Kohler KS530 User manual

1
22 690 01 Rev. -- KohlerEngines.com
KS530-KS595
Service Manual
2 Safety
3 Maintenance
5 Specifi cations
18 Tools and Aids
21 Troubleshooting
25 Air Cleaner/Intake
26 Fuel System
38 Governor System
40 Lubrication System
42 Electrical System
55 Starter System
57 Emission Compliant Systems
60 Disassembly/Inspection and Service
76 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.

2
Safety
KohlerEngines.com 22 690 01 Rev. --
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
fi res and severe burns.
Do not fi ll fuel tank while
engine is hot or running.
Gasoline is extremely fl ammable
and its vapors can explode if
ignited. Store gasoline only in
approved containers, in well
ventilated, unoccupied buildings,
away from sparks or fl ames.
Spilled fuel could ignite if it comes
in contact with hot parts or sparks
from ignition. Never use gasoline
as a cleaning agent.
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.
WARNING
Carbon Monoxide can
cause severe nausea,
fainting or death.
Avoid inhaling exhaust
fumes.
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 fl ammable. 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 fl ywheel.

3
Maintenance
22 690 01 Rev. -- 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 Hours or Annually¹ (whichever comes fi rst)
● Service/replace precleaner (if equipped). Air Cleaner/Intake
● Replace air cleaner element (if not equipped with precleaner). Air Cleaner/Intake
Every 100 Hours or Annually¹ (whichever comes fi rst)
● Replace air cleaner element (if equipped with precleaner). Air Cleaner/Intake
● Change oil and fi lter. Lubrication System
● Remove cooling shrouds and clean cooling areas. Air Cleaner/Intake
Every 100 Hours
● Replace fuel fi lter.
● Check that all fasteners are in place and components are properly secured. Reassembly
Every 200 Hours²
● Have valve lash checked/adjusted. Reassembly
Every 500 Hours
● Replace spark plug and set gap. Electrical System
1 Perform these procedures more frequently under severe, dusty, dirty conditions.
2 Have a Kohler authorized dealer perform this service.
REPAIRS/SERVICE PARTS
Kohler genuine service parts can be purchased from Kohler authorized dealers. To fi nd a local Kohler authorized
dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada).

4
Maintenance
KohlerEngines.com 22 690 01 Rev. --
OIL RECOMMENDATIONS
We recommend use of Kohler oils for best performance.
Other high-quality detergent oils (including synthetic)
of API (American Petroleum Institute) service class SJ
or higher are acceptable. Select viscosity based on
air temperature at time of operation as shown in table
below.
FUEL RECOMMENDATIONS
WARNING
Explosive Fuel can cause fi res and severe
burns.
Do not fi ll fuel tank while engine is hot or
running.
Gasoline is extremely fl ammable and its vapors can
explode if ignited. Store gasoline only in approved
containers, in well ventilated, unoccupied buildings,
away from sparks or fl ames. Spilled fuel could ignite
if it comes in contact with hot parts or sparks from
ignition. Never use gasoline as a cleaning agent.
NOTE: E15, E20 and E85 are NOT approved and
should NOT be used; eff ects of old, stale or
contaminated fuel are not warrantable.
Fuel must meet these requirements:
● Clean, fresh, unleaded gasoline.
● Octane rating of 87 (R+M)/2 or higher.
● Research Octane Number (RON) 90 octane minimum.
● Gasoline up to 10% ethyl alcohol, 90% unleaded is
acceptable.
● Methyl Tertiary Butyl Ether (MTBE) and unleaded
gasoline blend (max 15% MTBE by volume) are
approved.
● Do not add oil to gasoline.
● Do not overfi ll fuel tank.
● Do not use gasoline older than 30 days.
STORAGE
If engine will be out of service for 2 months or more
follow procedure below.
1. Add Kohler PRO Series fuel treatment or equivalent
to fuel tank. Run engine 2-3 minutes to get stabilized
fuel into carburetor (failures due to untreated fuel are
not warrantable).
2. Change oil while engine is still warm from operation.
Remove spark plug(s) and pour about 1 oz. of
engine oil into cylinder(s). Replace spark plug(s) and
crank engine slowly to distribute oil.
3. Disconnect negative (-) battery cable.
4. Store engine in a clean, dry place.

