Kohler SV810-840 User manual

SERVICE MANUAL
VERTICAL CRANKSHAFT
COURAGE SV710-740
COURAGE PRO SV810-840

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............................................................................................................
Section 11. Emission Compliance Systems............................................................................
1
2
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5
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7
8
9
10
11

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 WARNING
¡ȱȱȱȱęȱȱ
severe acid burns.
ȱĴ¢ȱ¢ȱȱȱȱ
ventilated area. Keep sources of
ignition away.
Lethal Exhaust Gases!
Engine exhaust gases contain
poisonous carbon monoxide. Carbon
monoxide is odorless, colorless, and can
cause death if inhaled. Avoid inhaling
exhaust fumes, and never run the
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 sparks,
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.
¡ȱȱȱȱęȱȱ
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.
Electrical Shock can cause injury.
Do not touch wires while engine is
running.
CAUTION
Electrical Shock!
Never touch electrical wires or
components while the engine is
running. They can be sources of
electrical shock.

1.3
Section 1
Safety and General Information
1
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When ordering parts, or in any communication
involving an engine, always give the Model,
ęȱȱȱǰȱȱĴȱ
Ĝ¡ȱȱȱȱ¢ǯ
ȱȱęȱȱȱȱȱǰȱ
ȱǰȱĜ¡ȱȱȱȱǯȱȱȱ
1-1. An explanation of these numbers is shown in
ȱŗȬŘǯ
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,GHQWL¿FDWLRQ
'HFDO
B. Spec. No.
Engine Model
Model
SV710
SV715
SV720
SV730
SV735
SV740
SV810
SV820
SV830
SV840
Engine Model Code
Complete Spec. Number
(Incorporating Model No.
with Variation No. of Basic Spec.)
C. Serial No.
Year Manufactured Code
Code Year
35 2005
36 2006
37 2007
38 2008
Factory Code
3505810334
SV730-0001
A. Model No.
Version Code
S V 730 S
Courage Engine
Vertical Crankshaft
1XPHULFDO'HVLJQDWLRQ
S = Electric Start

1.4
Section 1
Safety and General Information
Oil Recommendations
Using the proper type and weight of oil in the
crankcase is extremely important. So is checking oil
¢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 in the following table.
Refer to Section 6, Lubrication System for detailed
procedures on checking the oil, changing the oil and
ȱȱȱęǯ
Fuel Recommendations
WARNING: Explosive Fuel!
ȱȱ¡¢ȱĚȱȱȱȱȱ¡ȱ
if ignited. Before servicing the fuel system, make sure there
ȱȱǰȱȱĚȱȱȱȱȱȱ
nearby as these can ignite gasoline vapors. Disconnect and
ground the spark plug leads to prevent the possibility of
sparks from the ignition system.
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ǰȱ
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ȱ
expand.
Fuel Type
ȱȱǰȱȱ¢ȱǰȱǰȱȱ
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 and reduces
harmful exhaust emissions. Leaded gasoline is not
recommended.
Gasoline/Alcohol blends
Gasohol (up to 10% ethyl alcohol, 90% unleaded
gasoline by volume) is approved as a fuel for Kohler
engines. Other gasoline/alcohol blends are not
approved.
Gasoline/Ether blends
Methyl Tertiary Butyl Ether (MTBE) and unleaded
gasoline blends (up to a maximum of 15% MTBE by
volume) are approved as a fuel for Kohler engines.
Other gasoline/ether blends are not approved.
NOTE: Using other than service class SJ or higher oil
or extending oil change intervals longer than
recommended can cause engine damage.
DZȱ ¢ȱȱȱȱȱęȱ
may be used with oil changes 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ȱŗȬřǯ
Figure 1-3. Oil Container Logo.
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)
** *
SAE
10W-30
A
P
I
S
E
R
V
I
C
E
S
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1.5
Section 1
Safety and General Information
1
Periodic Maintenance Instructions
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
If the engine will be out of service for two months or
more, use the following storage procedure:
1. Clean the exterior surfaces of the engine. Avoid
spraying water at the wiring harness or any of the
electrical components.
ȱ Řǯȱ ȱȱȱȱȱęȱȱȱȱȱ
still warm from operation. See Section 6, Change
ȱȱȱǯ
ȱ řǯȱ ȱȱ¢ȱȱȱ¢ȱǰȱ
or the gasoline must be treated with a stabilizer
to prevent deterioration. If you choose to
use a stabilizer, follow the manufacturer’s
recommendations, and add the correct amount
for the capacity of the fuel system.
ȱ ȱ ȱȱȱȱȱǰȱȱǯȱȱ
ȱȱȱŘȱȱřȱȱȱȱ£ȱ
fuel into the rest of the system. Close the fuel
Ȭěȱȱȱȱȱȱȱȱȱ
transported.
To empty the system, run the engine until the
tank and the system is empty.
4. Remove the spark plugs and add one tablespoon
of engine oil into each spark plug hole. Install the
spark plugs, but do not connect the plug leads.
Crank the engine two or three revolutions.
ȱ śǯȱ ȱȱĴ¢ȱȱȱȱĴ¢ȱȱȱ
ȱȱĴ¢ȱȱȱǯ
6. Store the engine in a clean, dry place.
1Perform these maintenance procedures more frequently under extremely dusty, dirty conditions.
2Have a Kohler Engine Service Dealer perform these services.
Frequency Maintenance Required
ȱ Ȋȱ ȱȱǯȱ ȱś
• Check oil level. Section 6
• Check air cleaner for dirty1, loose, or damaged parts. Section 4
• Check air intake and cooling areas, clean as necessary1. Section 4
• Service precleaner element1. Section 4
'DLO\2U%HIRUH
Starting Engine
Every 25 Hours
• Replace air cleaner element and precleaner¹. Section 4
ȱ Ȋȱ ȱȱȱȱęǯȱǻȱ¢ȱȱȱǯǼȱ ȱŜ
• Remove cooling shrouds and clean cooling areas¹. Section 4
ȱȱȱȊȱ ȱȱȱęǰȱȱȱ¢ȱǻȱǼǯȱ ȱŜ
ȱȱȱȊȱ ȱȱęǯȱ ȱś
• Check spark plug condition and gap. Section 7
Every 50 Hours • Check air cleaner element, clean or replace as necessary¹. Section 4
Annually or
Every 100 Hours
• Have valve lash checked/adjustedŘ. Section 10
Every 300 Hours
Every 500 Hours • Have bendix starter drive servicedŘ. Section 7
Ȋȱ ȱȱĞȱȱȱȱŘ. Section 7
Refer to:

1.6
Section 1
Safety and General Information
)LJXUH7\SLFDO(QJLQH'LPHQVLRQV
'LPHQVLRQVLQPLOOLPHWHUV
Inch equivalents shown in [ ].

1.7
Section 1
Safety and General Information
1
'LPHQVLRQVLQPLOOLPHWHUV
Inch equivalents shown in [ ].
)LJXUH7\SLFDO(QJLQH'LPHQVLRQV
PRO
420.81
[16.567]
PRO
480.92
[18.934]
PRO
466.27
[18.357]
PRO
357.74
[14.084]
342.40
[13.480]

1.8
Section 1
Safety and General Information
*HQHUDO6SHFL¿FDWLRQV1
ȱǻȓȱřŜŖŖȱǰȱȱȱ¡ȱ¢ȱȱȱȱȱȱȱȱŗşŚŖǯǼ
SV710, SV810........................................................................................................ŗŚǯşȱȱǻŘŖȱǼ
SV715.....................................................................................................................ŗŜǯŚȱȱǻŘŘȱǼ
ȱ ŝŘŖǰȱŞŘŖ ........................................................................................................ŗŝǯŘȱȱǻŘřȱǼ
ȱ ŝŘś .....................................................................................................................ŗŝǯşȱȱǻŘŚȱǼ
ȱ ŝřŖǰȱŞřŖ ........................................................................................................ŗŞǯŜȱȱǻŘśȱǼ
ȱ ŝřśȱ ....................................................................................................................ŗşǯŚȱȱǻŘŜȱǼ
SV740, SV840........................................................................................................ŘŖǯŗȱȱǻŘŝȱǼ
Bore ............................................................................................................................ŞřȱȱǻřǯŘŝȱǯǼ
Stroke..........................................................................................................................ŜŝȱȱǻŘǯŜŚȱǯǼ
Displacement ............................................................................................................ŝŘśȱȱǻŚŚȱǯȱǯǼ
Compression Ratio ...................................................................................................9.0:1
Dry Weight ................................................................................................................ŚŗǯŘȱȱǻşŗȱǯǼ
ȱ¢ȱǻȦęǼȱȬȱ¡ǰ
ȱ¢ȱȱęȱȱȱȱȱ ..............................................1.6-1.8 L (1.7-1.9 qt)
ȱȱȱȬȱ¡ȱǻȱȱȱǼȱȱ...................Řśǚ
Blower Housing and Sheet Metal
M4 HI-LO Screws Torque ........................................................................................ŘǯŞȱȉȱǻŘśȱǯȱǯǼ
śȱȱ.................................................................................................ŚǯŖȱȉȱǻřśȱǯȱǯǼ
Ŝȱȱ.................................................................................................ŜǯŞȱȉȱǻŜŖȱǯȱǯǼ
ęȬȱȱ.......................................................................ŚǯŖȱȉȱǻřśȱǯȱǯǼ
Camshaft
End Play (With Shim)...............................................................................................ŖǯŖŝŜȦŖǯŗŘŝȱȱǻŖǯŖŖřŖȦŖǯŖŖśŖȱǯǼ
Running Clearance....................................................................................................ŖǯŖŘśȦŖǯŖŜřȱȱǻŖǯŖŖŗŖȦŖǯŖŖŘśȱǯǼ
Bore I.D.
New........................................................................................................................ŘŖǯŖŖŖȦŘŖǯŖŘśȱȱǻŖǯŝŞŝŚȦŖǯŝŞŞŚȱǯǼ
Max. Wear Limit ..................................................................................................ŘŖǯŖřŞȱȱǻŖǯŝŞŞşȱǯǼ
ȱĞȱȱȱǯǯ
New........................................................................................................................ŗşǯşŜŘȦŗşǯşŝśȱȱǻŖǯŝŞśşȦŖǯŝŞŜŚȱǯǼ
Max. Wear Limit ..................................................................................................19.959 mm (0.7858 in.)
Carburetor and Intake Manifold
ȱȱȱȱ
Torque in Two Stages..........................................................................................ęȱȱŝǯŚȱȉȱǻŜŜȱǯȱǯǼ
