Kohler KT17 User manual

Section 1 - GENERAL INFORMATION ............... .
Section 2- TROUBLESHOOTING ................... .
Section 3- AIR INTAKE SYSTEM ................... .
Section 4- FUEL SYSTEM AND GOVERNOR ........ .
Section 5- LUBRICATION SYSTEM ................. .
Section 6- ELECTRICAL SYSTEMS & COMPONENTS ..
Section 7- DISASSEMBLY .......................... .
Section 8 - ASSEMBLY ............................. .
SUBJECT INDEX ...................................... .
1
'
I
I
3-10
11-13
15-18
19-26
27-28
29-40
41-52
!
53-69
71-74

-------INTRODUCTION-------
Long-life strengthand on-the-job durability are designed and built into
these Kohler engines.
Parts subject to most wear and tear -like cylin-
ders, crankshaftsandcamshafts -aremadefrom precision-formulated
cast iron ... and because the cast iron cylinders can be rebored, these
engines can last even longer.
These Kohler engines are easy
to service. All routine service parts -
points, condenser, spark plugs, air cleaner, carburetor -are easily and
quickly accessible.
This manual provides the technician with information andinstructions
for servicingandrepairingtheKT17 & KT19 Series II, and KT17- KT19-
KT21 engines. It is recommended the technician study the procedures
and illustrations in this manual and use them
as references when per-
forming repairs.
KT engines use one of two types of Pressurized Lubrication Systems.
KT SMESJ[ engines have a Full Pressure lu-
bricationsystem. TheSpecification Numbers
for
KT Series II models are:
KT17 Series
II -Specifications 24300 And
Higher
KT19 Series
II -Specifications 49200 And
Higher
Other KT17-KT19·KT21 engines use a Pres-
surized Spray lubrication system. The Speci·
fication Numbers for those models are:
KT17 -Specifications 24299
And Lower
KT19- Specifications 49199 And Lower
KT21 -All Specifications
Refer to Section 5 - Lubrication System for additional information.
The SMESJ[logo appears throughout this
manual
to identify information and service
procedures unique
to the Series II models.
2

SECTION 1 -GENERAL INFORMATION
ENGINE IDENTIFICATION
NUMBERS
When ordering parts, or in any communication
involving an engine, always include the Model,
Specification,
and Serial numbers of the engine.
The Model and Specification numbers appear on
the engine identification decal, and directly below
it is the decal with the Serial number. Both decals
are located on the top of the engine shrouding.
The significance of each of- these numbers is
shown below.
Serial
Number Specification And Model Number
Figure 1·1. Engine Identification Decals
Engine Model Code
24- KT17
32- KT21
49- KT19
Year of Manufacture
90-94 1978
95-99 1979
100-109 1980
110-119 1981
120-129 1982
130-139 1983
140-149 1984
u-oHLER@illl~Dilll@ 'l
17HP I Variation
of
Basic Engine
Spec.n. 24102d·~=---~---f--~~~~~~--~
Model no. KT17§.- Version Code
Refer
to owners manual
for operation and
maintenance
instructions
I
W' KOHLER COMPANY
I~ KOHLER WISCONSIN USA
Serial
No.
3
G- Tapered Crankshaft
P- Threaded Crankshaft
S - Electric Start
Q- Quiet Model
EP -Electric Plant
Factory Code
•

SECTION 1
GENERAL INFORMATION
FOR YOUR SAFETY
This symbol points out important safety WARN-
INGS and CAUTIONS which should be followed
at all times. Follow WARNINGS to ensure the
safety of yourself and others. Follow CAUTIONS
to prevent damage to the engine or equipment.
General Safety Warnings
Before working on engine orequipment,disconnect
battery cables from battery. Always disconnect
the negative (ground) cablefirst. When connecting
battery cables, always connect the negative
(ground) cable last.
Never inhale exhaust fumes-all engine exhaust
contains poisonous carbon monoxide. Never run
the engine in a closed building or a confined area
without adequate ventilation.
Never operate engine or equipment with shrouds,
covers or
safety guards removed. Hands, feet,
clothing, or
hair can get caught in moving parts
resulting in personal injury.
Never touch the engine cylinder block. exhaust
system, or cylinder head while the engine is run·
ning-or immediately after it is turned off. These
parts can get hot and could burn you.