5
Specifi cations
22 690 01 Rev. -- KohlerEngines.com
Engine Dimensions-Flywheel Side
F
E
G
H
I
K
A
B
D
C
J
L
M
N
O
P
Q
R
S
A164.8 mm (6.49 in.)
to Starter B212.4 mm (8.36 in.) C201.3 mm (7.92 in.) to Oil Filter D100.0 mm (3.94 in.)
EOil Fill and Dipstick FØ 10.0 mm (0.39 in.)
Lifting Point GThrottle Cable Clip H109.0 mm (4.29 in.)
I46.5 mm (1.83 in.) J85.1 mm (3.35 in.) K
Connection for
Evaporative Hose
(7/32" I.D.)
L228.9 mm (9.01 in.)
M205.8 mm (8.10 in.) N182.5 mm (7.19 in.) O13.9 mm (0.55 in.) to
Center of Gravity P148.1 mm (5.83 in.)
Q317.8 mm (12.51 in.) R41.2 mm (1.62 in.) to
Center of Gravity S139.0 mm (5.47 in.)

6
Specifi cations
KohlerEngines.com 22 690 01 Rev. --
Engine Dimensions-Starter Side
F
E
G
H
I
K
A
B
D
C
J
L
M
N
O
P
Q
R
S
T
U
V
W
A
2 X Cored for M6
Self Tapping
Screw 17.7 mm
(0.70 in.) Min.
Depth
(Accessory
Mounting
Location)
BExhaust Port Axis C326.5 mm
(12.85 in.) D
179.0 mm (7.05 in.)
to Center of
Gravity
E145.2 mm (5.72 in.)
to Exhaust Port F81.3 mm (3.20 in.) G64.0 mm (2.52 in.) Keyway Length H
7/16-20 UNF-2B IN.
38.1 mm (1.50
in.) Depth
I250.3 mm (9.86 in.)
to Exhaust Port J2 X 30.0 mm (1.18 in.) K
21.6-21.8 mm (0.85-
0.86 in.) Keyway
Depth
L95.0 mm (3.74 in.)
MEngine Mounting
Surface N
Cored for M8 Self
Tapping Screw
20.0 mm (0.79 in.)
Min. Depth
(Ground Lug
Location)
O61.9 mm (2.44 in.) to
Starter Stud P55.0 mm (2.17 in.)
Q95.0 mm (3.74 in.) R171.5 mm (6.75 in.) S195.0 mm (7.68 in.)
Lifting Point T332.3 mm (13.08 in.)
UOptional Rectifi er-
Regulator VStarter Motor WOil Fill and Dipstick

7
Specifi cations
22 690 01 Rev. -- KohlerEngines.com
Engine Dimensions-PTO Side
F
E
G
H
I
K
A
B
D
C
J
L
M
N
O
F
J
A116.0 mm (4.57 in.) B55.0 mm (2.17 in.) C150° DAccessory Mounting
Surface
E2 X 288.8 mm
(11.37 in.) F35° GRotation Direction HØ 254.0 mm (10.00 in.)
I150.2 mm (5.91 in.) J45° K36.6 mm (1.44 in.) L105.2 mm (4.14 in.)
MØ 9.7 mm (0.38 in.)
Lifting Point NExhaust Port Axis OExhaust Flange Mounting Surface

8
Specifi cations
KohlerEngines.com 22 690 01 Rev. --
Engine Dimensions-Oil Filter Side
F
E
G
H
I
K
AB
D
C
J
L
M
N
O
P
Q
R
S
T
A317.1 mm (12.49 in.) B45.2 mm (1.78 in.) C34.3 mm (1.35 in.) D75.5° Speed Control
Lever Travel
EOptional Fuel Pump FThrottle Cable Clip G324.9 mm
(12.79 in.) H226.7 mm (8.93 in.) Lifting Point
I215.7 mm (8.49 in.) J14.5 mm (0.57 in.) Oil
Filter Removal K113.6 mm (4.47 in.) to Oil Filter LOil Filter
MEngine Mounting
Surface NOil Drain Plug 3/8 N.P.T. IN. O6.5° Choke Lever
Travel P17.0 mm (0.67 in.)
Q
39.4 mm (1.55 in.) to
Optional
Carburetor
Shutdown
Solenoid
R
127.1 mm (5.01 in.)
Connection for
Evaporative Hose
SAir Filter and Cover T
33.8 mm (1.33 in.) Air
Cleaner Cover
Removal

