Kohler Aegis 05810334 Service Manual Download Page 50

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7.8

Section 7
Cooling System

Summary of Contents for Aegis 05810334

Page 1: ...1 KOHLER AEGIS 17 20 23 HP SERVICE MANUAL LIQUID COOLED VERTICAL CRANKSHAFT...

Page 2: ...hooting Section 4 Air Cleaner and Air Intake System Section 5 Fuel System and Governor Section 6 Lubrication System Section 7 Cooling System Section 8 Electrical System and Components Section 9 Disass...

Page 3: ...ollowed at all times Failure to follow these precautions could result in injury to yourself and others LV560 LV625 LV675 Rotating Parts can cause severe injury Stay away while engine is in operation W...

Page 4: ...as Keep sparks open flames and other sources of ignition away from the battery at all times Keep batteries out of the reach of children Remove all jewelry when servicing batteries Before disconnecting...

Page 5: ...ine always give the Model Specification and Serial Numbers including letter suffixes if there are any The engine identification numbers appear on a decal or decals affixed to the engine shrouding See...

Page 6: ...in areas where the water contains a high mineral content Propylene glycol based anti freeze is not recommended This mixture will provide protection from 37 C 34 F to 108 C 226 F For protection and use...

Page 7: ...t the spark plug lead s 2 Disconnect negative battery cable from battery Maintenance Schedule These required maintenance procedures should be performed at the frequency stated in the table They should...

Page 8: ...then be attached to the equipment and or engine as a reminder to refill the cooling system before starting 4 The fuel system must be completely emptied or the gasoline must be treated with a stabiliz...

Page 9: ...Oil Fill Dipstick C L C L 199 0 Center of Gravity 95 8 Center of Gravity Mounting Hole A Mounting Surface 334 5 167 2 2x 89 8 2x 72 8 Coolant Drain Plug 3 8 N P T Inch 30 30 45 45 242 2 104 0 89 8 15...

Page 10: ...ty with filter 1 9 L 2 0 U S qt Coolant Capacity equal parts of water and ethylene glycol 1 4 L 1 5 U S qt Angle of Operation Maximum at full oil level All Directions 20 Lower Blower Housing M5 Fasten...

Page 11: ...oss Shaft Bore I D New 8 025 8 075 mm 0 3159 0 3179 in Max Wear Limit 8 088 mm 0 3184 in Breather Cover Fasteners Torque 10 7 N m 95 in lb Into new as cast hole 7 3 N m 65 in lb Into used hole Oil Dra...

Page 12: ...n Max Taper 0 05 mm 0 0020 in Cylinder Head Cylinder Head Fastener Torque torque in 2 increments 16 9 33 9 N m 150 300 in lb Max Out of Flatness 0 076 mm 0 003 in Rocker Pivot Fastener Torque if Screw...

Page 13: ...Rings and Piston Pin Piston to Piston Pin 0 006 0 018 mm 0 0002 0 0007 in Piston Pin Bore I D New 17 006 17 013 mm 0 6695 0 6698 in Max Wear Limit 17 025 mm 0 6703 in Piston Pin O D New 16 995 17 000...

Page 14: ...967 76 985 mm 3 0302 3 0309 in Max Wear Limit 76 840 mm 3 0252 in LV675 New 79 963 79 981 mm 3 1481 3 1488 in Max Wear Limit 79 831 mm 3 1430 in Piston Thrust Face to Cylinder Bore Running Clearance...

Page 15: ...lve Minimum Lift 8 88 mm 0 3496 in Nominal Valve Seat Angle 45 General Torque Values Metric Fastener Torque Recommendations for Standard Applications Tightening Torque N m in lb or 20 Property Class N...

Page 16: ...7 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 4 105 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...

Page 17: ...n locally Water Manometer 25 761 02 S Vacuum Gauge 25 761 22 S Cylinder Leakdown Tester 25 761 05 S Ignition System Tester 24 455 02 S Starter Ring Tool 25 761 18 S These items can be ordered through...