ȱ ȱ ę¢ȱȱşǯşȱȉȱǻŞŞȱǯȱǯǼ
Carburetor Mounting Nut Torque..........................................................................ŜǯŘȬŝǯřȱȉȱǻśśȬŜśȱǯȱǯǼ
¹Values are in Metric units. Values in parentheses are English equivalents. Lubricate threads with engine oil
prior to assembly.

1.9
Section 1
Safety and General Information
1
Connecting Rod
ȱȱȱǻȱȱǼ.........................................................ŗŗǯřȱȉȱǻŗŖŖȱǯȱǯǼ
Connecting Rod-to-Crankpin Running Clearance
New........................................................................................................................ŖǯŖřŖȦŖǯŖśśȱȱǻŖǯŖŖŗŘȦŖǯŖŖŘŘȱǯǼ
Max. Wear Limit ..................................................................................................ŖǯŖŝŖȱȱǻŖǯŖŖŘŞȱǯǼ
Connecting Rod-to-Crankpin Side Clearance.......................................................ŖǯŘŜȦŖǯŜřȱȱǻŖǯŖŗŖŘȦŖǯŖŘŚŞȱǯǼ
Connecting Rod-to-Piston Pin Running Clearance..............................................ŖǯŖŗśȦŖǯŖŘŞȱȱǻŖǯŖŖŖŜȦŖǯŖŖŗŗȱǯǼ
Piston Pin End I.D.
New........................................................................................................................ŗŝǯŖŗśȦŗŝǯŖŘřȱȱǻŖǯŜŜşşȦŖǯŜŝŖŘȱǯǼ
Max. Wear Limit ..................................................................................................ŗŝǯŖřŜȱȱǻŖǯŜŝŖŝȱǯǼ
Crankcase
ȱȱĞȱȱǯǯ
New........................................................................................................................ŞǯŖŘśȦŞǯŖŝśȱȱǻŖǯřŗśşȦŖǯřŗŝşȱǯǼ
Max. Wear Limit ..................................................................................................ŞǯŖŞŞȱȱǻŖǯřŗŞŚȱǯǼ
Breather Assembly
Inner Cover
ȱ ȱ....................................................................................................ŗŖǯŝȱȉȱǻşśȱǯȱǯǼȱȱȱ
ȱ ȱ ŝǯřȱȉȱǻŜśȱǯȱǯǼȱȱȱ
Outer Cover
Stud Torque ..........................................................................................................ŜǯŘȱȉȱǻśśȱǯȱǯǼȱȱȱ
ȱ ȱ ŚǯŖȱȉȱǻřśȱǯȱǯǼȱȱȱ
Hex Nut Torque ...................................................................................................ŗǯřȱȉȱǻŗŗǯśȱǯȱǯǼ
Oil Drain Plug Torque .............................................................................................ŗřǯŜȱȉȱǻŗŘŖȱǯȱǯǼ
Oil Pan
ȱȱȱ...........................................................................................ŘŚǯŚȱȉȱǻŘŗŜȱǯȱǯǼ
Crankshaft
ȱ¢ȱǻǼ ..........................................................................................................ŖǯŖŝŖȦŖǯśşŖȱȱǻŖǯŖŖŘŞȦŖǯŖŘřŖȱǯǼ
ĞȱȱǻȱǼ
New........................................................................................................................ŚŖǯşŜśȦŚŗǯŖŖřȱȱǻŗǯŜŗŘŞȦŗǯŜŗŚřȱǯǼ
Max. Wear Limit ..................................................................................................41.016 mm (1.6148 in.)
ȱĞȱȱǻȱȱǼȱȬȱ ......................................................................ŚŖǯşŞŝȦŚŖǯşŝŚȱȱǻŗǯŜŗřŜȦŗǯŜŗřŗȱǯǼ
ĞȱȱǻȱȱǼȱȬȬĞ
Running Clearance - New..................................................................................ŖǯŖřşȦŖǯŖŝŚȱȱǻŖǯŖŖŗśȦŖǯŖŖŘşȱǯǼ
¢ȱȱȱȱ
O.D. - New............................................................................................................ŚŖǯşŗřȦŚŖǯşřśȱȱǻŗǯŜŗŖŝȦŗǯŜŗŗŜȱǯǼ
O.D. - Max. Wear Limit.......................................................................................40.84 mm (1.608 in.)
Max. Taper ............................................................................................................ŖǯŖŘŘȱȱǻŖǯŖŖŖşȱǯǼ
Max. Out-of-Round.............................................................................................ŖǯŖŘśȱȱǻŖǯŖŖŗŖȱǯǼ