9
Specifi cations
22 690 01 Rev. -- KohlerEngines.com
Engine Dimensions-Valve Cover Side
F
E
G
H
I
K
A
B
D
C
J
L
M
NO
P
A64.2 mm (2.53 in.) B16.0 mm (0.63 in.) C24.3 mm (0.96 in.)
to Spark Plug D
Cored for M6 Self
Tapping Screw
16.5 mm (0.65
in.) Min. Depth
(Accessory
Mounting
Location)
E93.2 mm (3.67 in.) FCarburetor GOil Drain Plug H122.7 mm (4.83 in.)
I
6.32-6.36 mm
(0.249-0.250 in.)
Keyway Width
JØ 25.37-25.40 mm
(0.999-1.0 in.) K100.0 mm (3.94 in.) L
85.5 mm (3.37 in.)
Ground Lug
Mounting Boss
M
2 X Accessory
Mounting
Surface
N112.6 mm (4.43 in.) to
Spark Plug O88.0 mm (3.47 in.) P
Cored for M6 Self
Tapping Screw
Thru (Accessory
Mounting
Location)

10
Specifi cations
KohlerEngines.com 22 690 01 Rev. --
Model . . . . . . . . . . . . . . . . . . . . . KS530
5400 Series Engine
Numerical Designation
Specifi cation . . . . . . . . . . . . . . . KS530-3002
Serial . . . . . . . . . . . . . . . . . . . . . 4723500328
Year Manufactured Code Factory Code
Code Year
47 2017
48 2018
49 2019
ENGINE IDENTIFICATION NUMBERS
Kohler engine identifi cation numbers (model, specifi cation and serial) should be referenced for effi cient repair,
ordering correct parts, and engine replacement.
GENERAL SPECIFICATIONS3,4 KS530 KS540 KS590 KS595
Bore 94 mm (3.70 in.)
Stroke 78 mm (3.1 in.)
Displacement 541 cc (33.0 cu. in.)
Oil Capacity (refi ll) 1.4 L (1.5 U.S. qt.)
Maximum Angle of Operation (@ full oil level)525°
TORQUE SEQUENCES KS530 KS540 KS590 KS595
(Refer to Torque Specifi cations for torque values).
Connecting Rod Fasteners
1
2
3 Values are in Metric units. Values in parentheses are English equivalents.
4 Any and all horsepower (hp) references by Kohler are Certifi ed Power Ratings and per SAE J1940 & J1995 hp
standards. Details on Certifi ed Power Ratings can be found at KohlerEngines.com.
5 Exceeding maximum angle of operation may cause engine damage from insuffi cient lubrication.

11
Specifi cations
22 690 01 Rev. -- KohlerEngines.com
TORQUE SEQUENCES KS530 KS540 KS590 KS595
(Refer to Torque Specifi cations for torque values).
Closure Plate Fasteners
1
2
3
4
5
6
7
9
11
10
8
Cylinder Head Fasteners
1
2
3
4
5
6
Oil Passage Cover Fasteners
1
2
3
4
5
Valve Cover Fasteners
1
2
3
4

12
Specifi cations
KohlerEngines.com 22 690 01 Rev. --
TORQUE SPECIFICATIONS3,6 KS530 KS540 KS590 KS595
Auto Choke
Smart-Choke™ Diaphragm Assembly Fastener 1 N·m (9 in. lb.)
Barrel Baffl e
Fastener 9.3 N·m (82 in. lb.) into new hole
4.0 N·m (35 in. lb.) into used hole
Blower Housing to Adapter
4.8 Hi-Lo Fastener 1 N·m (9 in. lb.)
Blower Housing to Closure Plate
Fastener 11.3 N·m (100 in. lb.) into new hole
6.8 N·m (60 in. lb.) into used hole
Breather
Cover Fastener 6.5 N·m (58 in. lb.)
Reed/Retainer Fastener 6.5 N·m (58 in. lb.)
Cam Levers
Fastener 12.5 N·m (110 in. lb.)
Carburetor
Stud 4.3 N·m (38 in. lb.)
M6 Nut 9 N·m (80 in. lb.)
Fuel Bowl Retaining Screws 4.0 N·m (35 in. lb.)
Choke Wire Hold Down Clamp (if equipped)
Fastener 2.7 N·m (24 in. lb.)
Closure Plate (torque sequence on page 11)
Fastener 24 N·m (212 in. lb.)
Connecting Rod (torque sequence on page 10)
Cap Fastener (torque in 2 increments) 5.5, 11.8 N·m (50, 105 in. lb.)
Crankcase
Oil Drain Plug 14.0 N·m (125 in. lb.)
Cylinder Head (torque sequence on page 11)
Fastener (torque in 2 increments) 24.4, 42.7 N·m (216, 378 in. lb.)
Rocker Arm Pivot Stud 13.5 N·m (120 in. lb.)
Rocker Arm Adjustment Nut Set Screw 5.5 N·m (50 in. lb.)
Dipstick Tube
Fastener 6.5 N·m (58 in. lb.) into new hole
3.4 N·m (30 in. lb.) into used hole
3 Values are in Metric units. Values in parentheses are English equivalents.
6 Lubricate threads with engine oil prior to assembly.

