Kohler Comand Pro CH1000 Service Manual Download Page 17

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1.13

Section 1

Safety and General Information

Valves and Valve Lifters

Hydraulic Valve Li

er to Crankcase Running Clearance ......................... 0.012/0.050 mm (0.0004/0.0019 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

............................................................................................................ 7.038/7.058

mm (0.2771/0.2779 in.)

Max. Wear Limit ....................................................................................... 7.135 mm (0.2809 in.)

Exhaust Valve Guide I.D.
New

............................................................................................................ 7.038/7.058

mm (0.2771/0.2779 in.)

Max. Wear Limit ....................................................................................... 7.159 mm (0.2819 in.)

Valve Guide Reamer Size

Standard .................................................................................................... 7.048 mm (0.2775 in.)

0.25 mm O.S. ............................................................................................. 7.298 mm (0.2873 in.)

Nominal Valve Face Angle ............................................................................ 45°

General Torque Values

Metric Fastener Torque Recommendations for Standard Applications

Tightening Torque: N·m (in. lb.) + or - 10%

Property Class

Noncritical

Fasteners

Into Aluminum

Size
M4

1.2 (11)

1.7 (15)

2.9 (26)

4.1 (36)

5.0 (44)

2.0 (18)

2.5 (22)

3.2 (28)

5.8 (51)

8.1 (72)

9.7 (86)

4.0 (35)

4.3 (38)

5.7 (50)

9.9 (88)

14.0 (124)

16.5 (146)

6.8 (60)

10.5 (93)

13.6 (120)

24.4 (216)

33.9 (300)

40.7 (360)

17.0 (150)

Tightening Torque: N·m (ft. lb.) + or - 10%

Property Class

Noncritical

Fasteners

Into Aluminum

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 (55)

131.5 (97)

184.4 (136)

219.7 (162)

94.9 (70)

5.8

8.8

10.9

12.9

4.8

5.8

10.9

12.9

4.8

8.8

Summary of Contents for Comand Pro CH1000

Page 1: ...SERVICE MANUAL HORIZONTAL CRANKSHAFT CH940 CH1000...

Page 2: ......

Page 3: ...on 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 Sectio...

Page 4: ......

Page 5: ...hould 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 R...

Page 6: ...and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the engine is hot o...

Page 7: ...decal or decals a xed to the engine shrouding See Figure 1 1 An explanation of these numbers is shown in Figure 1 2 Figure 1 1 Engine Identification Decal Location Figure 1 2 Explanation of Engine Id...

Page 8: ...clean fresh unleaded gasoline with a pump sticker octane rating of 87 R M 2 or higher In countries using the Research Octane Number RON it should be 90 octane minimum Leaded gasoline is not recommende...

Page 9: ...ection 6 Section 4 Section 6 Every 200 Hours Check spark plug condition and gap Section 7 Seasonally or Every 300 Hours Change oil filter Replace heavy duty air cleaner element Section 6 Section 4 Yea...

Page 10: ...1 6 Section 1 Safety and General Information Figure 1 4 Typical CH PRO Series Engine Dimensions with Heavy Duty Air Cleaner Dimensions in millimeters Inch equivalents shown in...

Page 11: ...327 60 41 2 378 119 80 4 717 ENGINE MOUNTING SURFACE MOUNTING HOLE A 418 22 16 465 LIFTING POINT 5 3 0 207 SPARK PLUG WIRE STEPPING MOTOR CONNECTOR 484 33 19 068 85 47 3 368 LIFTING POINT LIFTING POI...

Page 12: ...5 in lb Used Tapped Hole casting 7 3 N m 65 in lb New Extruded Hole sheet metal 4 0 N m 35 in lb Used Extruded Hole sheet metal 2 0 N m 18 in lb Mounting Clip valley ba e 2 5 N m 22 in lb M6 Screw Tor...

Page 13: ...rque Torque In Increments 11 3 N m 100 in lb Crankpin End I D 70 F New 44 030 44 037 mm 1 7334 1 7337 in Max Wear Limit 0 070 mm 0 0028 in Connecting Rod to Crankpin Running Clearance New 0 030 0 055...

Page 14: ...1 771 in O D Max Wear Limit 44 90 mm 1 767 in Max Taper 0 022 mm 0 0009 in Max Out of Round 0 025 mm 0 0010 in Connecting Rod Journal O D New 43 982 44 000 mm 1 731 1 732 in O D Max Wear Limit 43 97 m...