Page 18: ...cylinder so that the tool teeth engage the ring gear teeth on the flywheel The bosses will lock the tool and flywheel in position for loosening tightening or removing with a puller Figure 2 2 Flywhee...

Page 19: ...ngines Starts Hard 1 PTO drive is engaged 2 Dirt or water in the fuel system 3 Clogged fuel line 4 Loose or faulty wires or connections 5 Faulty choke or throttle controls 6 Faulty spark plugs 7 Low c...

Page 20: ...ns grass screen blower housing and other external surfaces Dirt or debris on these areas are causes of higher operating temperatures and overheating Check for obvious fuel oil and coolant leaks or dam...

Page 21: ...igh idle speed 3200 to 3750 RPM 3 Open the clamp and note the water level in the tube The level in the engine side should be a minimum of 10 2 cm 4 in above the level in the open side If the level in...

Page 22: ...he spark plug hole but do not attach it to the tester at this time 5 Connect an adequate air source to the tester 6 Turn the regulator knob in the increase clockwise direction until the gauge needle i...

Page 23: ...and remove the upper blower housing screen assembly from the engine See Figure 4 2 Take the housing assembly outdoors or to a trash container and brush off the screen or use compressed air and blow i...

Page 24: ...th the retainer strap and the bottom of the element must be sealed against the air cleaner base Make sure the base is secured tightly to the carburetor and not cracked of damaged Also make sure the br...

Page 25: ...aining straps and remove the upper blower housing and screen assembly See Figure 4 2 2 Remove the precleaner from the paper element See Figure 4 7 3 Unhook the filter element retaining strap and remov...

Page 26: ...aner base off the stud 6 Reverse procedure to reassemble components Torque the hex flange nuts to 9 9 N m 88 in lb Radiator Cleaning Every time the upper blower housing assembly is removed to check or...

Page 27: ...roved containers A container with a capacity of 2 gallons or less with a pouring spout is recommended Such a container is easier to handle and helps eliminate spillage during refueling Do not use gaso...

Page 28: ...ion chamber If there is no fuel at the tip of the spark plug check for fuel flow from the fuel tank Test 3 3 Check for fuel flow from the tank to the fuel pump a Remove the fuel line from the inlet fi...

Page 29: ...the float stops fuel flow when the engine is at rest When fuel is being consumed the float will drop and fuel pressure will push the inlet needle away from the seat allowing more fuel to enter the bo...

Page 30: ...of air and delivered to the engine As the throttle plate opening increases greater amounts of air fuel mixture are drawn in through the fixed and metered idle progression holes As the throttle plate o...

Page 31: ...mixture is then delivered to the combustion chamber The carburetor has a fixed main circuit There is no adjustment feature present Figure 5 3 Main Circuit Check Valve Spring Outlet Check Valve Leak J...

Page 32: ...ow idle speed screw b Low idle fuel mixture circuit blocked restricted Clean carburetor as required 1 Engine starts hard runs roughly or stalls at idle speed 2 Engine runs rich indicated by black soot...

Page 33: ...in the center of the solenoid 4 If the pin retracted when the power source was turned on the solenoid is good If the power source is turned off the pin should return to its original position Adjustmen...

Page 34: ...e components and upper blower housing assembly Retest operation Disassembly Use the following procedure to disassemble the carburetor after removing it from the engine Refer to Figure 5 6 for identifi...

Page 35: ...Retaining Screw Passage Cover Set Screws Choke Plate Choke Shaft Air Filter Collar Spring Ring Choke Lever Throttle Shaft Lever Idle Speed Spring Idle Speed Screw Fuel Bowl Gasket Fuel Bowl Bowl Reta...

Page 36: ...r gear assembly is rotating The force applied by the regulating pin against the cross shaft tends to close the throttle plate The governor spring tension and the force applied by the regulating pin ba...

Page 37: ...rt a nail into the hole on the cross shaft and rotate the shaft counterclockwise as far as it will turn Tighten hex nut to 9 9 N m 88 in lb Sensitivity Adjustment Governor sensitivity is adjusted by r...