13
Specifi cations
22 690 01 Rev. -- KohlerEngines.com
TORQUE SPECIFICATIONS3,6 KS530 KS540 KS590 KS595
Electric Starter
10/24 Mounting Nut 3.8 N·m (34 in. lb.)
1/4-20 Nut 7.9 N·m (70 in. lb.)
Fixed Guard (if equipped)
Fastener 0.8 N·m (7 in. lb.)
Flywheel
M12 Retaining Screw 115 N·m (85 ft. lb.)
Fuel Line J-Clip
Fastener 6.5 N·m (58 in. lb.)
Fuel Pump Bracket
4.8 Hi-Lo Fastener 1 N·m (9 in. lb.)
Governor
Lever Nut 7.7 N·m (68 in. lb.)
Ignition
Spark Plug 27 N·m (20 ft. lb.)
Module Fastener 8.8 N·m (78 in. lb.) into new hole
3.4 N·m (30 in. lb.) into used hole
Rectifi er-Regulator Fastener 8.8 N·m (78 in. lb.)
Intake Manifold to Cylinder Head
Nuts 10.2 N·m (90 in. lb.)
Muffl er
Retaining Nuts 27.8 N·m (246 in. lb.)
Bracket Fastener 11.3 N·m (100 in. lb.)
Oil Filter Pad Pipe Plug
1/8” N.P.T.F. 8.5 N·m (75 in. lb.)
Oil Baffl e
Fastener 7.9 N·m (70 in. lb.)
Oil Passage Cover (torque sequence on page 11)
Fastener 6.5 N·m (58 in. lb.)
Oil Pump Housing
Fastener 4.8 N·m (42 in. lb.)
Oil Sentry™
Pressure Switch 6.2 N·m (55 in. lb.)
3 Values are in Metric units. Values in parentheses are English equivalents.
6 Lubricate threads with engine oil prior to assembly.

14
Specifi cations
KohlerEngines.com 22 690 01 Rev. --
TORQUE SPECIFICATIONS3,6 KS530 KS540 KS590 KS595
Speed Control Bracket Assembly
Fastener 11.3 N·m (100 in. lb.) into new hole
7.5 N·m (65 in. lb.) into used hole
Stator
Mounting Screw 8.8 N·m (78 in. lb.)
Stator Wire Clip Fastener 6.5 N·m (58 in. lb.)
Valve Cover
Fastener 12.9 N·m (114 in. lb.) into new hole
6.8 N·m (60 in. lb.) into used hole
CLEARANCE SPECIFICATIONS3KS530 KS540 KS590 KS595
Camshaft
End Play 0.317/1.187 mm (0.0125/0.0467 in.)
Running Clearance 0.025/0.126 mm (0.0009/0.0049 in.)
Bore I.D.
New
Max. Wear Limit
14.389/14.414 mm (0.5665/0.5675 in.)
14.427 mm (0.5680 in.)
Bearing Surface O.D.
New
Max. Wear Limit
14.288/14.364 mm (0.5625/0.5655 in.)
14.285 mm (0.5624 in.)
Connecting Rod
Connecting Rod-to-Crankpin Running Clearance
New
Max. Wear Limit
0.040/0.081 mm (0.0016/0.0032 in.)
0.096 mm (0.0038 in.)
Connecting Rod-to-Crankpin Side Clearance 0.400/0.630 mm (0.0157/0.0248 in.)
Connecting Rod-to-Piston Pin Running Clearance 0.012/0.034 mm (0.0005/0.0013 in.)
Piston Pin End I.D.
New
Max. Wear Limit
20.012/20.029 mm (0.7879/0.7885 in.)
20.042 mm (0.7891 in.)
Crankcase
Governor Cross Shaft Bore I.D.
New
Max. Wear Limit
6.026/6.05 mm (0.2372/0.2382 in.)
6.063 mm (0.2387 in.)
Crankshaft
End Play (free) 0.225/0.875 mm (0.0089/0.0344 in.)
Bore in Crankcase I.D.
New
Max. Wear Limit
41.003/41.027 mm (1.6143/1.6152 in.)
41.053 mm (1.6163 in.)
Bore in Closure Plate I.D.
New
Max. Wear Limit
40.9875/41.0125 mm (1.6137/1.6147 in.)
41.0385 mm (1.6157 in.)
Crankshaft Bore (PTO)-to-Crankshaft Running
Clearance
New 0.068/0.114 mm (0.0027/0.0045 in.)
3 Values are in Metric units. Values in parentheses are English equivalents.
6 Lubricate threads with engine oil prior to assembly.

