻŘşǯŗȱǯȱǯǼ
ȱȱ ŚŝŖǰȱŚŞŖǰȱśřŖǰȱśŚŖ ........................................................................śřśȱȱǻřŘǯŜȱǯȱǯǼ
ȱ śşŖǰȱŜŖŖǰȱŜŗŖǰȱŜŘŖ ........................................................................śşŝȱȱǻřŜǯŚȱǯȱǯǼ
ȱ
ȱ ŚŝŖǰȱŚŞŖǰȱśřŖǰȱśŚŖ ........................................................................şǯŚDZŗ
ȱ śşŖǰȱŜŖŖǰȱŜŗŖǰȱŜŘŖ ........................................................................ŞǯśDZŗ
Dry Weight............................................................................................................. 35.8 kg (79 lb.)
ȱ¢ȱǻȱęǼ..................................................................................... ŗǯŖŚȬŗǯřŖȱȱǻŗǯŗȬŗǯŚȱǯǼ
ȱȱȱȬȱ¡ȱǻȱȱȱǼȱȱ ...............ŘśǚȱĴ
Air Cleaner Base
¡ȱȱȱ .................................................................................... śǯśȱȉȱǻŚŞȱǯȱǯǼ
ȱȱȱȱǻȱ¢ȱȬȱȱȱǼ .................... ŞǯŖȱȉȱǻŝŖȱǯȱǯǼȱȱȱȬȱ
ȱ ȱ śǯśȱȉȱǻŚŞȱǯȱǯǼȱȱȱ
Blower Housing and Sheet Metal
Ŝȱȱ ..................................................................ŗŗǯŜȱȉȱǻşşȱǯȱǯǼȱȱȱȬȱ
ȱ ȱ ȱ ŝǯŝȱȉȱǻŜŞȱǯȱǯǼȱȱȱ
Cam Lever
ȱȱȱ ......................................................ȱŞǯŖȬŗŖǯśȱȉȱǻŝŖȬşŚǯŖȱǯȱǯǼȱȱȱȬȱ
ȱ ȱ ȱ ŝǯŗȬŞǯŜȱȉȱǻŜŗǯŞȬŝŚǯŞȱǯȱǯǼȱȱȱ
Cam Gears
End Play .............................................................................................................. ŖǯśȦŗǯśȱȱǻŖǯŖŗşȦŖǯŖśşȱǯǼ
ȱȱ.................................................................................... ŖǯŖŘȦŖǯŗřȱȱǻŖǯŖŖŗȦŖǯŖŖśȱǯǼ
ȱȬȬȱĞȱȱ¢................................................. ŖǯŖŘȦŖǯŗŖȱȱǻŖǯŖŖŗȦŖǯŖŖŚȱǯǼ
Carburetor
ȱȱȱȱ ................................................................. śǯŗȬŜǯŘȱȉȱǻŚśȬśśȱǯȱǯǼ
ŗȱȱȱȱǯȱȱȱȱȱȱǯȱȱȱȱȱȱȱ
to assembly, EXCEPT for air cleaner base thread forming screw - install dry.

1.8
Section 1
Safety and General Information
Closure Plate
ȱȱȱ ........................................................................ ŘŚǯśȱȉȱǻŘŗŜȱǯȱǯǼ
Balance Weight Guide Channel Width
New.............................................................................................................. ŗŝǯşśȦŗŞǯŖśȱȱǻŖǯŝŖŝȦŖǯŝŗŗȱǯǼ
ȱ ¡ǯȱȱ......................................................................................... ŗŞǯŗřȱȱǻŖǯŝŗŚȱǯǼ
Connecting Rod
ȱȱȱǻȱȱŘȱǼ.............................................. śǯśǰȱŗŗǯśȱȉȱǻśŖǰȱŗŖŖȱǯȱǯǼ
ȱȬȬȱȱ
New............................................................................................................... ŖǯŖřȦŖǯŖśśȱȱǻŖǯŖŖŗŘȦŖǯŖŖŘŘȱǯǼ
ȱ ¡ǯȱȱ.......................................................................................... ŖǯŖŝȱȱǻŖǯŖŖŘśȱǯǼ
ȱȬȬȱȱ................................................ ŖǯŘśȦŖǯśşȱȱǻŖǯŖŖşŞȦŖǯŖŘřŘȱǯǼ
ȱȬȬȱȱȱ....................................... ŖǯŖŗśȦŖǯŖŘŞȱȱǻŖǯŖŖŖŜȦŖǯŖŖŗŗȱǯǼ
Piston Pin End I.D.