Page 38: ...ull High Idle RPM Speed Adjustment See Figure 5 8 1 With the engine running move the throttle control to fast Use a tachometer to check the RPM speed 2 Loosen the lock nut on the high idle adjusting s...

Page 39: ...air temperature at the time of operation as shown in the following table Figure 6 1 Oil Container Logo The top portion of the symbol shows service class such as API SERVICE CLASS SJ The symbol may sh...

Page 40: ...filter after every 200 hours or annually whichever comes first more often under severe conditions Refill with service class SG SH SJ or higher oil as specified in the Viscosity Grades table on previou...

Page 41: ...oil level to assure crankcase oil level is at the FULL mark on the dipstick Refer to the operating instructions of the equipment this engine powers Because of equipment design or application there ma...

Page 42: ...ne way valve to provide the desired vacuum Breather Design and Function The breather system on these engines is designed to serve two functions prevent excess oil from accumulating in the rocker arm c...

Page 43: ...ough separate parallel circuits within each head and the corresponding sides of the crankcase As the coolant moves through these passages in the engine it absorbs heat from the engine parts After trav...

Page 44: ...gns of leakage Servicing Every 100 hours of operation more often under extremely dusty dirty conditions remove the upper blower housing Clean the air intake screen as instructed in Section 4 and clean...

Page 45: ...r the coolant has drained apply pipe sealant with Teflon not Teflon tape to the threads and reinstall the plugs Torque the plugs to 13 5 N m 120 in lb Some early production engines contained steel plu...

Page 46: ...en assembly Filling Cooling System NOTE To prevent engine damage do not use anti freeze mixture greater than 70 ethylene glycol in the cooling system Do not use anti freeze with stop leak additive s o...

Page 47: ...debris accumulation obstruction leaks coolant level and damaged components are eliminated as possible causes To Test Remove the thermostat from the system Hang or suspend the thermostat by its frame i...

Page 48: ...tem tester with the appropriate adapter may be used to check the cooling system and the radiator cap A typical tester and adapter is shown in Figure 7 11 Figure 7 11 A Typical Tester and Adapter Test...

Page 49: ...ile testing the system they may be weak and should be replaced Pressure drops quickly A steady drop or loss of pressure indicates serious leakage is occurring within the system which must be located a...

Page 50: ...7 8 Section 7 Cooling System...

Page 51: ...ration whichever comes first remove the spark plugs check condition and reset the gap or replace with new spark plugs as necessary Every 500 hours of operation replace the spark plugs To service the s...

Page 52: ...plugs are shown in the following photos Carbon Fouled Soft sooty black deposits indicate incomplete combustion caused by a restricted air cleaner overrich carburetion weak ignition or poor compression...

Page 53: ...ep batteries out of the reach of children Remove all jewelry when servicing batteries Before disconnecting the negative ground cable make sure all switches are OFF If ON a spark will occur at the grou...

Page 54: ...e timing of the spark is controlled directly by the location of the flywheel magnet group as referenced to engine top dead center Figure 8 4 Electronic CD Ignition System For Customer Connected Tracto...

Page 55: ...charged or damage to the system can result Do not crank or run an engine with a spark plug lead disconnected Always provide a path for the spark to discharge to ground D1 C1 T1 Spark Plug P S SCS L2 L...

Page 56: ...e first spark plug lead Conclusion Ground Clip Post Terminal Test Procedure for Standard CD Ignition Battery Charging System General Most engines are equipped with a 15 amp regulated battery charging...

Page 57: ...tch W Ignition Kill Carburetor Assembly Intake Manifold Screw Fuse Y Ground B Carburetor Solenoid Ignition Module Coolant Temp Gauge W Coolant Temp Switch Oil Pressure Switch Oil Sentry Light Coolant...

Page 58: ...onents Lighting Lead Yellow Charging Lead Black Diode Lighting Stator 3 Amp Charging Stator Figure 8 9 3 amp 70 Watt Stator Figure 8 8 15 20 25 amp Stator and Rectifier Regulator Rectifier Regulator C...

Page 59: ...replace it remove the upper blower housing disconnect the connector plug remove the single mounting screw with the ground lead and lift out the rectifier regulator NOTE When installing the rectifier r...