1.10
Section 1
Safety and General Information
Crankshaft (Continued)
Oil Pan End Main Bearing Journal
O.D. - New............................................................................................................ŚŖǯşŗřȦŚŖǯşřśȱȱǻŗǯŜŗŖŝȦŗǯŜŗŗŜȱǯǼ
O.D. - Max. Wear Limit.......................................................................................40.84 mm (1.608 in.)
Max. Taper ............................................................................................................ŖǯŖŘŘȱȱǻŖǯŖŖŖşȱǯǼ
Max. Out-of-Round.............................................................................................ŖǯŖŘśȱȱǻŖǯŖŖŗŖȱǯǼ
Connecting Rod Journal
O.D. - New............................................................................................................řśǯşśśȦřśǯşŝřȱȱǻŗǯŚŗśŜȦŗǯŚŗŜřȱǯǼ
O.D. - Max. Wear Limit.......................................................................................řśǯşŚȱȱǻŗǯŚŗśȱǯǼ
Max. Taper ............................................................................................................0.018 mm (0.0007 in.)
Max. Out-of-Round.............................................................................................ŖǯŖŘśȱȱǻŖǯŖŖŗŖȱǯǼ
Ğȱǯǯǯ
PTO End, Crank in Engine.................................................................................ŖǯŘŝşȱȱǻŖǯŖŗŗŖȱǯǼ
Entire Crank, in V-Blocks....................................................................................ŖǯŗŖȱȱǻŖǯŖŖřşȱǯǼ
Cylinder Bore
Cylinder Bore I.D.
New .......................................................................................................................ŞřǯŖřŗȦŞřǯŖŖŜȱȱǻřǯŘŜŞşȦřǯŘŜŝşȱǯǼ
Max. Wear Limit ..................................................................................................ŞřǯŖŜşȱȱǻřǯŘŝŖŚȱǯǼ
Max. Out-of-Round.............................................................................................ŖǯŗŘȱȱǻŖǯŖŖŚŝȱǯǼ
Max. Taper ............................................................................................................ŖǯŖśȱȱǻŖǯŖŖŘŖȱǯǼ
Cylinder Head
¢ȱȱȱ
Head Bolt - Torque in Two Stages.....................................................................ęȱȱŘŘǯŜȱȉȱǻŘŖŖȱǯȱǯǼ
ȱ ȱ ę¢ȱȱŚŗǯŞȱȉȱǻřŝŖȱǯȱǯǼ
¡ǯȱȬȬ ................................................................................................ŖǯŖŝŜȱȱǻŖǯŖŖřȱǯǼ
Rocker Arm Screw Torque.......................................................................................ŗŗǯřȱȉȱǻŗŖŖȱǯȱǯǼ
Rocker Arm Stud Torque (AVT)..............................................................................ŗŗǯřȱȉȱǻŗŖŖȱǯȱǯǼ
Rocker Arm/Valve Adjustment Jam Nut Torque..................................................ŝǯřȱȉȱǻŜśȱǯȱǯǼ
Rocker Arm/Valve Adjustment Setscrew Torque (AVT) .....................................ŝǯşȱȉȱǻŝŖȱǯȱǯǼ
Fan/Flywheel
¢ȱȱȱ..........................................................................ŝŚǯśȱȉȱǻśśȱĞǯȱǯǼ
Governor
ȱȱĞȬȬȱȱ....................................ŖǯŖŘśȦŖǯŗŘŜȱȱǻŖǯŖŖŖşȦŖǯŖŖŚşȱǯǼ
ȱȱĞȱǯǯ
New........................................................................................................................ŝǯşŚşȦŞǯŖŖŖȱȱǻŖǯřŗŘşȦŖǯřŗŚşȱǯǼ
Max. Wear Limit ..................................................................................................ŝǯşřŜȱȱǻŖǯřŗŘŚȱǯǼ
ȱȱĞȬȬ
Gear Running Clearance.....................................................................................0.015/0.140 mm (0.0006/0.0055 in.)
ȱȱĞȱǯǯ
New........................................................................................................................śǯşşŖȦŜǯŖŖŖȱȱǻŖǯŘřśŞȦŖǯŘřŜŘȱǯǼ
Max. Wear Limit ..................................................................................................śǯşŝŝȱȱǻŖǯŘřśřȱǯǼ