Page 15: ...160 mm 0 0027 0 0063 in Governor Gear Shaft O D New 5 990 6 000 mm 0 2358 0 2362 in Max Wear Limit 5 977 mm 0 2353 in Governor Lever Nut Torque 7 3 N m 65 in lb Ignition Spark Plug Type Champion or Eq...

Page 16: ...ed Bore Max 0 94 mm 0 037 in Piston Thrust Face O D New 89 953 89 967 mm 3 5414 3 5420 in Max Wear Limit 89 925 mm 3 540 in Piston Thrust Face to Cylinder Bore Running Clearance New 0 033 0 72 mm 0 00...

Page 17: ...d 7 048 mm 0 2775 in 0 25 mm O S 7 298 mm 0 2873 in Nominal Valve Face Angle 45 General Torque Values Metric Fastener Torque Recommendations for Standard Applications Tightening Torque N m in lb or 10...

Page 18: ...6 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 3 175 9 16 18 135 6 100 223 7 165 311 9 230 5 8 11 149 2 110 244 1 1...

Page 19: ...l K M Series To hold balance gears in timed position when assembling engine Kohler 25 455 06 S Formerly Y 357 Camshaft Endplay Plate For checking camshaft endplay SE Tools KLR 82405 Camshaft Seal Prot...

Page 20: ...nents Available CS PRO Regulator Test Harness Special Regulator Test Harness with Diode Design Technology Inc DTI 031 DTI 033 Spark Advance Module SAM Tester To test the SAM ASAM and DSAM on engines w...

Page 21: ...357 01 S 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...

Page 22: ...removing with a puller Figure 2 1 Flywheel Holding Tool Rocker Arm Crankshaft Tool A spanner wrench to lift the rocker arms or turn the crankshaft may be made out of an old junk connecting rod 1 Find...

Page 23: ...ne 4 Loose or faulty wires or connections 5 Faulty or misadjusted choke or throttle controls 6 Faulty spark plugs 7 Low compression 8 Weak spark 9 Fuel pump malfunction causing lack of fuel 10 Engine...

Page 24: ...eners Check the air cleaner cover and base for damage or indications of improper fit and seal Check the air cleaner element Look for holes tears cracked or damaged sealing surfaces or other damage tha...

Page 25: ...test the crankcase vacuum with the Vacuum Pressure Gauge Kit see Section 2 1 Remove the dipstick or oil fill plug cap 2 Install the adapter into the oil fill dipstick tube opening 3 Push the barbed fi...

Page 26: ...tool and crankshaft PTO If the flywheel end is more accessible use a breaker bar and socket on the flywheel nut screw to hold it in position An assistant may be needed to hold the breaker bar during...

Page 27: ...d remove the end caps Perform inspection of the paper element and inlet screen area Seasonally or every 300 hours of operation more often under extremely dusty or dirty conditions replace the paper el...

Page 28: ...r element See Figure 4 5 Element Precleaner Cover Knobs Air Cleaner Cover Element Latch Figure 4 5 Low Profile Air Cleaner Service Precleaner If so equipped wash and reoil the precleaner every 25 hour...

Page 29: ...ining knobs 9 When element replacement is necessary order genuine Kohler parts Air Cleaner Components Whenever the air cleaner cover is removed or the paper element or inner element are serviced check...

Page 30: ...4 4 Section 4 Air Cleaner and Air Intake System...

Page 31: ...chamber Fuel Recommendations General Recommendations Purchase gasoline in small quantities that can be used within 30 days and store only in clean approved containers Do not use gasoline left over fr...

Page 32: ...es not flow from the line check the fuel tank cap vent fuel pickup screen in line filter shut o valve and fuel line Correct any observed problem and reconnect the line 4 Check the operation of the fue...

Page 33: ...Figure 5 2 Optional Electric Fuel Pump Fuel Pump Replacement Replacing the Mechanical Fuel Pump The mechanical fuel pump is an integral part of the valve cover assembly and not serviced separately See...

Page 34: ...medy 1 Engine starts hard runs roughly or stalls at idle speed 1 Low idle fuel mixture some models speed improperly adjusted Adjust the low idle speed tab then adjust the low idle fuel needle 2 Engine...