Never touch electrical wires or components while
engine is running-they may be sources of electri·
cal shock, which could severely injure or kill you.
Make sure cleaning solvents and other flammable
liquids areproperly identified and stored in cover·
ed containers safely away from the danger of
combustion from open flames, sparks, etc.
------------------------------------
OIL RECOMMENDATIONS
The importance if checking and changing crankcase
oil cannot be overemphasized. Insufficient, or dirty
oil causes premature engine wear and failure.
Oil Type
Use high quality detergent oil of API (American Pe-
troleum Institute) service class SF or SG. Select the
viscosity based on the air temperature at the time of
operation as shown below:
Recommended SAE Grades Oil Change
Straight 3D-weight oil is recommended. Do not use
multi-viscosity oils above 32°F (D°C) as consider-
able increases in oil consumption and combustion
deposits will result.
NOTE: Using other than service class SF or SG oil
or extending oil change intervals longer than
recommended can cause engine damage
which is not covered by the engine warranty.
A logo
or symbol on oil containers identifies the API
service class and SAE viscosity grade.
4
On a new engine, change oil after the first 5 hours
of operation and then
every 25 operating hours
thereafter.
Drain oil while the engine is still warm from operation
-it flows freely and
carries away more impurities.
Better drainage will result if
the engine is tilted
slightly toward
the oil drain. After draining, reinstall
drain plug.
Fill with
proper viscosity oil to the "F" mark on dip-
stick. Always
check level on dipstick before adding
more oil. Engine must be level for accurate read-
ing. Overfilling can
cause engine to overheat.
On overhauled engines or those rebuilt with a new
shortblock, use straight 3D weight service class SF
or SG for the first 5 hours of operation. Change the
oil after this initial run-in period. Refill with oil as
specified in oil
type.
Checking Oil
Before checking oil level, clean areas around dip-
stick and oil fill
to prevent dirt from falling into en-
gine.

Always check oil with engine stopped and on a level
surface.
Check oil before each use when the engine is cool
and the oil
has drained back into the sump. Add
oil, if low, to bring level up to, but not over the "F"
mark on the dipstick.
NOTE: Do not operate engine with oil level below
the "L" mark or over the "F" mark on the
dipstick.
t
Operating
Range
~
FUEL RECOMMENDATIONS
WARNING: Explosive Fuel!
A Gasoline is extremely flammable
.. and its vapors can explode if ig-
nited. Store gasoline only in ap-
proved containers, in well-venti-
lated, unoccupied buildings, away
from sparks
or flames. Do not fill
the fuel tank while the engine is hot
or running, since spilled fuel could
ignite
if it comes in contact with hot
parts or sparks from ignition. Do not
start the engine near spilled fuel.
Never use gasoline as a cleaning
agent.
General Recommendations
Purchase gasoline in small quantities and store in
clean, approved containers. A container with a ca-
pacity of 2 gallons or less with a pouring spout is
recommended. Such a container is easier to handle
and helps eliminate spoilage during refueling.
Do not use gasoline left over from the previous sea-
son, to minimize gum deposits in your fuel system
and to insure easy starting.
Do not add oil to the Qasoline.
Do not overfill the fuel tank. Leave room for the
fuel to expand.
5
SECTION 1
GENERAL INFORMATION
On gravity feed systems, turn the fuel valve off
when the engine is not in use. Keep the vent hole
in the tank filler cap open. If vent hole is plugged,
pressure may build up in tank causing flooding or
dangerous spraying of gasoline when cap is re-
moved. A vacuum may also be created which
could disrupt fuel flow to the carburetor during en-
gine operation.
Fuel Type
For best results, use only clean, fresh, unleaded
gasoline with a pump sticker octane rating of 87 or
higher. In countries using the Research method, it
should be 90
octane minimum.
Unleaded gasoline is recommended, as it leaves
less combustion chamber deposits. Leaded gaso-
line may be used in areas where unleaded is not
available and exhaust emissions are not regulated.
Be aware however, that the cylinder head will re-
quire more frequent service.
Gasoline/Alcohol blends
Gasohol (up to 10% ethyl alcohol, 90% unleaded
gasoline by volume) is approved as a fuel for Kohler
engines. Other gasoline/alcohol blends are not ap-
proved.