Page 60: ...e running at 3600 RPM measure AC voltage across stator leads using an AC voltmeter 3a With engine stopped measure the resistance across stator leads using an ohmmeter 3b With the engine stopped measur...

Page 61: ...t the lighting lead from the wiring harness With engine running at 3000 RPM measure voltage from lighting lead to ground using an AC voltmeter 3 With engine stopped measure the resistance of stator fr...

Page 62: ...Sections for starter removal and installation procedures Troubleshooting Guide Starting Difficulties Problem Starter Energizes But Turns Slowly Possible Fault Battery Wiring Starter Switch or Solenoid...

Page 63: ...the recess in the housing See Figure 8 15 Figure 8 15 Removing Plunger 4 Remove the two thru larger bolts See Figure 8 16 Figure 8 16 Removing Thru Bolts Figure 8 12 Starter Disassembly 1 Remove the...

Page 64: ...Plate Assembly 6 Remove the frame from the armature and drive end cap See Figure 8 18 Figure 8 18 Starter Frame Removed 7 Remove the drive lever pivot bushing and backing plate from the end cap See Fi...

Page 65: ...OTE Do not reuse the old retainer Figure 8 22 Removing Retaining Ring 12 Remove the drive pinion assembly from the armature 13 Clean the parts as required NOTE Do not soak the armature or use solvent...

Page 66: ...ndercut to ensure proper operation of the commutator See Figure 8 25 Figure 8 25 Commutator Mica Inspection 2 Use an ohmmeter set to the Rx1 scale Touch the probes between two different segments of th...

Page 67: ...Mobil Temp SHC 32 Clean and check the other starter parts for wear or damage as required Starter Reassembly 1 Apply new drive lubricant Kohler Part No 52 357 02 S to the armature shaft splines Instal...

Page 68: ...housing which receives the backup washer See Figure 8 31 Figure 8 31 Installing Armature and Pivot Lever 7 Install the backup washer followed by the rubber grommet into the matching recess of the dri...

Page 69: ...ing caps from over each of the brush assemblies Do not lose the springs Figure 8 36 Removing Retaining Clips b Position each of the brushes back in their slots so they are flush with the I D of the br...

Page 70: ...lts Figure 8 40 Torquing Brush Holder Screws 13 Hook the plunger behind the upper end of the drive lever and install the spring into the solenoid Insert the three mounting screws through the holes in...

Page 71: ...ever moves back and the drive pinion moves out of mesh with the ring gear into the retracted position Starter Disassembly 1 Disconnect the wire from the solenoid 2 Remove the hex nuts securing the sol...

Page 72: ...st 4 The replacement brushes have a solid portion on them which should be crimped on the post 5 Solder the crimped portion to the post 6 Replace the brush holder in the frame and place the brushes in...

Page 73: ...and safety precautions carefully Make sure all traces of the cleaner are removed before the engine is reassembled and placed into operation Even small amounts of these cleaners can quickly break down...

Page 74: ...Plug 3 There is likely to be some oil left in the filter Place a shallow pan under the filter pad and filter to catch the overflow Remove the oil filter by turning it in a counterclockwise direction...

Page 75: ...8 Removing Radiator Cap 2 Carefully remove the coolant drain plugs in the lower side of both cylinder heads See Figure 9 9 Drain the coolant into a suitable container Early production units contained...

Page 76: ...n assembly Slide the fuel line out of the clip attached to mounting stud See Figure 9 12 Figure 9 12 Removing Fuel Pump Remove Air Cleaner Base 1 Disconnect the breather hose from the air cleaner base...

Page 77: ...onnect the fuel solenoid leads most models from the wiring harness 2 Disconnect the dampening spring and throttle linkage from the governor arm Remove the black bushing and clip it back onto the linka...

Page 78: ...emove the starter assembly from the adapter plate Figure 9 21 Removing Adapter Plate Screws Remove Flywheel Fan and Blocking Plates 1 Remove the four shoulder screws securing the fan to the flywheel a...