15
Specifi cations
22 690 01 Rev. -- KohlerEngines.com
CLEARANCE SPECIFICATIONS3KS530 KS540 KS590 KS595
Crankshaft (continued)
Flywheel End Main Bearing Journal O.D.
New
Max. Wear Limit
Max. Taper
Max. Out of Round
40.913/40.935 mm (1.6107/1.6116 in.)
40.880 mm (1.6094 in.)
0.0220 mm (0.0009 in.)
0.0250 mm (0.0010 in.)
PTO End Main Bearing Journal O.D.
New
Max. Wear Limit
Max. Taper
Max. Out of Round
40.913/40.935 mm (1.6107/1.6116 in.)
40.880 mm (1.6094 in.)
0.0200 mm (0.0008 in.)
0.0250 mm (0.0010 in.)
Connecting Rod Journal O.D.
New
Max. Wear Limit
Max. Taper
Max. Out of Round
40.982/41.000 mm (1.6135/1.6142 in.)
40.964 mm (1.612 in.)
0.0120 mm (0.0005 in.)
0.0250 mm (0.0010 in.)
T.I.R.
PTO End, Crankshaft in Engine
Entire Crankshaft , in V-Blocks
0.150 mm (0.0059 in.)
0.100 mm (0.0039 in.)
Cylinder Bore
Bore I.D.
New 94.010/94.035 mm (3.7011/3.7021 in.)
Max. Wear Limit 94.073 mm (3.704 in.)
Max. Taper
Max. Out of Round
0.050 mm (0.0020 in.)
0.120 mm (0.0047 in.)
Cylinder Head
Max. Out-of-Flatness 0.076 mm (0.003 in.)
Governor
Governor Cross Shaft -to-Crankcase Running
Clearance 0.014/0.075 mm (0.0006/0.0030 in.)
Cross Shaft O.D.
New
Max. Wear Limit
5.975/6.012 mm (0.2352/0.2367 in.)
5.962 mm (0.2347 in.)
Governor Gear Shaft -to-Governor Gear Running
Clearance 0.070/0.160 mm (0.0028/0.0063 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.)
Module Air Gap 0.203/0.305 mm (0.008/0.012 in.)
3 Values are in Metric units. Values in parentheses are English equivalents.

16
Specifi cations
KohlerEngines.com 22 690 01 Rev. --
CLEARANCE SPECIFICATIONS3KS530 KS540 KS590 KS595
Piston, Piston Rings, and Piston Pin
Piston-to-Piston Pin Running Clearance 0.007/0.017 mm (0.0003/0.0007 in.)
Pin Bore I.D.
New
Max. Wear Limit
20.007/20.012 mm (0.7877/0.7879 in.)
20.025 mm (0.7884 in.)
Pin O.D.
New
Max. Wear Limit
19.995/20.000 mm (0.7872/0.7874 in.)
19.994 mm (0.7872 in.)
Top Compression Ring-to-Groove Side Clearance 0.025/0.065 mm (0.0010/0.0026 in.)
Middle Compression Ring-to-Groove Side
Clearance 0.040/0.080 mm (0.0016/0.0032 in.)
Oil Control Ring-to-Groove Side Clearance 0.090/0.210 mm (0.0035/0.0083 in.)
Top Compression Ring End Gap New Bore
New Bore
Used Bore (max.)
0.150/0.400 mm (0.0059/0.0157 in.)
0.770 mm (0.0300 in.)
Middle Compression Ring End Gap New Bore
New Bore
Used Bore (max.)
1.000/1.250 mm (0.0394/0.0492 in.)
1.504 mm (0.0592 in.)
Thrust Face O.D.7
New 93.975/93.989 mm (3.6998/3.7003 in.)
Max. Wear Limit 93.875 mm (3.6960 in.)
Piston Thrust Face-to-Cylinder Bore7 Running
Clearance 0.034/0.073 mm (0.0013/0.0029 in.)
Valves and Valve Tappets
Valve Lash80.101/0.152 mm (0.004/0.006 in.)
Intake Valve Stem-to-Valve Guide Running
Clearance
0.038/0.076 mm (0.0015/0.0030 in.)
Exhaust Valve Stem-to-Valve Guide Running
Clearance
0.050/0.088 mm (0.0020/0.0035 in.)
Intake Valve Guide I.D.
New
Max. Wear Limit
6.038/6.058 mm (0.2377/0.2385 in.)
6.135 mm (0.2415 in.)
Exhaust Valve Guide I.D.
New
Max. Wear Limit
6.038/6.058 mm (0.2377/0.2385 in.)
6.160 mm (0.2425 in.)
Intake Valve Minimum Lift 9.4 mm (0.370 in.)
Exhaust Valve Minimum Lift 9.3 mm (0.366 in.)
Nominal Valve Seat Angle 45°
3 Values are in Metric units. Values in parentheses are English equivalents.
7 Measure 7.5 mm (0.2953 in.) above bottom of piston skirt at right angles to piston pin.
8 Check valve lash every 200 hours, adjust as required.