Page 35: ...stable The idle fuel adjusting needles are also set at the factory and normally do not need adjustment NOTE Engines operating at altitudes above approximately 1219 m 4000 ft may require a special high...

Page 36: ...t counterclockwise from the preliminary setting until the engine speed decreases rich Note the position of the needle Now turn the adjusting needle in clockwise The engine speed may increase then it w...

Page 37: ...pically 300 RPM approximate higher than the low idle speed See Figure 5 10 Figure 5 9 Throttle Lever in Idle Position Figure 5 10 Setting Governed Idle Speed RPM Air Cleaner Removed For Clarity 5 Move...

Page 38: ...e a float kit to replace the float pin float valve clip and screw 1 Perform the removal procedures for the appropriate air cleaner and the carburetor outlined in Section 8 Disassembly 2 Clean the exte...

Page 39: ...r body Install the new pivot pin through the float hinge and secure with the new retaining screw See Figure 5 15 Retaining Screw Pivot Pin Figure 5 15 Installing Float Assembly 7 Hold the carburetor b...

Page 40: ...ving Float and Inlet Needle 3 Use an appropriate size flat screwdriver and carefully remove the two main jets from the carburetor Note and mark the jets by location for proper installation The main je...

Page 41: ...age Inspect the fuel inlet seat for wear or damage Check the spring loaded choke plate to make sure it moves freely on the shaft 7 Clean the carburetor fuel bowl as required 8 Install the two main noz...

Page 42: ...er and carburetor 2 Clean the areas around the choke shaft and the self relieving choke mechanism thoroughly 12 Attach the inlet needle to the plastic tang of the float with the wire clip The formed 9...

Page 43: ...the protruding boss on the carburetor housing is between the two stops formed in the choke lever See Figure 5 30 Boss Stops Figure 5 30 Assembling Choke Lever 8 Turn the old bushing upside down and u...

Page 44: ...t then tighten the screws securely Do not overtighten See Figure 5 34 Figure 5 34 Installing Choke Plate 12 Check for proper operation and free movement of the parts Install the new cap Always use new...

Page 45: ...de 8 Slow Jet LH Side 9 O ring Slow Jet 2 10 Fuel Bowl 11 O ring Fuel Bowl Upper 12 O ring Fuel Bowl Lower 13 Drain Screw 14 Bowl Screw 4 15 Fuel Solenoid 16 Sealing Washer 17 Float 18 Pin 19 Screw 20...

Page 46: ...by the regulating pin will again o set each other to hold a steady engine speed Adjustments NOTE Do not tamper with the governor setting Overspeed is hazardous and could cause personal injury General...

Page 47: ...irty oil causes premature engine wear and failure Oil Type Use high quality detergent oil of API American Petroleum Institute service class SG SH SJ or higher Select the viscosity based on the air tem...

Page 48: ...ure 6 4 Oil Drain Plug Starter Side The top portion of the symbol shows service class such as API SERVICE CLASS SJ The symbol may show additional categories such as SH SG CC or CD The center portion s...

Page 49: ...he new filter Partial prefilling of the oil filter is recommended 6 Install the new oil filter to the filter adapter or oil cooler Refer to instructions on the oil filter for proper installation Oil D...

Page 50: ...ean the underside After cleaning reinstall the oil cooler to the backing shroud with the two mounting screws Figure 6 10 Cleaning Top of Oil Cooler Oil Cooler Figure 6 11 Cleaning Underside of Oil Coo...

Page 51: ...to the switch the tester should indicate continuity switch closed 2 Gradually increase the pressure to the switch As the pressure increases through the range of 7 11 psi the tester should indicate a c...

Page 52: ...6 6 Section 6 Lubrication System...

Page 53: ...new plug as necessary Replace spark plugs every 600 hours To service the plugs perform the following steps 1 Before removing each spark plug clean the area around the base of the plug to keep dirt an...

Page 54: ...d and the gap will be greater than the specified gap Replace a worn spark plug immediately Wet Fouled A wet plug is caused by excess fuel or oil in the combustion chamber Excess fuel could be caused b...

Page 55: ...ventilated areas Keep 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 the negative g...

Page 56: ...agnet assembly which is permanently a xed to the flywheel Two electronic capacitive discharge ignition modules Figure 7 4 which mount on the engine crankcase A kill switch or key switch which grounds...

Page 57: ...cted Always provide a path for the spark to discharge to ground Reported ignition problems are most often due to poor connections Before beginning the test procedure check all external wiring Be certa...