New............................................................................................................... ŘŘǯŖŗśȦŘŘǯŖŘřȱȱǻŖǯŞŜŜŝȦŖǯŞŜŝŖȱǯǼ
ȱ ¡ǯȱȱ.......................................................................................... ŘŘǯŖřŜȱȱǻŖǯŞŜŝśȱǯǼ
Crankcase
ȱȱĞȱȱǯǯȱ
New............................................................................................................... ŜǯŖŘśȦŜǯŖśȱȱǻŖǯŘřŝŘȦŖǯŘřŞŘȱǯǼ
ȱ ¡ǯȱȱ.......................................................................................... ŜǯŖŜřȱȱǻŖǯŘřŞŝȱǯǼ
Oil Drain Plug Torque ....................................................................................... ŗŚǯŖȱȉȱǻŗŘśȱǯȱǯǼ
Crankshaft
End Play (free) .................................................................................................... ŖǯŘŘśȦŗǯŖŘśȱȱǻŖǯŖŖŞşȦŖǯŖŚŖȱǯǼ
Ğȱȱȱȱǯǯ
New.............................................................................................................. ŚŗǯşŜśȦŚŗǯşşŖȱȱǻŗǯŜśŘŗȦŗǯŜśřŗȱǯǼ
ȱ ¡ǯȱȱ......................................................................................... ŚŘǯŖŗŜȱȱǻŗǯŜśŚȱǯǼ
Ğȱȱȱȱȱǯǯ
New.............................................................................................................. ŚŚǯşŜśȦŚŚǯşşŖȱȱǻŗǯŝŝŖřȦŗǯŝŝŗřȱǯǼ
ȱ ¡ǯȱȱ......................................................................................... ŚśǯŖŗŜȱȱǻŗǯŝŝŘřȱǯǼ
¢ȱȱȱȱȱǯǯ
ȱ ȱȱȬȱȱȱǯȱřŝŖřŘŖŖŖŖř....................................................... ŚŚǯşŗřȦŚŚǯşřśȱȱǻŗǯŝŜŞŘȦŗǯŝŜşŗȱǯǼ
ȱ ȱȱȬȱĞȱȱǯȱřŝŖřŘŖŖŖŗř......................................................... ŚŚǯŞŝŖȦŚŚǯŞşśȱȱǻŗǯŝŜŜśȦŗǯŝŜŝśȱǯǼ
ȱ ǯǯȱȬȱ¡ǯȱȱ ............................................................................. ŚŚǯŞŚȱȱǻŗǯŝŜśȱǯǼ
Max. Taper .................................................................................................. ŖǯŖŘŘŖȱȱǻŖǯŖŖŖşȱǯǼ
ȱ ¡ǯȱȱȱ .................................................................................... ŖǯŖŘśȱȱǻŖǯŖŖŗȱǯǼ
PTO End Main Bearing Journal O.D.
ȱ ȱȬȱȱȱǯȱřŝŖřŘŖŖŖŖř........................................................ ŚŗǯşŗřȦŚŗǯşřśȱȱǻŗǯŜśŖŗȦŗǯŜśŗŖȱǯǼ
ȱ ȱȬȱĞȱȱǯȱřŝŖřŘŖŖŖŗř.......................................................... ŚŗǯŞśśȦŚŗǯŞŞŖȱȱǻŗǯŜŚŝŞȦŗǯŜŚŞŞȱǯǼ
ȱ ǯǯȱȬȱ¡ǯȱȱ ............................................................................. ŚŗǯŞřȱȱǻŗǯŜŚŝȱǯǼ
Max. Taper .................................................................................................. ŖǯŖŘŖȱȱǻŖǯŖŖŖŞȱǯǼ
ȱ ¡ǯȱȱȱ .................................................................................... ŖǯŖŘśȱȱǻŖǯŖŖŗȱǯǼ

1.9
Section 1
Safety and General Information
1
Crankshaft (Continued)
Ğȱȱȱȱȱȱȱ
ȱ ȱȬȱȱȱǯȱřŝŖřŘŖŖŖŖř........................................................ ŖǯŖřŖȦŖǯŖŝŝȱȱǻŖǯŖŖŗŘȦŖǯŖŖřŖȱǯǼ
ȱ ȱȬȱĞȱȱǯȱřŝŖřŘŖŖŖŗř.......................................................... ŖǯŖŝŖȦŖǯŗŘŖȱȱǻŖǯŖŖŘŝȦŖǯŖŖŚŝȱǯǼ
Ğȱȱȱȱȱȱ
ȱ ȱȬȱȱȱǯȱřŝŖřŘŖŖŖŖř........................................................ ŖǯŖřŖȦŖǯŖŝŝȱȱǻŖǯŖŖŗŘȦŖǯŖŖřŖȱǯǼ
ȱ ȱȬȱĞȱȱǯȱřŝŖřŘŖŖŖŗř.......................................................... ŖǯŖŞśȦŖǯŗřśȱȱǻŖǯŖŖřřȦŖǯŖŖśřȱǯǼ
ȱȱȱǯǯȱ
New.............................................................................................................. ŚŖǯşŞŘȦŚŗǯŖŖŖȱȱǻŗǯŜŗřŚȦŗǯŜŗŚŗȱǯǼ
ȱ ¡ǯȱȱ......................................................................................... ŚŖǯşŜŚȱȱǻŗǯŜŗŘȱǯǼ
Max. Taper .................................................................................................. ŖǯŖŗŘȱȱǻŖǯŖŖŖśȱǯǼ
ȱ ¡ǯȱȱȱ .................................................................................... ŖǯŖŘśȱȱǻŖǯŖŖŗȱǯǼ
Ğȱǯǯǯ
ȱ ȱǰȱĞȱȱ............................................................... ŖǯŗśȱȱǻŖǯŖŖśşȱǯǼ
ȱ ȱĞǰȱȱȬ ................................................................. ŖǯŗŖȱȱǻŖǯŖŖřşȱǯǼ
Ğȱȱǯǯ
New.............................................................................................................. ŜŜǯşŚŖȦŜŜǯşŝŖȱȱǻŘǯŜřśŚȦŘǯŜřŜŜȱǯǼ
ȱ ¡ǯȱȱ......................................................................................... ŜŜǯŞşȱȱǻŘǯŜřřȱǯǼ
Balance Weight
ȱȱȱȱǯǯ
New.............................................................................................................. ŜŝǯŖŗŗȦŜŝǯŖŞŜȱȱǻŘǯŜřŞŘȦŘǯŜŚŗŘȱǯǼ
ȱ ¡ǯȱȱ......................................................................................... ŜŝǯŗŚŖȱȱǻŘǯŜŚřŖȱǯǼ
Balance Weight Pin O.D.