Page 79: ...nhook the locking tab and remove the reservoir from under the bracket See Figure 9 25 Figure 9 25 Removing the Reservoir Remove Ignition Modules 1 Rotate the flywheel to position one of the tapered se...

Page 80: ...Loosening Flywheel 3 Slide the ignition module onto the contoured section of the flywheel Disconnect the lead and remove the module from the engine Note On modules containing 90 terminals the leads m...

Page 81: ...9 33 Rear Bracket Clamp Figure 9 34 Unseating By pass Hose 3 Remove the two screws attaching the rear support bracket and half clamp to the crankcase on the oil filter side See Figure 9 33 Figure 9 35...

Page 82: ...f Figure 9 39 Removing Rectifier Regulator 3 Unplug the connector from the rectifier regulator Using a small screwdriver or other narrow flat blade bend down the locking tang on the center terminal an...

Page 83: ...the camshaft See Figure 9 41 Figure 9 41 Removing Cam Pulley Mounting Hardware 2 Lift the pulley off the camshaft and work the belt off the coolant pump pulley See Figure 9 42 Figure 9 42 Removing Cam...

Page 84: ...rvice department for specific instructions if the fitting is damaged or its mounting is affected in any way Figure 9 46 Lifting Out Water Pump and Transfer Tube 5 If required remove the hose clamps no...

Page 85: ...Remove the two No 1 side intake manifold mounting screws securing the ground leads and clip for the wiring harness Note the locations of the clip and ground leads See Figure 9 48 Figure 9 49 Temperat...

Page 86: ...securing the intake manifold to the cylinder heads See Figure 9 52 Remove Lower Blower Housing and Oil Fill Dipstick Tube 1 Remove the breather hose from the No 1 side valve cover fitting 2 Remove th...

Page 87: ...hex flange screws securing the breather cover to the crankcase See Figure 9 58 2 Carefully pry under the protruding edge of the breather cover with a screwdriver to separate the cover See Figure 9 59...

Page 88: ...g Push Rods 3 Repeat for the opposite cylinder 4 Remove the four hex flange nuts and washers from the studs securing each cylinder head See Figure 9 65 Figure 9 61 Removing Spark Plug s Remove Valve C...

Page 89: ...67 Removing Lifters from Lifter Bores Disassemble Cylinder Heads 1 Remove the two hex flange screws shims rocker arms and pivots from one of the cylinder heads See Figure 9 68 Figure 9 68 Removing Roc...

Page 90: ...items can be removed see Figures 9 70 and 9 71 valve spring retainers valve springs valve spring caps intake and exhaust valves valve stem seals intake valve only NOTE These engines use a valve stem s...

Page 91: ...ng Do not reuse the old retaining ring Figure 9 76 Removing Governor Cross Shaft Remove Connecting Rods with Pistons and Rings 1 Remove the two hex flange screws securing the closest connecting rod en...

Page 92: ...Use the numbers to mark each end cap connecting rod and piston for reassembly Do not mix end caps and connecting rods Figure 9 78 Removing Connecting Rod and Piston Assembly 3 Repeat the above proced...

Page 93: ...ge the surfaces and could result in leaks Refer to A Guide to Engine Rebuilding TP 2150 for additional information Measurement Guide TP 2159 A and Engine Inspection Data Record TP 2435 are also availa...

Page 94: ...kshaft is ground provides easy access for cleaning any grinding deposits that may collect in the oil passages High Point From Fillet Intersections The Fillet Must Blend Smoothly With The Bearing Journ...

Page 95: ...with either portable drills or drill presses the use of a low speed drill press is preferred as it facilitates more accurate alignment of the bore in relation to the crankshaft crossbore Honing is be...

Page 96: ...defects such as warped head excessive corrosion or worn stem end Replace valves found to be in bad condition A normal valve and valves in bad condition are shown in the accompanying illustrations Clea...

Page 97: ...st Valve E F A Exhaust Insert Intake Insert F E G H B A Intake Valve Figure 10 5 Valve Details Normal Even after long hours of operation a valve can be reconditioned and reused if the face and margin...