1.11
Section 1
Safety and General Information
1
Governor (Continued)
Governor Lever Nut Torque....................................................................................ŜǯŞȱȉȱǻŜŖȱǯȱǯǼ
Ignition
Spark Plug Type (Champion®or Equivalent).......................................................ŗŘǰȱŗŘǰȱȱȱřŖŝŗ
Spark Plug Gap..........................................................................................................ŖǯŝŜȱȱǻŖǯŖřŖȱǯǼ
Spark Plug Torque.....................................................................................................ŘŚǯŚȬŘşǯŞȱȉȱǻŗŞȬŘŘȱĞǯȱǯǼ
Ignition Module Air Gap .........................................................................................ŖǯŘŞȦŖǯřřȱȱǻŖǯŖŗŗȦŖǯŖŗřȱǯǼ
ȱȱȱ ...........................................................................ŚǯŖȬŜǯŘȱȉȱǻřśȬśśȱǯȱǯǼ
0XIÀHU
ĝȱȱ
M8 Hex Nuts ........................................................................................................ŘŚǯŚȱȉȱȱǻŘŗŜȱǯȱǯǼ
5/16-18 Capscrews ...............................................................................................ŗŜǯşȱȉȱǻŗśŖȱǯȱǯǼ
Oil Filter
ȱȱ.................................................................................................řȦŚȬŗȱȱĞȱȱ
ȱȱǻȱȦȱȱǼ.....................................................řřǯşȱȉȱǻřŖŖȱǯȱǯǼ
Piston, Piston Rings, and Piston Pin
Piston-to-Piston Pin Running Clearance ...............................................................ŖǯŖŖŜȦŖǯŖŗŝȱȱǻŖǯŖŖŖŘȦŖǯŖŖŖŝȱǯǼ
Piston Pin Bore I.D.
New........................................................................................................................ŗŝǯŖŖŜȦŗŝǯŖŗŘȱȱǻŖǯŜŜşśȦŖǯŜŜşŞȱǯǼ
Max. Wear Limit ..................................................................................................ŗŝǯŖŘśȱȱǻŖǯŜŝŖřȱǯǼ
Piston Pin O.D.
New........................................................................................................................ŗŜǯşşśȦŗŝǯŖŖŖȱȱǻŖǯŜŜşŗȦŖǯŜŜşřȱǯǼ
Max. Wear Limit ..................................................................................................16.994 mm (0.6691 in.)
Top Compression Ring-to-Groove Side Clearance ..............................................ŖǯŖŘśȦŖǯŖŚŞȱȱǻŖǯŖŖŗŖȦŖǯŖŖŗşȱǯǼ
Middle Compression Ring-to-Groove Side Clearance........................................ŖǯŖŗśȦŖǯŖřŝȱȱǻŖǯŖŖŖŜȦŖǯŖŖŗśȱǯǼ
Oil Control Ring-to-Groove Side Clearance..........................................................ŖǯŖŘŜȦŖǯŗŝŜȱȱǻŖǯŖŖŗŖȦŖǯŖŖŝŖȱǯǼ
Top and Center Compression Ring End Gap
New Bore ............................................................................................................ŖǯŘśȦŖǯśŜȱȱǻŖǯŖŗŖŖȦŖǯŖŘŘŚȱǯǼ
Used Bore (Max.) .................................................................................................ŖǯşŚȱȱǻŖǯŖřŝȱǯǼ
ȱȱȱǯǯŶ
New .......................................................................................................................ŞŘǯşŚŝȱȱǻřǯŘŜśŜȱǯǼ
Max. Wear Limit .................................................................................................ŞŘǯŞŖŘȱȱǻřǯŘśşşȱǯǼ
ȱȱȬȬ¢ȱŶȱȱ
New .......................................................................................................................ŖǯŖŜȦŖǯŗŖŖȱȱǻŖǯŖŖŘřȦŖǯŖŖřşȱǯǼ
ŶȱȱŜȱȱǻŖǯŘřŜȱǯǼȱȱȱĴȱȱȱȱȱȱȱȱȱȱȱǯ