New.............................................................................................................. ŗŗǯşśŖȦŗŗǯşŝśȱȱǻŖǯŚŝŖśȦŖǯŚŝŗśȱǯǼ
ȱ ¡ǯȱȱ......................................................................................... ŗŗǯşŖŖȱȱǻŖǯŚŜŞśȱǯǼ
ȱȱȱȬȱȱȱȱǯȱřŜŗŞŖŖŖŖŖř
New ............................................................................................................. ŗŝǯŞśȦŗŝǯşŖȱȱǻŖǯŝŖřȦŖǯŝŖśȱǯǼ
ȱ ¡ǯȱȱ......................................................................................... ŗŝǯŝśȱȱǻŖǯŜşŞŞȱǯǼ
ȱȱȱǯǯȱ
New.............................................................................................................. ŗŘǯŖŖŖȦŗŘǯŖŘśȱȱǻŖǯŚŝŘŚȦŖǯŚŝřŚȱǯǼ
ȱ ¡ǯȱȱ......................................................................................... ŗŘǯŖśŖȱȱǻŖǯŚŝŚŚȱǯǼ
ȱȱǯǯȱǻǼȱȬȱĞȱȱǯȱřŜŗŞŖŖŖŖŗř
New.............................................................................................................. ŗŗǯşŜŚȦŗŗǯşŝśȱȱǻŖǯŚŝŗŖȦŖǯŚŝŗśȱǯǼ
ȱ ¡ǯȱȱ......................................................................................... ŗŗǯşŖŖȱȱǻŖǯŚŜŞśȱǯǼ
ȱȱȬȱĞȱȱǯȱřŜŗŞŖŖŖŖŗř
New.............................................................................................................. ŗŗǯşŞśȦŗŘǯŖŗŖȱȱǻŖǯŚŝŗşȦŖǯŚŝŘŞȱǯǼ
ȱ ¡ǯȱȱ......................................................................................... ŗŘǯŖřśȱȱǻŖǯŚŝřŞȱǯǼ
Balance Weight Screw Torque......................................................................... ŗŖǯşȬŗřǯŘȱȉȱǻşśǯŖȬŗŗśǯŖȱǯȱǯǼ

1.10
Section 1
Safety and General Information
Cylinder Bore
¢ȱȱǯǯ
New
ȱ ȱ ŚŝŖǰȱŚŞŖȬŖŖ.................................................................................. ŞŚǯŖŖŖȦŞŚǯŖŘśȱȱǻřǯřŖŝȦřǯřŖŞȱǯǼ
ȱ ȱ ŚŝŖǰȱŚŞŖȬŖŗ.................................................................................. ŞşǯŖŖŖȦŞşǯŖŘśȱȱǻřǯśŖŚȦřǯśŖśȱǯǼ
ȱ ȱ śřŖǰȱśŚŖ............................................................................................. ŞşǯŖŖŖȦŞşǯŖŘśȱȱǻřǯśŖŚȦřǯśŖśȱǯǼ
ȱȱ ȱ śşŖǰȱŜŖŖǰȱŜŗŖǰȱŜŘŖ................................................................... şŚǯŖŗŖȦşŚǯŖřśȱȱǻřǯŝŖŗȦřǯŝŖŘȱǯǼ
ȱȱȱȱ ¡ǯȱȱ
ȱ ȱȱŚŝŖǰȱŚŞŖȬŖŖ.................................................................................. ŞŚǯŖŝřȱȱǻřǯřŗŖȱǯǼ
ȱ ȱȱŚŝŖǰȱŚŞŖȬŖŗ.................................................................................. ŞŚǯŖŝřȱȱǻřǯřŗŖȱǯǼ
ȱ ȱȱśřŖǰȱśŚŖ............................................................................................. 89.073 mm (3.507 in.)
ȱ ȱȱśşŖǰȱŜŖŖǰȱŜŗŖǰȱŜŘŖ................................................................... şŚǯŖŝřȱȱǻřǯŝŖŚȱǯǼ
Max. Taper .................................................................................................. ŖǯŖśȱȱǻŖǯŖŖŘȱǯǼ
ȱ ¡ǯȱȱȱ .................................................................................... ŖǯŗŘȱȱǻŖǯŖŖŚŝȱǯǼ
Cylinder Head
¢ȱȱȱȱǻȱȱŘȱǼ .......................... ŘŖǯśǰȱŚŗǯŖȱȉȱǻŗŞŖǰȱřŜŖȱǯȱǯǼ
¡ǯȱȬȬ ........................................................................................ 0.8 mm (0.003 in.)
ȱȱȱȱ ....................................................................... ŗřǯśȱȉȱǻŗŘŖȱǯȱǯǼ
ȱȱȱȱȱ ........................................................ 5.5 N·m (50 in. lb.)
Electric Starter
Thru Bolt Torque ............................................................................................... 3.3-3.9 N·m (30-35 in. lb.)