Gasoline/Ether blends
Methyl Tertiary Butyl Ether (MTBE) and unleaded
gasoline blends (up to a maximum of 15% MTBE by
volume) are approved as a fuel tor Kohler engines.
Other gasoline/ether blends are not approved.
SERVICE SCHEDULE
NOTE: Intervals stated are for good, clean opera-
ting conditions. Service more frequently (even
daily)
if extremely dusty or dirty conditions prevail.
Service Frequency
Change Lube Oil ............................. 25 hrs.
Service Precleaner ............................ 25 hrs.
Check Air Cleaner ............................ 50 hrs.
Clean Cooling Fins and External Surfaces ...... 50 hrs.
Check Spark Plugs .......................... 100 hrs.
Check Compression ......................... 500 hrs.
Service Breaker Points ....................... 500 hrs.
Check Ignition Timing ....................... 500 hrs.
Check Valve & Tappet Clearance .............. 500 hrs.
Service Cylinder Head
....................... 500 hrs.
Service Starting Motor Drive .................. 500 hrs.
'250 hours when leaded gasoline is used.
The above service
procedures should also be performed as part
of any seasonal tune-up.

SECTION 1
GENERAL INFORMATION
AIR CLEANER SERVICE
KT engines have tear drop, square, or round air
cleaners with dry type filter elements. Elements
should be checked every 50 operating hours and
replaced when dirty. Check and replace more often
under extremely dirty, dusty conditions.
Replace
with a genuine Kohler element. Carefully
handle element -do not use if sealing surfaces are
damaged.
Somemodels are equipped with Precleaners, which
should be washed and oiled every 25 hours-see
Section 3 for details, and for proper disassembly
and reassembly procedures of air cleaners.
Air lnlake
Tube
Housing
COOLING SYSTEM SERVICE
Air is drawn into the cooling shrouds by fins on the
flywheel. The air intake screen and cooling fins on
the cylinder heads and barrels must be kept clean
and unobstructed at all times.
CAUTION:
Do not operate engine with blower
housing or cooling shrouds removed.
They direct air flow past cooling fins
and removal results in improper air
circulation, overheating and engine
damage.
External surfaces (see Figure 1-2), must be kept
clean, free of oil and dirt accumulation. Dirty
external surfaces result in poorcooling efficiency.
Figure 1-2. Keep These Areas Clean
SPECIFICATIONS AND TOLERANCES
GENERAL SPECIFICATIONS
KT17 KT19 KT21
Bore (Nominal).............. 3.125" (79.375 mm) 3.125" (79.375 mm) 3.312" (84.125 mm)
Stroke . . . . . . . . . . . . . . . . . . . . . 2.750" (69.8 mm) 3.063" (77.8 mm) 3.063" (77.8 mm)
Displacement ............... 42.18 cu. in. (691.4 cc) 47 cu. in. (770.4 cc) 52.76 cu. in. (864.7 cc)
Horsepower at 3600 RPM...... 17 (12.7 kW) 19 (14.2 kW) 21 (15.7 kW)
Weight . . . . . . . . . . . . . . . . . . . . . 1181b. (53.5 kg)
121 lb. (54.9 kg) 1241b. (56.2 kg)
Oil Capacity................. 3 pts. (1.42 L) 3 pts. (1.42 L) 3 pts. (1.42 L)
Spark Plug Gap.... . . . . . . . . . . .025" (0.635 mm) .025" (0.635 mm) .025" (0.635 mm)
Spark Plug Size.............. 14 mm 14 mm 14 mm
SparkPiugReach............ .460 (11.7mm) .460" (11.7mm) .460" (11.7mm)
Spark Plug Type ............ _ .............................. Champion RBL15Y or Equivalent .............................. .
Breaker Point Gap............ .017/.023" (.432/.580 mm) .017/.023" (.432/.580 mm) .017/.023" (.432/.580 mm)
6

SECTION 1
GENERAL
INFORMATION
TORQUE SETTINGS -Special KT17 KT19 KT21
Spark Plugs (ft. lbs.) ......... .
Flywheel Retaining Screw
{ft. lbs.) ............•...•..
Manifold Screws (in. lbs.) ..... .