Page 58: ...n of DSAI Ignition Systems DSAI Ignition System Explanation A digital spark advance ignition system DSAI is used on some models The DSAI ignition system is an advanced 12 volt version of the fixed tim...

Page 59: ...on tester Kohler Part No 25 455 01 S must be used to test ignition on these engines Use of any other tester can result in inaccurate findings The battery on the unit must be fully charged and properly...

Page 60: ...a good engine ground NOTE If two testers are available testing can be performed simultaneously for both cylinders However if only one tester is available two individual tests must be performed The sid...

Page 61: ...k that a proper ground is established between the ground black lead of the DSAI module closest to spark plug lead and a known good ground location on the engine 4 Turn the key switch to the ON positio...

Page 62: ...7 9 25 Amp Stator and 20 25 Amp Rectifier Regulator NOTE 20 amp charging systems use a 15 amp stator with a 25 amp rectifier regulator Figure 7 10 15 Amp Stator and Rectifier Regulator Figure 7 11 Wir...

Page 63: ...7 11 Section 7 Electrical System and Components 7 Figure 7 12 Wire Diagram 15 20 25 Amp Regulated Battery Charging System with Fixed Timing Five Pin Connector Key Switch and Fuse...

Page 64: ...7 12 Section 7 Electrical System and Components Figure 7 13 Wire Diagram 15 20 25 Amp Regulated Battery Charging System with DSAI Ignition Five Pin Connector and Key Switch...

Page 65: ...13 Section 7 Electrical System and Components 7 Figure 7 14 Wire Diagram 15 20 25 Amp Regulated Battery Charging System with DSAI Ignition and Four Pin Connector LP NG Kohler Power Systems Applicatio...

Page 66: ...ction 7 Electrical System and Components Figure 7 15 Wire Diagram 15 20 25 Amp Regulated Battery Charging System with DSAI Ignition and Five Pin Connector Gasoline LP NG Non Kohler Power Systems Appli...

Page 67: ...Disconnect all electrical connections attached to the rectifier regulator Testing may be performed with the rectifier regulator mounted or loose The figures show the part removed from the engine for c...

Page 68: ...n Make certain the connection location is clean and the clamp is secure 15 Amp Rectifier Regulators 1 Connect the tester ground lead with spring clamp to the body of the rectifier regulator being test...

Page 69: ...plied the charging system is OK and battery was fully charged If voltage is less than 13 8 or charge rate does not increase when load is applied test stator Tests 2 and 3 2 Remove connector from recti...

Page 70: ...inion and flywheel ring gear may clash resulting in damage to the starter NOTE If the starter does not crank the engine shut o the starter immediately Do not make further attempts to start the engine...

Page 71: ...orroded connections and tighten loose connections 2 Replace wires in poor condition and with frayed or broken insulation Starter Switch or Solenoid 1 By pass the switch or solenoid with a jumper wire...

Page 72: ...sembly containing the brush holder brushes springs and locking caps Remove the thrust washer from inside the commutator end See Figure 7 28 Figure 7 28 Removing Commutator End Plate Assembly 6 Remove...

Page 73: ...etail 11 Remove the retainer from the armature shaft Save the stop collar NOTE Do not reuse the old retainer Figure 7 33 Removing Retaining Ring 12 Remove the drive pinion assembly from the armature 1...

Page 74: ...s Armature 1 Clean and inspect the commutator outer surface The mica insulation must be lower than the commutator bars undercut to ensure proper operation of the commutator See Figure 7 36 Mica Insula...

Page 75: ...ed Starter Service Clean the drive lever and armature shaft Apply Kohler electric starter drive lubricant see Section 2 Versilube G322L or Mobil Temp SHC 32 to the lever and shaft Clean and check the...

Page 76: ...ever into the housing NOTE Correctly installed the center pivot section of the drive lever will be flush or below the machined surface of the housing which receives the backup washer See Figure 7 42 F...

Page 77: ...n the cutout of the frame See Figure 7 46 The protective tube may be saved and used for future servicing Figure 7 46 Installing Brush Holder Assembly with Supplied Tube Starter reassembly when not rep...

Page 78: ...ush lead 12 Install the two thru bolts and the two brush holder mounting screws Torque the thru bolts to 5 6 9 0 N m 49 79 in lb Torque the brush holder mounting screws to 2 5 3 3 N m 22 29 in lb See...