Mounting Nut Torque ...................................................................................... řǯŜȱȉȱǻřŘȱǯȱǯǼ
ȱǻǼȱȱǻƸǼȱȱȱ ................................................. ŗǯŜȬŘǯŞȱȉȱǻŗśȬŘśȱǯȱǯǼ
ȱǻǼȱȱǻƸǼȱȱȱ ............................................ ŘǯŘȬŚǯśȱȉȱǻŘŖȬŚŖȱǯȱǯǼ
Fan/Flywheel
¢ȱȱȱȱŗŘ ......................................................... ŞŞǯŖȱȉȱǻŜśȱĞǯȱǯǼ
¢ȱȱȱȱŗŖ ......................................................... ŜŜǯśȱȉȱǻŚşȱĞǯȱǯǼ
Governor
ȱȱĞȬȬȱȱȱ........................... ŖǯŖŗřȦŖǯŖŝśȱȱǻŖǯŖŖŖśȦŖǯŖŖřȱǯǼ
ȱȱĞȱǯǯ
New.............................................................................................................. śǯşŝśȦŜǯŖŗŘȱȱǻŖǯŘřśŘȦŖǯŘřŜŝȱǯǼ
ȱ ¡ǯȱȱ......................................................................................... śǯşŜŘȱȱǻŖǯŘřŚŝȱǯǼ
ȱȱĞȬȬȱȱȱ ..................... ŖǯŖşȦŖǯŗŜȱȱǻŖǯŖŖřśȦŖǯŖŖŜřȱǯǼ
ȱȱĞȱǯǯ
New ............................................................................................................. śǯşşȦŜǯŖŖȱȱǻŖǯŘřśŞȦŖǯŘřŜŘȱǯǼ
ȱ ¡ǯȱȱȱ........................................................................................ śǯşŝŝȱȱǻŖǯŖŘřśřȱǯǼ
Ignition
Spark Plug Type (Champion®or Equivalent) ............................................... ŗŘȱȱŗŘ
Spark Plug Gap.................................................................................................. ŖǯŝŜȱȱǻŖǯŖřŖȱǯǼ

1.11
Section 1
Safety and General Information
1
Ignition (Continued)
Spark Plug Torque............................................................................................. ŘŚȬřŖȱȉȱǻŗŞȬŘŘȱĞǯȱǯǼ
ȱȱȱȱ ................................................................................ ŖǯŘŖřȦŖǯřŖśȱȱǻŖǯŖŖŞȦŖǯŖŗŘȱǯǼ
ȱȱȱ ................................................................... ŜǯŖȱȉȱǻśśȱǯȱǯǼȱȱȱȬȱ
ȱ ȱ ŚǯŖȱȉȱǻřśȱǯȱǯǼȱȱȱ
ĝ
ĝȱȱȱȱ...................................................................... ŘŚǯŚȱȉȱǻŘŗŜȱǯȱǯǼ
Oil Filter
ȱȱ ................................................................................................ ŗŖȬŗřȱȉȱǻşŖȬŗŗŖȱǯȱǯǼ
Oil Filter Pad Pipe Plug
ŗȦŞȄȱǯǯǯǯȱ .......................................................................................... ŚǯśȬśǯŖȱȉȱǻŚŖȬŚŜȱǯȱǯǼ
Oil Pump
Mounting Screw Torque.............................................................śǯŖȬŝǯśȱȉȱǻŚŚǯŚȬŜŜǯŖȱǯȱǯǼȱȱȱȬȱ
ȱ ȱ ȱ řǯŞȬŚǯŜȱȉȱǻřřǯřȬŚŖǯřȱǯȱǯǼȱȱȱ
Pump Gears-to-Crankcase Side Clearance.................................................... ŖǯŗŜśȦŖǯřŗśȱȱǻŖǯŖŖŜśȦŖǯŖŗŘŚȱǯǼ
Oil Sentry™
Pressure Switch Torque.................................................................................... ŚǯśȬśǯŖȱȉȱǻŚŖȬŚśȱǯȱǯǼ
Piston, Piston Rings, and Piston Pin
ȱȱȱǯǯ
New.............................................................................................................. ŘŘǯŖŖŜȦŘŘǯŖŗŘȱȱǻŖǯŞŜŞśȦŖǯŞŜŜŜȱǯǼ
ȱ ¡ǯȱȱ......................................................................................... ŘŘǯŖŘśȱȱǻŖǯŞŜŝŗȱǯǼ
Piston Pin O.D.
New.............................................................................................................. ŘŗǯşşśȦŘŘǯŖȱȱǻŖǯŞŜśşȦŖǯŞŜŜŗȱǯǼ
ȱ ¡ǯȱȱ......................................................................................... ŘŗǯşşŚȱȱǻŖǯŞŜśŞȱǯǼ
ȱȱȬȬȱȱȱ ..................................... ŖǯŖŚȱȱǻŖǯŖŖŗŜȱǯǼ
ȱȱȬȬȱȱȱ ............................... ŖǯŖŚȱȱǻŖǯŖŖŗŜȱǯǼ
ȱȱȱȱȱȱ
New Bore
ȱ ȱ .................................................................................................... ŖǯŗśȦŖǯŚŖȱȱǻŖǯŖŖŜȦŖǯŖŗŜȱǯǼ
ȱ ȱ .............................................................................................. ŖǯřŖȦŖǯśśȱȱǻŖǯŖŗŘȦŖǯŖŘŘȱǯǼ
Used Bore (max.)........................................................................................ 0.77 mm (0.030 in.)