Closure Plate Screws
10-15 {14-20 N m)
{1.4-2.1
kgm)
40 {54 N m) {5.5 kgm)
150 {17 N m) {1.7 kgm)
10-15 {14-20Nm)
{1.4-2.1 kgm)
40 {54 N m) {5.5 kgm)
150 {17 N m) {1.7 kgm)
10-15 {14-20 N m)
{1.4-2.1
kgm)
40 {54 N m) {5.5 kgm)
150 {17 N m) {5.5 kgm)
{in. tbs.) . . . . . . . . . . . . . . . . . . 150 {17 N m) {1.7 kgm) 150 {17 N m) {1.7 kgm) 150 {17 N m) {1.7 kgm)
............... (See Closure Plate Diagram Page 62 for Correct Tightening Sequence) ............. .
Cylinder Head Screws*
{ft. tbs.) ...........•.......
15-20 {20-27 N m) 15-20 {20-27 N m) 15-20 {20-27 N m)
{2.8-3.7
kgm) {2.8-3.7 kgm) {2.8-3.7 kgm)
.............. (See Cylinder Head Diagram Page 63 for Correct Tightening Sequence) ............. .
Cylinder Barrel Stud Nuts
{in. lbs.) . . . . . . . . . . . . . . . . . . 360 {40.5 N m) {4 kgm) 360 {40.5 N m) {4 kgm) 360 {40.5 N m) {4 kgm)
.................. {See Barrel Diagram Page 62 for Correct Tightening Sequence) ................ .
Connecting Rod Screws*
(in. lbs.) ................. .
Connecting Rod Nuts*
(Posi-Lock Rods)
New Rod {in. lbs.) ......... .
Used Rod (in. lbs.)
....... .. .
Crankcase Stud Nuts
200 {23 N m) {2.3 kgm)
140 {15.8 Nm) (1.6 kgm)
100 {11.3 Nm) (1.2 kgm)
200 {23 N m) {2.3 kgm)
140 {15.8 Nm) {1.6 kgm)
100 {11.3 Nm) {1.2 kgm)
200 {23 N m) {2.3 kgm)
{in. lbs.) . . . . . • . . . . . . . . . . . . 260 {29 N m) {3 kgm) 260 {29 N m) {3 kgm) 260 {29 N m) {3 kgm)
Crankcase Cap Screws .......................... (See Crankcase Diagram Page 60 for Torque and Sequence) ............. ..... .
Crankcase Slot Head Screw
(in. lbs.) ................. . 35 {4 N m) {0.4 kgm)
35 {4 N m) {0.4 kgm)
35 {4 N m) {0.4 kgm)
·Lubricate with oil at assembly.
TOLERANCES, FITTED PARTS
Crankcase End Play
(Ball Bearing) ............. .002/.023" {.051/.580
mm)
.002/.023" {.051/.580
mm) .002/.023" {.051/.580
mm)
Crankshaft End Play
(Sleeve Bearing) ........... .002/.014" {.051/.355
mm)
.002/.014" {.051/.355
mm) .002/.014" {.051/.355
mm)
Crankshaft Running Clearance
(Sleeve Bearing) ........... .0013/.0033" {.034/.083 mm) .0013/.0033" {.034/.083 mm)
.0013/.0033" {.034/.083 mm)
Camshaft End Play ........... .003/.013" {.077/.330 mm) .003/.013" {.077/.330
mm) .003/.013" {.077/.330
mm)
Camshaft Bearing ............
.0010/.0025" {.025/.063 mm) .0010/.0025" {.025/.063 mm)
.0010/.0025" {.025/.063 mm)
Connecting Rod to
Piston Pin Running .........