1.12
Section 1
Safety and General Information
Speed Control Bracket
ȱ .........................................................................................................ŗŖǯŝȱȉȱǻşśȱǯȱǯǼȱȱȱ
ŝǯřȱȉȱǻŜśȱǯȱǯǼȱȱȱȱ
Starter Assembly
Thru Bolt Torque
ȱ ȱǻȱǼ.........................................................................................ŚǯśȬśǯŝȱȉȱǻŚŖȬśŖȱǯȱǯǼ
ȱ Ȭ¢ȱǻȱĞǼ..............................................................................śǯŜȬşǯŖȱȉȱǻŚşȬŝşȱǯȱǯǼ
Mounting Screw Torque (All)..................................................................................ŗśǯřȱȉȱǻŗřśȱǯȱǯǼ
Brush Holder Mounting Screw Torque
Delco-Remy Starter..............................................................................................ŘǯśȬřǯřȱȉȱǻŘŘȬŘşȱǯȱǯǼ
Solenoid (Starter)
Mounting Hardware Torque
Delco-Remy Starter..............................................................................................ŚǯŖȬŜǯŖȱȉȱǻřśȬśřȱǯȱǯǼ
Nut, Positive (+) Brush Lead Torque
Delco-Remy Starter..............................................................................................ŞǯŖȬŗŗǯŖȱȉȱǻŝŗȬşŝȱǯȱǯǼ
Stator
Mounting Screw Torque...........................................................................................ŜǯŘȱȉȱǻśśȱǯȱǯǼ
Valve Cover
ȱȱȱ...................................................................................ŜǯŘȱȉȱǻśśȱǯȱǯǼ
Valves and Valve Tappets
Valve Clearance ........................................................................................................ŖǯŗŖŗȦŖǯŗśŘȱȱǻŖǯŖŖŚȦŖǯŖŖŜȱǯǼ
Valve Tappet to Crankcase Running Clearance....................................................ŖǯŖŗřȦŖǯŖŝřȱȱǻŖǯŖŖŖśȦŖǯŖŖŘşȱǯǼ
Intake Valve Stem-to-Valve Guide Running Clearance.......................................ŖǯŖřŞȦŖǯŖŝŜȱȱǻŖǯŖŖŗśȦŖǯŖŖřŖȱǯǼ
Exhaust Valve Stem-to-Valve Guide Running Clearance....................................ŖǯŖśŖȦŖǯŖŞŞȱȱǻŖǯŖŖŘŖȦŖǯŖŖřśȱǯǼ
Intake Valve Guide I.D.
New........................................................................................................................ŝǯŖřŞȦŝǯŖśŞȱȱǻŖǯŘŝŝŗȦŖǯŘŝŝşȱǯǼ
Max. Wear Limit ..................................................................................................ŝǯŗřŚȱȱǻŖǯŘŞŖşȱǯǼ
Exhaust Valve Guide I.D.
New........................................................................................................................ŝǯŖřŞȦŝǯŖśŞȱȱǻŖǯŘŝŝŗȦŖǯŘŝŝşȱǯǼ
Max. Wear Limit ..................................................................................................ŝǯŗśşȱȱǻŖǯŘŞŗşȱǯǼ
Valve Guide Reamer Size
Standard................................................................................................................ŝǯŖŚŞȱȱǻŖǯŘŝŝśȱǯǼ
ȱ ŖǯŘśȱȱǯǯ.........................................................................................................ŝǯŘşŞȱȱǻŖǯŘŞŝřȱǯǼ
ȱȱȱĞ .....................................................................................ŞǯŖŝȱȱǻŖǯřŗŝŝȱǯǼ
¡ȱȱȱĞ ..................................................................................ŞǯŖŝȱȱǻŖǯřŗŝŝȱǯǼ
Nominal Valve Seat Angle.......................................................................................Śśǚ