ȱȱȱǯǯŶ
ȱȱȱȱ ŚŝŖǰȱŚŞŖȬŖŖ
New............................................................................................................ ŞřǯşŚŞȦŞřǯşŜŘȱȱǻřǯřŖśŖȦřǯřŖśŜȱǯǼ
ȱ ȱ ¡ǯȱȱ....................................................................................... ŞřǯŞŘŞȱȱǻřǯřŖŖřȱǯǼ
ȱ ȱŚŝŖǰȱŚŞŖȬŖŗ
New............................................................................................................ ŞŞǯşŚŞȦŞŞǯşŜŘȱȱǻřǯśŖŗŞȦřǯśŖŘŚȱǯǼ
ȱ ȱ ¡ǯȱȱ....................................................................................... ŞŞǯŞŘŞȱȱǻřǯŚşŝŘȱǯǼ
ŶȱŞȱȱǻŖǯřŗŚȱǯǼȱȱȱĴȱȱȱȱȱȱȱȱȱȱȱǯȱ

1.12
Section 1
Safety and General Information
Piston, Piston Rings, and Piston Pin (Continued)
śřŖǰȱśŚŖ
New............................................................................................................ ŞŞǯşŚŞȦŞŞǯşŜŘȱȱǻřǯśŖŗŞȦřǯśŖŘŚȱǯǼ
ȱ ȱ ¡ǯȱȱ....................................................................................... ŞŞǯŞŘŞȱȱǻřǯŚşŝŘȱǯǼ
śşŖǰȱŜŖŖǰȱŜŗŖǰȱŜŘŖ
New............................................................................................................ şřǯşŘŞȦşřǯşŚŘȱȱǻřǯŜşŞŖȦřǯŜşŞśȱǯǼ
ȱ ȱ ¡ǯȱȱ....................................................................................... şřǯŞŘŞȱȱǻřǯŜşŚŖȱǯǼ
ȱȱȬȬ¢ȱŘȱȱ
ȱ ŚŝŖǰȱŚŞŖǰȱśřŖǰȱśŚŖ .................................................................... ŖǯŖŚśȱȱǻŖǯŖŖŗŞȱǯǼ
ȱ śŜŖǰȱśşŖǰȱŜŖŖǰȱŜŗŖǰȱŜŘŖ ....................................................... 0.0880 mm (0.0035 in.)
5HFWL¿HU5HJXODWRU
Mounting Screw Torque................................................................................... ŜǯŖȱȉȱǻśśȱǯȱǯǼȱȱȱȱȱ
ȱ ȱ ŚǯŖȱȉȱǻřśȱǯȱǯǼȱȱȱ
Speed Control
ȱȱȱ¢ȱȱ ......................................ŗŗǯŖȱȉȱǻşśȱǯȱǯǼȱȱȱȬȱ
ȱ ȱ ŝǯśȱȉȱǻŜśȱǯȱǯǼȱȱȱ
Stator
Stator Mounting Screw Torque ....................................................................... ŜǯŖȱȉȱǻśśȱǯȱǯǼȱȱȱȬȱ
ȱ ȱ ŚǯŖȱȉȱǻřśȱǯȱǯǼȱȱȱ
Throttle/Choke Controls
ȱȱȱȱ ..................................................... ŝǯŖȬŞǯśȱȉȱǻŜŖȬŝśȱǯȱǯǼ
Valve Cover
ȱȱȱ........................................................................... ŗŗǯŖȱȱȉȱǻşśȱǯȱǯǼȱȱȱȬȱ
ȱ ȱ ŝǯśȱȉȱǻŜśȱǯȱǯǼȱȱȱȱ
Valves and Valve Lifters
ȱȱ3............................................................................................. ŖǯŗŘŝȱȱǻŖǯŖŖśȱǯǼ
¡ȱȱ3.......................................................................................... ŖǯŗŝŞȱȱǻŖǯŖŖŝȱǯǼ
ȱȱȱĞ ............................................................................. 8.9 mm (0.350 in.)
¡ȱȱȱĞ .......................................................................... 8.9 mm (0.350 in.)
ȱȱȱ ............................................................................... Śśǚ