17
Specifi cations
22 690 01 Rev. -- KohlerEngines.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
18 22 690 01 Rev. --KohlerEngines.com
Certain quality tools are designed to help you perform specifi c 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
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 05-S
Design Technology Inc.
DTI-731-03
Dealer Tool Kit (Domestic)
Complete kit of Kohler required tools.
Components of 25 761 39-S
Ignition System Tester
Cylinder Leakdown Tester
Oil Pressure Test Kit
Rectifi er-Regulator Tester (120 V AC/60Hz)
Kohler 25 761 39-S
Kohler 25 455 01-S
Kohler 25 761 05-S
Kohler 25 761 06-S
Kohler 25 761 20-S
Dealer Tool Kit (International)
Complete kit of Kohler required tools.
Components of 25 761 42-S
Ignition System Tester
Cylinder Leakdown Tester
Oil Pressure Test Kit
Rectifi er-Regulator Tester (240 V AC/50Hz)
Kohler 25 761 42-S
Kohler 25 455 01-S
Kohler 25 761 05-S
Kohler 25 761 06-S
Kohler 25 761 41-S
Digital Vacuum/Pressure Tester
For checking crankcase vacuum.
Individual component available:
Rubber Adapter Plug
Design Technology Inc.
DTI-721-01
Design Technology Inc.
DTI-721-10
Electronic Fuel Injection (EFI) Diagnostic Software
For Laptop or Desktop PC.
Kohler 25 761 23-S
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
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-037
DTI-031
DTI-033
Kohler 25 176 23-S
Kohler Wireless Diagnostic System Module (Bluetooth®)
For wireless Android EFI diagnostics.
Individual component available:
Wireless Diagnostic System Interface Cable
Kohler 25 761 45-S
Kohler 25 761 44-S

Tools and Aids
1922 690 01 Rev. -- KohlerEngines.com
TOOLS
Description Source/Part No.
Flywheel Puller
For properly removing fl ywheel from engine.
SE Tools KLR-82408
Flywheel Anchor Bolts, Washers, Nuts Tool
Used with Flywheel Puller to properly removing fl ywheel 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
Hydraulic Valve Lifter Tool
For removing and installing hydraulic lifters.
Kohler 25 761 38-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
Off set Wrench (K and M Series)
For removing and reinstalling cylinder barrel retaining nuts.
Kohler 52 455 04-S
Oil Pressure Test Kit
For testing/verifying oil pressure on pressure lubricated engines.
Kohler 25 761 06-S
Rectifi er-Regulator Tester (120 volt current)
Rectifi er-Regulator Tester (240 volt current)
For testing rectifi er-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

Tools and Aids
20 22 690 01 Rev. --KohlerEngines.com
FLYWHEEL HOLDING TOOL ROCKER ARM/CRANKSHAFT TOOL
A fl ywheel holding tool can be made out of an old junk
fl ywheel ring gear and used in place of a strap wrench.
1. Using an abrasive cut-off wheel, cut out a six tooth
segment of ring gear as shown.
2. Grind off any burrs or sharp edges.
3. Invert segment and place it between ignition bosses
on crankcase so tool teeth engage fl ywheel ring
gear teeth. Bosses will lock tool and fl ywheel 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
fl at.
3. Find a 1 in. long capscrew with correct thread size to
match threads in connecting rod.
4. Use a fl at washer with correct I.D. to slip on
capscrew and approximately 1 in. O.D. Assemble
capscrew and washer to joint surface of rod.
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