1.13
Section 1
Safety and General Information
1
Tightening Torque: N·m (in. lb.) + or - 10%
Property Class Noncritical
Fasteners
Into Aluminum
Size
M4ȱ ŗǯŘȱǻŗŗǼȱ ŗǯŝȱǻŗśǼȱ ŘǯşȱǻŘŜǼȱ ŚǯŗȱǻřŜǼȱ śǯŖȱǻŚŚǼȱ ŘǯŖȱǻŗŞǼ
M5ȱ ŘǯśȱǻŘŘǼȱ řǯŘȱǻŘŞǼȱ śǯŞȱǻśŗǼȱ ŞǯŗȱǻŝŘǼȱ şǯŝȱǻŞŜǼȱ ŚǯŖȱǻřśǼ
M6ȱ ŚǯřȱǻřŞǼȱ śǯŝȱǻśŖǼȱ şǯşȱǻŞŞǼȱ ŗŚǯŖȱǻŗŘŚǼȱ ŗŜǯśȱǻŗŚŜǼȱ ŜǯŞȱǻŜŖǼ
M8ȱ ŗŖǯśȱǻşřǼȱ ŗřǯŜȱǻŗŘŖǼȱ ŘŚǯŚȱǻŘŗŜǼȱ řřǯşȱǻřŖŖǼȱ ŚŖǯŝȱǻřŜŖǼȱ ŗŝǯŖȱǻŗśŖǼ
Tightening Torque: N·m (ft. lb.) + or - 10%
Property Class Noncritical
Fasteners
Into Aluminum
M10 ŘŗǯŝȱǻŗŜǼȱ ŘŝǯŗȱǻŘŖǼȱ ŚŝǯśȱǻřśǼȱ ŜŜǯŚȱǻŚşǼȱ ŞŗǯŚȱǻŜŖǼȱ řřǯşȱǻŘśǼ
M12 řŜǯŜȱǻŘŝǼȱ ŚŝǯśȱǻřśǼȱ ŞŘǯŝȱǻŜŗǼȱ ŗŗŜǯŜȱǻŞŜǼȱ ŗřşǯŝȱǻŗŖřǼȱ ŜŗǯŖȱǻŚśǼ
M14 śŞǯřȱǻŚřǼȱ ŝŜǯŚȱǻśśǼȱ ŗřŗǯśȱǻşŝǼȱ ŗŞŚǯŚȱǻŗřŜǼȱ ŘŗşǯŝȱǻŗŜŘǼȱ şŚǯşȱǻŝŖǼ
5.8 8.8 10.9 12.9
4.8 5.8 10.9 12.9
4.8
8.8
General Torque Values
Metric Fastener Torque Recommendations for Standard Applications