Page 79: ...onnection Only Figure 7 53 Testing Pull In Coil Plunger Actuation Test 2 Solenoid Pull In Coil Contact Continuity Test Use an ohmmeter set to the audible or Rx2K scale and connect the two ohmmeter lea...

Page 80: ...meter leads to the two large post terminals Perform the preceding test 3 and check for continuity See Figure 7 56 The meter should indicate continuity If no continuity is indicated the solenoid should...

Page 81: ...pply 3 Drain oil from crankcase and remove oil filter 4 Remove mu er 5 Remove cylinder shrouds and blower housing 6 Remove electric starter motor 7 Remove air cleaner assembly 8 Remove control bracket...

Page 82: ...llow ample time for the oil to drain from the crankcase Remove Muffler 1 Remove the exhaust system and attaching hardware from the engine Remove Cylinder Shrouds and Blower Housing 1 Remove the top mo...

Page 83: ...g the air cleaner and main control bracket to the intake manifold bosses See Figure 8 9 NOTE The low profile air cleaner is removed the same way as the heavy duty air cleaner Mounting Screws Figure 8...

Page 84: ...ining fuel 3 Remove the carburetor and linkages with choke return components as an assembly See Figure 8 14 Figure 8 14 Removing Carburetor 4 Remove the carburetor gasket 3 Carefully pry o the pal nut...

Page 85: ...es to the cylinder heads and backing shroud assembly Figure 8 16 Removing Valley Baffles 2 Remove the four screws securing each of the outer cylinder ba es in place Two of the screws are accessed fro...

Page 86: ...ousing and individual O rings to the adapter Carefully separate the parts See Figure 8 21 NOTE Further disassembly of the oil filter housing assembly is not required unless individual servicing must b...

Page 87: ...Remove Ignition Modules 1 Rotate the flywheel so the magnet is away from the modules 2 Remove the mounting screws and disconnect the kill lead from the ignition modules Note the position of ignition...

Page 88: ...ankcase and carefully separate the stator wires from the blower housing clips Mounting Screws Mounting Screws Figure 8 29 Removing Fan Remove Flywheel 1 Use a flywheel strap wrench or holding tool see...

Page 89: ...uel Pump WARNING Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from spark...

Page 90: ...ead Note the locations of washers and spacer See Figure 8 40 Washers Spacer Figure 8 40 Removing Cylinder Head Fasteners 3 Mark the position of the push rods as either intake or exhaust and cylinder 1...

Page 91: ...ark position Valve stem seals Figure 8 46 Valve Train Components Valve Stem Seals Valve Stem Seals Figure 8 47 Valve Stem Seals Figure 8 42 Removing Hydraulic Lifters Match Numbers Figure 8 43 Match N...

Page 92: ...cause damage resulting in leaks Note the assembly and orientation of parts See Figures 8 48 and 8 49 Breather Breather Adapter Figure 8 48 Removing Breather Assembly Breather Adapter Breather Adapter...

Page 93: ...ted to the inside of the closure plate If service is required refer to the service procedures under Oil Pump Assembly in Section 9 Remove Camshaft 1 Remove the camshaft and shim if used See Figure 8 5...

Page 94: ...nkshaft Removal of Governor Gear Assembly The governor gear is held onto the shaft by small molded tabs in the gear When the gear is removed from the shaft these tabs are destroyed and the gear must b...

Page 95: ...re 8 62 Baffle Some Baffle Some Models Only Models Only Gasket Gasket Cover Cover Screws Screws Figure 8 62 Removing Lifter Feed Chamber Cover Components Remove Flywheel and PTO End Oil Seals 1 Remove...

Page 96: ...8 16 Section 8 Disassembly...

Page 97: ...or additional information Measurement Guide TP 2159 B and Engine Inspection Data Record TP 2435 are also available use these to record inspection results Camshaft Inspection and Service Check the lobe...

Page 98: ...aces to make sure they are free of gasket fragments Gasket surfaces must also be free of deep scratches or nicks Inspect the main bearing if so equipped for wear or damage refer to Section 1 Specifica...

Page 99: ...easurements should be taken at three locations in the cylinder at the top middle and bottom Two measurements should be taken perpendicular to each other at each of the three locations Clean Cylinder B...