Page 98: ...a prevalent cause of valve sticking The cure is to ream the valve guides and clean or replace the valves depending on their condition Stem Corrosion Moisture in fuel or from condensation are the most...

Page 99: ...serts are not replaceable on the engines but can be reconditioned if not too badly pitted or distorted If cracked or badly warped the cylinder head should be replaced Recondition the valve seat insert...

Page 100: ...o the cylinder wall Oil control is also lost when ring gaps are not staggered during installation When cylinder temperatures get too high lacquer and varnish collect on pistons causing rings to stick...

Page 101: ...igure 10 8 against the listed specifications below Top and Middle Compression Ring End Gap LV560 New Bore Top Ring 0 180 0 380 mm 0 0071 0 0150 in Middle Ring 0 180 0 440 mm 0 0071 0 0173 in Used Bore...

Page 102: ...n and Service Check bearing area big end for excessive wear score marks running and side clearances refer to Section 1 Specifications Tolerances and Special Torque Values Replace rod and cap if scored...

Page 103: ...he governor gear flyweights assembly and slide both onto governor shaft Oil Pump Assembly Disassembly 1 Remove the two hex flange screws 2 Remove the oil pump assembly from the oil pan Figure 10 14 Re...

Page 104: ...er of the recess Figure 10 18 Water Pump The impeller assembly is not serviceable but it should be inspected for wear or damage 1 Inspect the impeller to make sure the blades are in good condition and...

Page 105: ...ll camshaft 6 Install oil seal in oil pan 7 Install oil pan assembly 8 Install cylinder studs 9 Install hydraulic lifters 10 Install cylinder heads and set valve lash 11 Install breather cover 12 Inst...

Page 106: ...and end cap into its appropriate cylinder bore as previously marked at disassembly Do not mix end caps and connecting rods Figure 11 4 Installing Piston 1 in Bore NOTE Proper orientation of the piston...

Page 107: ...llustrated instructions are also provided in the service rod package NOTE Make sure to align the chamfer of the connecting rod with the chamfer of its mating end cap The chamfer should be toward the o...

Page 108: ...vernor cross shaft to the left until the lower end of the shaft contacts the crankcase Make sure the cross shaft stays in this position while installing the camshaft See Figure 11 9 5 Carefully slide...

Page 109: ...4 and 5 until end play is within specified range Oil Pump Assembly The oil pump is mounted in the oil pan If service was required and the oil pump was removed refer to the assembly procedures under O...

Page 110: ...different studs were used in production and cannot be interchanged or damage to the threads in the crankcase casting will occur Use only the correct replacement stud s Refer to the parts manual for s...

Page 111: ...at Steps 1 3 for each of the studs Install Hydraulic Lifters 1 Bleed the hydraulic lifters of internal oil so the plunger in the lifter can be depressed by hand Use an old cutoff push rod mounted in a...

Page 112: ...ls if they are deteriorated or damaged in any way Never reuse an old seal Figure 11 23 Installing Valve with Spring Compressor Install Cylinder Heads 1 Check to make sure there are no nicks or burrs o...

Page 113: ...ession stroke Engines Below Serial No 34065xxxxx with Adjustable Valve Train Valve Lash Setting Procedure Using a Dial Indicator The preferred and recommended procedure for setting valve lash involves...

Page 114: ...from turning and sliding off the end of the valve but do not disturb the dial indicator setting Slowly loosen the rocker arm mounting screw until the dial indicator needle movement stops Note and rec...

Page 115: ...alve Lash Setting Procedure Not Using a Dial Indicator Adjustable Valve Train The following procedure may be used as an alternate method for setting the valve lash Although not as precise as using the...

Page 116: ...to cover all possible combinations on one engine NOTE Do not use the shim selection chart on page 11 10 when using this procedure Available Shim Thickness Identification 004 in Shims contain a Blue Li...

Page 117: ...ntacting surfaces of the rocker arms and rocker arm pivots Install the rocker arm pivots Install the rocker arms and rocker arm pivots on the one cylinder head and start the two hex flange screws 2 Al...