1.14
Section 1
Safety and General Information
English Fastener Torque Recommendations for Standard Applications
Grade 2 or 5
Fasteners Into
Aluminum
Size
8-32ȱ ŘǯřȱǻŘŖǼȱ ŘǯŞȱǻŘśǼȱ ȱȬȬȬȬȬȬȬȬȬȱ ŘǯřȱǻŘŖǼ
10-24ȱ řǯŜȱǻřŘǼȱ ŚǯśȱǻŚŖǼȱ ȱȬȬȬȬȬȬȬȬȬȱ řǯŜȱǻřŘǼ
10-32ȱ řǯŜȱǻřŘǼȱ ŚǯśȱǻŚŖǼȱ ȱȬȬȬȬȬȬȬȬȬȱ ȱȬȬȬȬȬȬȬȬȬ
1/4-20ȱ ŝǯşȱǻŝŖǼȱ ŗřǯŖȱǻŗŗśǼȱ ŗŞǯŝȱǻŗŜśǼȱ ŝǯşȱǻŝŖǼ
1/4-28ȱ şǯŜȱǻŞśǼȱ ŗśǯŞȱǻŗŚŖǼȱ ŘŘǯŜȱǻŘŖŖǼȱ ȱȬȬȬȬȬȬȬȬȬ
5/16-18ȱ ŗŝǯŖȱǻŗśŖǼȱ ŘŞǯřȱǻŘśŖǼȱ řşǯŜȱǻřśŖǼȱ ŗŝǯŖȱǻŗśŖǼ
5/16-24ȱ ŗŞǯŝȱǻŗŜśǼȱ řŖǯśȱǻŘŝŖǼȱ ȱȬȬȬȬȬȬȬȬȬȱ ȱȬȬȬȬȬȬȬȬȬ
3/8-16ȱ ŘşǯŚȱǻŘŜŖǼȱ ȱȬȬȬȬȬȬȬȬȬȱ ȱȬȬȬȬȬȬȬȬȬȱ ȱȬȬȬȬȬȬȬȬȬ
3/8-24ȱ řřǯşȱǻřŖŖǼȱ ȱȬȬȬȬȬȬȬȬȬȱ ȱȬȬȬȬȬȬȬȬȬȱ ȱȬȬȬȬȬȬȬȬȬ
Size
5/16-24 ȱȬȬȬȬȬȬȬȬȬȱ ȱȬȬȬȬȬȬȬȬȬȬȱ ŚŖǯŝȱǻřŖǼȱ ȱȬȬȬȬȬȬȬȬȬ
3/8-16ȱ ȱȬȬȬȬȬȬȬȬȬȱ ŚŝǯśȱǻřśǼȱ ŜŝǯŞȱǻśŖǼȱ ȱȬȬȬȬȬȬȬȬȬ
3/8-24ȱ ȱȬȬȬȬȬȬȬȬȬȱ śŚǯŘȱǻŚŖǼȱ ŞŗǯŚȱǻŜŖǼȱ ȱȬȬȬȬȬȬȬȬȬ
7/16-14ȱ ŚŝǯśȱǻřśǼȱ ŝŚǯŜȱǻśśǼȱ ŗŖŞǯśȱǻŞŖǼȱ ȱȬȬȬȬȬȬȬȬȬ
7/16-20ȱ ŜŗǯŖȱǻŚśǼȱ ŗŖŗǯŝȱǻŝśǼȱ ŗŚŘǯŚȱǻŗŖśǼȱ ȱȬȬȬȬȬȬȬȬȬ
1/2-13 67.8 (50) 108.5 (80) 155.9 (115) ---------
1/2-20ȱ şŚǯşȱǻŝŖǼȱ ŗŚŘǯŚȱǻŗŖśǼȱ ŘŘřǯŝȱǻŗŜśǼȱ ȱȬȬȬȬȬȬȬȬȬ
9/16-12ȱ ŗŖŗǯŝȱǻŝśǼȱ ŗŜşǯśȱǻŗŘśǼȱ ŘřŝǯřȱǻŗŝśǼȱ ȱȬȬȬȬȬȬȬȬȬ
9/16-18ȱ ŗřśǯŜȱǻŗŖŖǼȱ ŘŘřǯŝȱǻŗŜśǼȱ řŗŗǯşȱǻŘřŖǼȱ ȱȬȬȬȬȬȬȬȬȬ
5/8-11ȱ ŗŚşǯŘȱǻŗŗŖǼȱ ŘŚŚǯŗȱǻŗŞŖǼȱ řśŘǯŜȱǻŘŜŖǼȱ ȱȬȬȬȬȬȬȬȬȬ
5/8-18ȱ ŗŞşǯŞȱǻŗŚŖǼȱ řŗŗǯşȱǻŘřŖǼȱ ŚŚŝǯśȱǻřřŖǼȱ ȱȬȬȬȬȬȬȬȬȬ
3/4-10ȱ ŗşşǯřȱǻŗśŖǼȱ řřŘǯŘȱǻŘŚśǼȱ ŚŝŚǯŜȱǻřśŖǼȱ ȱȬȬȬȬȬȬȬȬȬ
3/4-16ȱ ŘŝŗǯŘȱǻŘŖŖǼȱ ŚŚŖǯŝȱǻřŘśǼȱ ŜřŝǯřȱǻŚŝŖǼȱ ȱȬȬȬȬȬȬȬȬȬ
Tightening Torque: N·m (ft. lb.) + or - 20%
Tightening Torque: N·m (in. lb.) + or - 20%
Grade 2 Grade 5 Grade 8
Bolts, Screws, Nuts and Fasteners
Assembled Into Cast Iron or Steel
ȉȱƽȱǯȱǯȱ¡ȱŖǯŗŗř
ȉȱƽȱĞǯȱǯȱ¡ȱŗǯřśŜ
ǯȱǯȱƽȱȉȱ¡ȱŞǯŞś
Ğǯȱǯȱƽȱȉȱ¡ȱŖǯŝřŝ
Torque
Conversions

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.
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