Page 100: ...r for cracks or damage Kohler does not provide the ring gear as a serviceable part Replace the flywheel if the ring gear is damaged Cylinder Head and Valves Inspection and Service After cleaning check...

Page 101: ...Valve Margin Min Valve Stem Diameter Dimension 89 30 8 5 mm 0 334 in 7 038 7 058 mm 0 2771 0 2779 in 38 625 38 685 mm 1 5206 1 5230 in 45 1 0 mm 0 0393 in 6 982 7 000 mm 0 2749 0 2756 in Intake Exhau...

Page 102: ...1000 hours under controlled test conditions Bad Condition The valve depicted here should be replaced Note the warped head margin damaged and too narrow These conditions could be attributed to excessi...

Page 103: ...on their condition Stem Corrosion Moisture in fuel or from condensation are the most common causes of valve stem corrosion Condensation occurs from improper preservation during storage and when engine...

Page 104: ...89 cutter as specified for the valve seat angle in Figure 9 6 Cutting the proper 45 valve face angle as specified in Figure 9 6 and the proper valve seat angle 44 5 half of the full 89 angle will ach...

Page 105: ...o stick which results in rapid wear A worn ring usually takes on a shiny or bright appearance Scratches on rings and pistons are caused by abrasive material such as carbon dirt or pieces of hard metal...

Page 106: ...gs on the piston place the top two rings each in turn in its running area in the cylinder bore and check the end gap See Figure 9 9 Compare the ring gap to the specifications listed in Section 1 Figur...

Page 107: ...n to ensure that correct replacements are used Hydraulic Lifters Inspection Check the base surface of the hydraulic lifters for wear or damage If the lifters need to be replaced apply a liberal coatin...

Page 108: ...d to the oil pump housing removal should not be attempted nor is internal servicing possible If a problem with the relief valve is encountered the oil pump should be replaced See Figure 9 15 Mounting...

Page 109: ...Tube Clamp and Screw Mounting Screws Figure 9 17 Installed Oil Pump and Pickup Tube 7 Install the clamp for the pickup tube and finger tighten the screw Check the alignment of the parts and torque the...

Page 110: ...Section 9 Inspection and Reconditioning 9 14...

Page 111: ...Install lifter feed chamber gaskets and cover 3 Install flywheel end main bearing 4 Install governor shafts seal and governor gear 5 Install crankshaft 6 Install connecting rods with pistons and ring...

Page 112: ...at of clean engine oil to the inner surface of the main bearing Figure 10 5 Installing Main Bearing 2 Apply a light coat of clean engine oil to the outside diameter of the oil seal 3 Install the oil s...

Page 113: ...r gear yoke into the crankcase first and position so the flat is up See Figure 10 11 Governor Governor Cross Shaft Cross Shaft Figure 10 11 Installing Governor Cross Shaft Notch Main Bearing Figure 10...

Page 114: ...yweight assembly in down onto the governor shaft until it locks into position Apply a small amount of grease to the locking tab thrust washer and install on top of the governor gear so the tang is fac...

Page 115: ...ston using a piston ring compressor 3 Lubricate the crankshaft journals and connecting rod bearing surfaces with engine oil 4 Make sure the FLY stamping on the piston is facing toward the flywheel sid...

Page 116: ...oved during servicing install a new bearing 1 Make sure the closure plate bore for the main bearing is clean dry and free of nicks or burrs 2 Install a new bearing with the notch in the 12 o clock pos...

Page 117: ...tall a new O ring in the closure plate See Figure 10 27 O ring Figure 10 27 O ring Installed 2 Install a new closure plate gasket onto the crankcase 3 Make sure the oil pump is installed and the oil p...

Page 118: ...ure Plate 6 Install the fourteen hex flange screws securing the closure plate to the crankcase Torque the fasteners in the sequence shown in Figure 10 31 to 24 4 N m 216 in lb Figure 10 30 Torquing Cl...

Page 119: ...Pins Gasket Gasket Figure 10 34 Installing Oil Reservoir Gasket 3 Install the oil reservoir onto the crankcase and temporary alignment pins The flywheel side is indicated on the cover Install and fing...

Page 120: ...properly aligned Figure 10 38 Breather Chamber and Gasket Figure 10 39 Breather Assembly Details Breather Hose Flange Nuts 4 Breather Gasket Screw Baffle Filter Adapter Gasket Studs 4 Filter Must Not...