.0006/.0011" {.016/.027 mm) .0006/.0011" {.016/.027 mm)
.0003/.0008" {.008/.020 mm)
Connecting Rod to
Side Play on Crankpin ...... .005/.016" {.13/.41
mm)
.005/.016" {.13/.41
mm) .005/.016" {.13/.41
mm)
Connecting Rod to
Crankpin Running .......... .0012/.0024" {.030/.060
mm)
.0012/.0024" {.030/.060
mm) .0012/.0024" {.030/.060
mm)
Piston Thrust Face to Bore
Running
(@Gage Dia.) ...... .006/.008" {.15/.20
mm)
.0065/.0085" {.165/.216
mm) .0065/.0085" {.165/.216
mm)
Rings- Side Clearance .... Top .002/.004" {.051/.10
mm) .002/.004" {.051/.10 mm) .002/.004" {.051/.10
mm)
..... lnt .001/.003" {.025/.077
mm)
.0011.003" {.025/.077
mm) .0015/.004" {.038/.01 mm)
..... Oil .001/.003" {.025/.077
mm)
.001/.003" {.025/.077
mm) .001/.003" {.025/.077
mm)
Rings- End Gap ............. .010/.020" {.254/.508 mm) .010/.020" {.254/.508 mm)
.010/.020" {.254/.508 mm)
Wrist Pin to Piston Boss-
Max ......................
.0003" {.008 mm) .0003" {.008 mm)
.0003" {.008 mm)
Wrist Pin to Rod ............. .0006/.0011" {.016/.027
mm)
.0006/.0011" {.016/.027
mm) .0003/.0008" {.008/.020
mm)
Intake Valve to Tappet-
Cold ..................... .003/.006" {.076/.150
mm)
.003/.006" {.076/.150 mm)
.003/.006" {.076/.150 mm)
Exhaust Valve to Tappet -
Cold .....................
.011/.014" {.279/.355 mm) .011/.014" {.279/.355 mm) .011/.014" {.279/.355
mm)
Valve Lift -Zero Lash .........
.280" {7.11 mm) .280" {7.11 mm)
.280" {7.11 mm)
Intake Valve Stem to Guide-
Max. .....................
.0045" {.114mm)
.0045" {.114
mm) .0045" {.114
mm)
Exhaust Valve Stem to Guide-
Max. ..................... .0065" {.165
mm)
.0065" {.165
mm) .0065"
{.165mm)
7

SECTION 1
GENERAL INFORMATION
TOLERANCES, FITTED PARTS (Cont'd)
KT17 KT19
KT21
Tappet Clearance in Guide-
Max . ..................... .0005/.0024" (.013/.060 mm) .0005/.0024" (.013/.060 mm) .0005/.0024" (.013/.060 mm)
Valve Guide Interference
Fit in Cylinder ............. .005/.002" (.013/.051 mm) .005/.002" (.013/.051
mm) .005/.002" (.013/.051 mm)
Valve Guide Ream
Diameter
......... ......... .312/.313" (7.925/7.950 mm) .312/.313" (7.925/7.950 mm) .312/.313" (7.925/7.950 mm)
Pump Shaft to Crankcase
Running
.................. .001 0/.0025" (.025/.063 mm) .0010/.0025"
(.025/063 mm) .0010/.0025" (.025/.063 mm)
Pump Drive Gear End Play ..... .010/.029" (.254/.736 mm) .01 0/.029" (.254/.736 mm) .010/.029" (.254/.736
mm)
WEAR TOLERANCES
Cylinder Bore-
New Diameter ............. 3.125" (79.375 mm) 3.125" (79.375 mm) 3.312" (84.125 mm)
Cylinder Bore-
Max. Wear Diameter ........
3.128" (79.45 mm)
3.128" (79.45 mm) 3.315" (84.201
mm)
Cylinder Bore -
Max. Taper
................
.0015'' (.038 mm) .0015'' (.038 mm) .0015" (.038 mm)
Cylinder Bore-
Max. Out of Round ......... .002" (.05 mm) .002" (.05mm) .002" (.05mm)
Crankshaft Crankpin
New Diameter
............... 1.3733 (34.882/34.895
mm) 1.3733/ (34.882/34.895 mm) 1.4993/ (38.082/38.095 mm)
1.3738" 1.3738" 1.4998"
Series II ...... ............
1.3733/ (34.882/34.895
mm)
1.4993/ (38.082/38.095
mm)
1.3738" 1.4998"
Crankshaft Crankpin-
Max. Out of Round ......... .0005" (.013 mm) .0005" (.013 mm) .0005" (.013 mm)
Crankshaft Crankpin-
Max. Taper .. .............. .001" (.025 mm) .001" (.025 mm) .001" (.025 mm)
Crankshaft Main Bearing
New Diameter ............. 1.7412/ (44.226/44.252 mm) 1.7412/ 44.226/44.252 mm) 1.7412/ (44.226/44.252 mm)
1.7422" 1.7422" 1.7422"
Crankshaft Main Bearing-
Min. Diameter .............