ȱȱȬȬȱȱȱ ............................... ŖǯŖřŞȦŖǯŖŝŜȱȱǻŖǯŖŖŗśȦŖǯŖŖřȱǯǼ
¡ȱȱȬȬȱȱȱ............................ ŖǯŖśŖȦŖǯŞŞȱȱǻŖǯŖŖŘŖȦŖǯŖŖřśȱǯǼ
ȱȱȱǯǯ
New.............................................................................................................. ŜǯŖřŞȦŜǯŖśŞȱȱǻŖǯŘřŝŝȦŖǯŘřŞśȱǯǼ
ȱ ¡ǯȱȱ......................................................................................... ŜǯŗřśȱȱǻŖǯŘŚŗśȱǯǼ
ŘȱŞȱȱǻŖǯřŗŚȱǯǼȱȱȱĴȱȱȱȱȱȱȱȱȱȱȱǯȱ
3ȱȱȱ¢ȱŘŖŖȱǰȱȱȱǯ

1.13
Section 1
Safety and General Information
1
General Torque Values
Metric Fastener Torque Recommendations for Standard Applications
Size
M4ȱ ŗǯŘȱǻŗŗǼȱ ŗǯŝȱǻŗśǼȱ ŘǯşȱǻŘŜǼȱ ŚǯŗȱǻřŜǼȱ śǯŖȱǻŚŚǼȱ ŘǯŖȱǻŗŞǼ
M5ȱ ŘǯśȱǻŘŘǼȱ řǯŘȱǻŘŞǼȱ śǯŞȱǻśŗǼȱ ŞǯŗȱǻŝŘǼȱ şǯŝȱǻŞŜǼȱ ŚǯŖȱǻřśǼ
Ŝȱ ŚǯřȱǻřŞǼȱ śǯŝȱǻśŖǼȱ şǯşȱǻŞŞǼȱ ŗŚǯŖȱǻŗŘŚǼȱ ŗŜǯśȱǻŗŚŜǼȱ ŜǯŞȱǻŜŖǼ
M8ȱ ŗŖǯśȱǻşřǼȱ ŗřǯŜȱǻŗŘŖǼȱ ŘŚǯŚȱǻŘŗŜǼȱ řřǯşȱǻřŖŖǼȱ ŚŖǯŝȱǻřŜŖǼȱ ŗŝǯŖȱǻŗśŖǼ
Tightening Torque: N·m (ft. lb.) + or - 10%
Property Class
M10 ŘŗǯŝȱǻŗŜǼȱ ŘŝǯŗȱǻŘŖǼȱ ŚŝǯśȱǻřśǼȱ ŜŜǯŚȱǻŚşǼȱ ŞŗǯŚȱǻŜŖǼȱ řřǯşȱǻŘśǼ
M12 řŜǯŜȱǻŘŝǼȱ ŚŝǯśȱǻřśǼȱ ŞŘǯŝȱǻŜŗǼȱ ŗŗŜǯŜȱǻŞŜǼȱ ŗřşǯŝȱǻŗŖřǼȱ ŜŗǯŖȱǻŚśǼ
M14 śŞǯřȱǻŚřǼȱ ŝŜǯŚȱǻśśǼȱ ŗřŗǯśȱǻşŝǼȱ ŗŞŚǯŚȱǻŗřŜǼȱ ŘŗşǯŝȱǻŗŜŘǼȱ şŚǯşȱǻŝŖǼ
Noncritical
Fasteners
Into Aluminum
Noncritical
Fasteners
Into Aluminum
Tightening Torque: N·m (in. lb.) + or - 10%
Property Class
4.8 5.8 8.8 10.9 12.9
4.8 5.8 8.8 10.9 12.9
ȉȱƽȱǯȱǯȱ¡ȱŖǯŗŗř
ȉȱƽȱĞǯȱǯȱ¡ȱŗǯřśŜ
in. lb. = N·m x 8.85
Ğǯȱǯȱƽȱȉȱ¡ȱŖǯŝřŝ
Torque
Conversions
Oil Drain Plugs Tightening Torque: N•m (English)
Size
1/8" NPT
1/4"
3/8"
1/2"
3/4"
X-708-1
Into Cast Iron
–
ŗŝǯŖȱǻŗśŖȱǯȱǯǼ
ŘŖǯřȱǻŗŞŖȱǯȱǯǼ
ŘŝǯŗȱǻŘŖȱĞǯȱǯǼ
řřǯşȱǻŘśȱĞǯȱǯǼ
ŘŝǯŗȦřřǯşȱǻŘŖȦŘśȱĞǯȱǯǼ
Into Aluminum
ŚǯśȱǻŚŖȱǯȱǯǼ
ŗŗǯřȱǻŗŖŖȱǯȱǯǼ
ŗřǯŜȱǻŗŘŖȱǯȱǯǼ
ŗŝǯŜȱǻŗřȱĞǯȱǯǼ
ŘŗǯŝȱǻŗŜȱĞǯȱǯǼ
ŘŝǯŗȦřřǯşȱǻŘŖȦŘśȱĞǯȱǯǼ
Valves and Valve Lifters (Continued)
ȱȱȱȱ
New.............................................................................................................. śǯşŞŘȦŜǯŖȱȱǻŖǯŘřśśȦŖǯŘřŜŘȱǯǼ
¡ȱȱȱǯǯ
New.............................................................................................................. ŜǯŖřŞȦŜǯŖśŞȱȱǻŖǯŘřŝŝȦŖǯŘřŞśȱǯǼ
ȱ ¡ǯȱȱ......................................................................................... ŜǯŗŜŖȱȱǻŖǯŘŚŘśȱǯǼ
ȱ¡ȱȱȱ
New.............................................................................................................. śǯşŝŖȦśǯşŞŞȱȱǻŖǯŘřśȦŖǯŘřśŝȱǯǼ

2.1
Section 2
Tools & Aids
2
Section 2
Tools & Aids
ȱ¢ȱȱȱȱȱȱ¢ȱȱęȱ¢ǰȱǰȱȱ¢ȱǯȱ
¢ȱȱȱȱȱȱǰȱ¢ȱȱ¢ȱȱȱǰȱǰȱȱǷȱȱǰȱ¢Ȃȱ
ȱ¢ȱȱȱȱȱȱ¢ȱȱȱǯ
ȱȱȱȱȱȱȱȱǯȱȱ
Separate Tool Suppliers:
Kohler Tools
Contact your source
ȱ¢ǯȱ
SE Tools
Śŗśȱȱǯ
ǰȱȱȱŚŞŚŚŜ
ȱŞŗŖȬŜŜŚȬŘşŞŗȱȱ
ȱȱŞŖŖȬŜŜŚȬŘşŞŗȱ
¡ȱŞŗŖȬŜŜŚȬŞŗŞŗ
ȱ¢ȱǯ
ŝŜŞȱȱȱ
ǰȱȱȱŜŖśśş
ȱŜřŖȬşŘŖȬŗřŖŖ
Tools
Description Source/Part No.