Page 121: ...use a magnet See Figure 10 42 Figure 10 42 Installing Hydraulic Lifters NOTE Hydraulic lifters should always be installed in the same position as they were disassembled The exhaust lifters are located...

Page 122: ...of the cylinder head or the crankcase 2 Check that the dowel pins are in place in the two lower locations and install a new cylinder head gasket printed side up See Figure 10 47 Figure 10 47 Installi...

Page 123: ...fore disassembly 1 Note the mark or tag identifying the push rod as either intake or exhaust and cylinder 1 or 2 Dip the ends of the push rods in engine oil and install making sure that each push rod...

Page 124: ...he crankshaft to check for free operation of the valve train Check the clearance between the valve spring coils at full lift Minimum allowable clearance is 0 25 mm 0 010 in Install Valve Covers 1 Make...

Page 125: ...o the dowel pins of the oil filter adapter See Figure 10 59 O rings O rings O rings O rings Crankcase Adapter Figure 10 59 Installed O rings on Crankcase and Oil Filter Adapter 2 Install the oil filte...

Page 126: ...locked flange to flange and tighten each of the studs until bottomed tight Install Oil Filter Housing Assembly Reassemble the oil filter housing if disassembled previously Reassembly 1 Install the sm...

Page 127: ...the adapter and secure with the M8 hex head screw Make sure the housing is flat on the crankcase and all O rings remain in position Torque the screw to 24 4 N m 216 in lb Oil Filter Housing Mounting S...

Page 128: ...2 N m 55 in lb See Figure 10 73 4 Route the stator wires under the two molded clips in the backing shroud assembly See Figure 10 73 Mounting Screws Molded Clips Figure 10 73 Installing Stator 5 Check...

Page 129: ...ankshaft taper and the flywheel hub are clean dry and completely free of any lubricants The presence of lubricants can cause the flywheel to be over stressed and damaged when the hex flange screw is t...

Page 130: ...ble and snug the screws to hold them in that position Clamp Kill Lead Figure 10 81 Ignition Module Mounting Details 4 Rotate the flywheel to position the magnet directly under one ignition module 5 In...

Page 131: ...Torque the M6 screws going into the cylinder head and crankcase to 10 7 N m 95 in lb for new holes or 7 3 N m 65 in lb for used holes See Figure 10 84 Cylinder Baffle Mounting Mounting Screws Screws...

Page 132: ...ee Figure 10 87 3 Install the sti ener followed by the metal grass screen onto the four hex studs Secure with the four special washers and mounting screws using Loctite 243 Threadlocker on the threads...

Page 133: ...Return Spring and Bracket Choke Choke Lever Lever Figure 10 91 Choke Return Spring and Bracket Details 3 Connect the throttle and choke linkages to the carburetor if they were previously disconnected...

Page 134: ...4 Slide the air cleaner assembly onto the four carburetor mounting studs Align the two forward mounting holes in the base with the mounting holes bosses of the intake manifold and control bracket Atta...

Page 135: ...ull control cable actuation See Figures 10 99 and 10 100 1 Connect the choke linkage to the appropriate hole in the choke lever and secure with the small clip Linkages Connected Here A A Throttle Cont...

Page 136: ...t be toward the governor lever Make sure the springs do not contact the valley ba e See Figure 10 103 Governed Idle Governed Idle Spring Spring Governor Spring Governor Spring Figure 10 103 Governor S...

Page 137: ...e the screws to 4 0 N m 35 in lb for initial installations or 2 0 N m 18 in lb for reinstallations See Figure 10 108 Mounting Locations Cylinder Shrouds Figure 10 108 Installing Cylinder Shrouds Insta...

Page 138: ...E Make sure that both oil drain plugs are installed and torqued to the above specifications to prevent oil leakage Oil Drain Plug Location Starter Side Shown Figure 10 111 Reinstall Oil Drain Plugs 2...

Page 139: ...Lubrication System 4 Adjust the carburetor idle fuel needles or idle speed adjusting screw as necessary Refer to Section 5 Fuel System and Governor Testing the Engine It is recommended that the engin...

Page 140: ...10 30 Section 10 Reassembly...

Page 141: ......

Page 142: ...0 01 Rev A ISSUED 9 10 REVISED 3 11 FOR SALES AND SERVICE INFORMATION IN U S AND CANADA CALL 1 800 544 2444 KohlerEngines com ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 2011 by Kohler Co All rig...

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