1.7407" (44.22 mm) 1.7407" (44.22
mm) 1.7407" (44.22 mm)
Connecting Rod Crankpin
Bore -
New Diameter
...............
1.3750/ (34.925/34.943
mm) 1.3750/ (34.925/34.943 mm) 1.5010/ (38.125/38.143 mm)
1.3757" 1.3757" 1.5017"
Series II ............ ......
1.3750/ (34.925/34.943 mm) 1.5010/ (38.125/38.143
mm)
1.3757" 1.5017"
Connecting Rod Crankpin
Bore- Max. Diameter
............... 1.3765 (34.963
mm)
1.3765 (34.963 mm) 1.5025 (38.164 mm)
Series II .......... ........ 1.3765 (34.963 mm) 1.5025 (38.164 mm)
Connecting Rod Wristpin
Bore- New Diameter .... .... .62565" (15.891
mm)
.7511" (19.078 mm) .85975" (21.837 mm)
Piston Thrust Face-
Max. Wear Dia.* ............ 3.1165" (79.159 mm) 3.1165" (79.159 mm) 3.303" (83.896 mm)
*Measured just below oil ring at right angles to pin.
8

SECTION1.
GENERAL INFORMATION
TORQUE SETTINGS -General
Tightening Torque Into Cast iron or Steel
00@
Size Grade 2 Grade 5 Grade 8
8-32 20 in. lb.
25 in. lb.
10-24 32 in. lb. 40 in. lb.
10-32
32 in. lb. 40 in. lb.
1/4-20 70 in. lb. 115 in. lb. 165 in. lb.
1/4-28 85 in. lb. 140 in. lb. 200 in. lb.
5/16-18 150 in. lb. 250 in. lb. 350 in. lb.
5/16-24 165 in. lb. 270 in. lb. 30 ft. lb.
3/8-16 260 in. lb. 35 ft. lb. 50 ft. lb.
3/8-24 300 in. lb. 40ft. lb. 60ft. lb.
7/16-14
35 ft. lb. 55 ft. lb.
80ft. lb.
7/16-20 45 ft. lb. 75ft. lb. 105ft. lb.
1/2-13 50 ft. lb. 80 ft. lb. 115ft. lb.
1/2-20 70 ft. lb. 105ft. lb. 165 ft. lb.
9/16-12
75 ft. lb.
125ft. lb. 175 ft. lb.
9/16-18 100ft. lb. 165ft. lb. 230 ft. lb.
5/8-11
110ft. lb. 180ft. lb. 260 ft. lb.
5/8-18 140ft.
lb. 230 ft. lb.
330ft. lb.
3/4-10 150 ft. lb. 245 ft. lb.
350ft. lb.
3/4-16 200 ft. lb.
325ft.
lb. 470ft. lb.
SPECIAL TOOLS
Service and repair procedures will be made easier
by using proper tools. Use only the correct size tool
to fit each size of fastener.
Some procedures detailed in this manual recom-
mend use of tools which can be made by the service
man. (Figures 1-5 and 1-6)
Some procedures require the use of special Kohler
designed tools (Figures 1-3 and 1-4) which are
available from your Kohler distributor.
Figure 1-3. Flywheel Strap Wrench (52 455 03)
Replacement Strap (52 445 04) 9
Tightening Torque Into Aluminum
Size
8-32
10-24
1/4-20
5/16-18
00@
Grade 2 Grade 5 Grade 8
20 in. lb. 20 in. lb. 20 in. lb.
32 in. lb.
32 in. lb.
32 in. lb.
70 in. lb. 70 in. lb.
70 in. lb.
150 in. lb. 150 in. lb. 150 in. lb.
Conversions
in. lbs. x .083 -ft. lbs.
ft. lbs. x 12 -in. lbs.
ft. lbs. x .1383- kgm
ft. lbs. x
1.3558- N m
WARNING: Suitable
eye protection through the
use of safety glasses, goggles, or face
hood should be worn for any proce-
dure involving the use of compressed
air, punches, hammers, chisels, drills,
or
grinding tools.
Part No. 52 455 02 (9/16")
Figure 1-4. Barrel Wrench