Balance Gear Timing Tool (K & M Series)
ȱȱȱȱȱȱȱȱȱǯ
ȱŘśȱŚśśȱŖŜȬ
ǻ¢ȱȬřśŝǼ
Ğȱ¢ȱ
ȱȱĞȱ¢ǯ ȱȱȬŞŘŚŖś
ĞȱȱȱǻǼ
ȱȱȱȱĞȱǯ ȱȱȬŞŘŚŗŝ
¢ȱȱ
ȱȱȱȱȱȱ¢ǰȱǰȱǰȱȱȱȱǯ ȱŘśȱŝŜŗȱŖśȬ
ȱȱȱǻǼȱȱĞ
ȱȱȱȱȱǯ ȱȱŘśȱŝŜŗȱŘřȬ
ȱȱ
ȱȱȱĴȱȱȱȱǯ
ȱŘŚȱŝŜŗȱŖŗȬ
ȱȱȱȱ
Pressure Tester
Noid Light
ȱȱȱȱşŖǚȱ
ȱȱȱȱȱȱ
ȱȱȱȱȱǰȱȱ
ȱȱȱȱȱǰȱȱȱ
ȱ¢ȱǯ
ȬŖŗş
ȬŖŘŗ
ȬŖŘř
ȬŖŘś
ȬŖŘŝ
ȬŖŘş
¢ȱȱȱǻȱǼ ȱȱȬŞŘŚŖŝ
¢ȱȱ
ȱȱĚ¢ȱȱǯ ȱȱȬŞŘŚŖŞ
¢ȱȱ
ȱȱĚ¢ȱȱǯ ȱȱȬŞŘŚŖş

2.2
Section 2
Tools & Aids
Tools (Continued)
Description Source/Part No.
¢ȱȱĞȱ
ȱȱȱȱ¢ȱĞǯ ȱŘśȱŝŜŗȱřŞȬ
ȱ¢ȱ
ȱȱȱȱȱ¢ǰȱ¡ȱǯ
ȱȱȱȱȱȱǻǼȱȱ¢ǯ
ȱŘśȱŚśśȱŖŗȬ
ȱŘŚȱŚśśȱŖŘȬ
ěȱȱǻȱǭȱȱǼȱ
ȱȱȱȱ¢ȱȱȱǯ ȱȱȬŞŘŚŗŖ
ȱȱȱ
ȱȱȱ¢ȱȱǯȱ ȱŘśȱŝŜŗȱŖŜȬȱ
ęȬȱȱǻŗŘŖȱȱǼ
ęȬȱȱǻŘŚŖȱȱǼ
ȱȱȱęȬǯȱ
ȱŘśȱŝŜŗȱŘŖȬ
ȱŘśȱŝŜŗȱŚŗȬ
ȱȱȱ
ȱȱȱȬȱȱȱ
ȱȱȱȱȱȱȱȱ
ȱ¢ȱǯ
ȬŖřŗ
ȬŖřř
ȱȱȱǻǼȱ
ȱȱȱȱǻȱȱǼȱȱȱȱȬȜǯ ȱŘśȱŝŜŗȱŚŖȬ
ȱȱȱȱǻȱǼ
ȱȱȱȱȱȱȱǻ¡ȱȱǼǯ ȱŘśȱŝŜŗȱŗŞȬ
ȱȱȱǻȱǼ
To remove and reinstall drive retaining rings and brushes. SE Tools KLR-82411
Individual Component Available
Starter Brush Holding Tool (Solenoid Shift) SE Tools KLR-82416
Tachometer (Digital Inductive)
For checking operating speed (RPM) of an engine.
Design Technology Inc.
DTI-110
Vacuum/Pressure Tester
Alternative to a water manometer. Kohler 25 761 22-S
Valve Guide Reamer (K & M Series)
For sizing valve guides after installation. SE Tools KLR-11843

2.3
Section 2
Tools & Aids
2
Aids
Description Source/Part No.
ĞȱȱǻȱŜŗřǼ ȱŘśȱřśŝȱŗŚȬ
ȱȱǻȦȱŜŜŗǼ ȱŘśȱřśŝȱŗŗȬ
ȱȱǻȬǼ Ȭ
ȱȱȱȱǻȱǼ ȱȱśŘȱřśŝȱŖŗȬ
ȱȱȱȱǻȱĞǼȱ ȱśŘȱřśŝȱŖŘȬȱ
ȱȱ
țȱśşŖŖȱ¢ȱ¢ȱȱŚȱ£ȱȱǯ
¢ȱ¡Ȭǰȱȱȱȱǰȱȱȱȱǰȱȱȱ
ȱǯȱțȱǯȱśşŖŖȱȱśşŗŖȱȱȱȱȱȱȬ
ǯ
ȱȱțȱśşŗŖȱ
ȱȱțȱȱȱśşŞȱ
ȱȱțȱȱȱśŞŝ
Loctite® Ultra Copper
ȱŘśȱśşŝȱŖŝȬ
ȱȱ ȱŘśȱřśŝȱŗŘȬ

2.4
Section 2
Tools & Aids
Special Tools You Can Make
Flywheel Holding Tool
ȱĚ¢ȱȱȱȱȱȱȱȱȱȱ
ȱĚ¢ȱȱȱȱȱȱȱŘȬŗǰȱȱ
ȱȱȱȱȱȱǯ
ŗǯȱ ȱȱȱȬěȱǰȱȱȱȱ¡ȱ
ȱȱȱȱȱȱȱǯȱ
ȱ Řǯȱ ȱěȱ¢ȱȱȱȱǯȱ
ȱ řǯȱ ȱȱȱȱȱȱȱȱ
ȱȱȱȱȱȱȱȱȱȱ
ȱȱȱĚ¢ȱȱȱǯȱȱ
ȱȱȱȱȱȱĚ¢ȱȱȱ ȱ
ȱȱǰȱȱȱȱ
ȱȱǯ
Figure 2-1. Flywheel Holding Tool.