Page 118: ...restrain the lower hose tube assembly Do not use plastic tie straps as adequate tension will not be maintained Figure 11 39 Torquing Drain Plug Install Breather Cover and Gasket Figure 11 40 Breather...

Page 119: ...h if removed from lower housing earlier Install Intake Manifold If the thermostat and thermostat housing were removed from the intake manifold reassemble them at this time Figure 11 46 Installing Ther...

Page 120: ...t in Place Figure 11 50 Intake Manifold in Place 6 If the connector fitting for the by pass hose was removed from the manifold previously reinstall it at this time Apply pipe sealant with Teflon not T...

Page 121: ...ads Torque to 22 6 N m 200 in lb Connect the wire leads to the safety interlock switch and the temperature warning switch or audible alarm as equipped Figure 11 56 Temperature Switch Figure 11 57 Audi...

Page 122: ...e and position the tangs of the clamp parallel to those of the first clamp Figure 11 61 Tube and Second Clamp Installed 7 Holding the water pump in a raised position assemble the transfer tube to the...

Page 123: ...NOT loosen remove or alter the mounting position of this fitting at any time Contact the Factory Service Department for specific instructions if the fitting is damaged or its original mounting positio...

Page 124: ...of the pulley and the hose tube clamp assembly See Figure 11 68 Remove the pulley and reposition the tube or clamps if required Install the flat washer and hex flange screw to secure the pulley in pl...

Page 125: ...he blower housing See Figure 11 72 12 Attach the by pass hose to the fitting on the water pump and secure with the hose clamp The tangs of the clamp should point outward Completed installation should...

Page 126: ...nter Nut Figure 11 76 Rear Bracket Clamp Figure 11 74 Installing Clamp on Thermostat 6 Position the rubber mount assembly over the stud with spacer on the intake manifold Apply rubber lubricant to top...

Page 127: ...The lifting bracket must be on the bolt closest to the solenoid and should extend down and out 3 Slide the adjacent radiator support bracket under the heads of the starter bolts and behind the liftin...

Page 128: ...extensive engine damage but can also cause personal injury since broken fragments could be thrown from the engine Always observe and use the following precautions and procedures when installing the f...

Page 129: ...the ignition modules away from the flywheel as far as possible and tighten the four screws 3 Rotate the flywheel to position the magnet directly under one of the ignition modules 4 Insert a 0 36 mm 0...

Page 130: ...s in the locations closest to the intake manifold Torque all screws to 3 9 N m 35 in lb Figure 11 88 Torquing Spark Plugs Install Overflow Reservoir 1 Insert the two molded protrusions on the bottom o...

Page 131: ...stays aligned See Figure 11 91 Figure 11 91 1 Side Valve Cover 4 Install the other cover on the 2 side in the same manner 5 Torque the mounting screws of each cover in the sequence shown to 6 2 N m 5...

Page 132: ...ue the hex nut on the clamp screw to 9 9 N m 88 in lb See Figure 11 96 If after torquing no gap exists between the metal clamp surfaces replace the governor lever Figure 11 94 Installing Carburetor In...

Page 133: ...ivot lever on the main bracket to the appropriate hole in the governor lever as indicated in the following chart Note that the hole positions are counted outward from the governor shaft Governor Sprin...

Page 134: ...lement outside of the retainer Completed installation is shown in Figure 11 101 Recheck Governor Linkage Setting 1 Unhook the dampening spring and throttle linkage from the governor arm Remove the bla...

Page 135: ...t contacts the adapter then tighten the filter an additional 2 3 1 turn See Figure 11 104 Figure 11 105 Install Oil Drain Plug s NOTE Make sure that both oil drain plugs are installed and torqued to t...

Page 136: ...up the engine on a test stand Install an oil pressure gauge Kohler Part No 25 761 06 S is recommended Start the engine and check to be certain that oil pressure 20 psi or more is present Run for 5 10...

Page 137: ...ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 FOR SALES AND SERVICE INFORMATION IN U S AND CANADA CALL 1 800 544 2444 LITHO IN U S A FORM NO TP 2509 ISSUED 9 01 REVISED 5 04 MAILED 6 04...

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