Rocker Arm/Crankshaft Tool
ȱȱȱȱĞȱȱȱȱȱȱȱ
Ğȱ¢ȱȱȱȱȱȱȱȱȱ
ǯȱ
ȱ ŗǯȱ ȱȱȱȱȱȱȱŗŖȱȱȱ
ȱǯȱȱȱȱȱȱǯȱ
ȱ Řǯȱ ȱȱȱȱȱȬȱȱȱȱěȱ
ȱȱȱȱȱȱǰȱȱȱȱ
ȱȱĚǯȱ
ȱ řǯȱ ȱȱŗȱǯȱȱȱȱȱȱȱ
£ȱȱȱȱȱȱȱȱǯȱ
ȱ Śǯȱ ȱȱĚȱȱȱȱȱǯǯȱȱȱȱ
ȱȱȱ¡¢ȱŗȄȱǯǯȱǻȱ
ȱǯȱŗŘȱŚŜŞȱŖśȬǼ.ȱȱȱ
ȱȱȱȱȱȱȱȱǰȱȱ
ȱȱȱŘȬŘǯ
Figure 2-2. Rocker Arm/Crankshaft Tool.

3.1
Section 3
Troubleshooting
3
Section 3
Troubleshooting
Troubleshooting Guide
When troubles occur, be sure to check the simple
ȱǰȱȱęǰȱ¢ȱȱȱȱȱȱ
considered. For example, a starting problem could be
ȱ¢ȱȱ¢ȱȱǯ
ȱȱ¢ȱȱȱȱȱȱ
below. Use these to help locate the possible cause(s).
Engine Cranks But Will Not Start
ȱ ŗǯȱ ¢ȱȱǯ
ȱ Řǯȱ ȱȬěȱȱǯ
ȱ řǯȱ ȱǰȱȱȱȱȱȱȱ¢ǯ
ȱ Śǯȱ ȱȱǯ
5. Spark plug lead disconnected.
ȱ Ŝǯȱ ȱȱȱěȱǯ
ȱ ŝǯȱ ¢ȱȱǯ
ȱ Şǯȱ ¢ȱȱǯ
ȱ şǯȱ ȱȱǯ
10. Choke not closing.
ŗŗǯȱ Ĵ¢ȱȱǯ
ŗŘǯȱ ¢ȱȱ¢ȱǯ
Engine Starts But Does Not Keep Running
ȱ ŗǯȱ ȱȱȱȱǯ
ȱ Řǯȱ ȱǰȱȱȱȱȱȱȱ¢ǯ
ȱ řǯȱ ¢ȱȱȱȱȱĴȱǯ
4. Loose wires or connections that short the kill
ȱȱȱȱȱǯ
ȱ śǯȱ ¢ȱ¢ȱȱǯ
ȱ Ŝǯȱ ¢ȱǯ
ȱ ŝǯȱ ȱ¢ȱǯ
Engine Starts Hard
ȱ ŗǯȱ ȱȱȱǯ
ȱ Řǯȱ ȱǰȱȱȱȱȱȱȱ¢ǯ
ȱ řǯȱ ȱȱǯ
ȱ Śǯȱ ȱȱ¢ȱȱȱǯ
ȱ śǯȱ ¢ȱȱȱȱȱĴȱǯ
ȱ Ŝǯȱ ¢ȱȱǯ
7. Low compression.
ȱ Şǯȱ ¢ȱȱǯ
9. Weak spark.
ȱŗŖǯȱ ȱȱȱȱȱȱǯ
ŗŗǯȱ ȱȬȦȱȱ
restricted.
ŗŘǯȱ ¢ȱ¢ȱǯ
ȱŗřǯȱ ȱ¢ȱǯ
Engine Will Not Crank
ȱ ŗǯȱ ȱȱȱǯ
ȱ Řǯȱ Ĵ¢ȱȱǯ
ȱ řǯȱ ¢ȱȱȱȱǯ
ȱ Śǯȱ ȱȱ¢ȱȱȱǯ
ȱ śǯȱ ¢ȱ¢ȱȱȱȱǯ
ȱ Ŝǯȱ ¢ȱȱǯ
7. Seized internal engine components.
Engine Runs But Misses
ŗǯȱ ȱȱȱȱȱȱ¢ǯ
Řǯȱ ȱȱ¢ȱȱǯ
ȱřǯȱ ȱ¢ȱȱǯ
4. Spark plug lead boot loose on plug.
ȱ śǯȱ ȱȱȱȱȱĴ¢ȱ
ȱȱȱȱȱȱȱȱ
ground.
ȱ Ŝǯȱ ȱǯ
ȱ ŝǯȱ ¢ȱȱȱȱ¢ȱǯ
ȱ Şǯȱ ȱȱ¢ǯ
Engine Will Not Idle
ȱ ŗǯȱ ȱȱȱȱȱȱ¢ǯ
ȱ Řǯȱ ȱȱȦȱȱȱǯ
ȱ řǯȱ ¢ȱȱǯ
ȱ Śǯȱ ȱ¢ȱǯ
ȱ śǯȱ ȱȱȱȱ¢ȱǯ
ȱ Ŝǯȱ ȱȱȱȱ¢ȱǯ
7. Low compression.
ȱ Şǯȱ ȱȱȱȱǯ
ȱ şǯȱ ȱȬȱ¢Ȧȱȱ
problem.