Kohler COMMAND CH18-CH26 Service Manual Download Page 3

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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 5A. LPG Fuel Systems ...............................................................................................

Section 5B. Electronic Fuel Injection (EFI) Fuel System ......................................................

Section 6. Lubrication System ................................................................................................

Section 7. Retractable Starter .................................................................................................

Section 8. Electrical System and Components .....................................................................

Section 9. Disassembly ...........................................................................................................

Section 10. Inspection and Reconditioning ...........................................................................

Section 11. Reassembly ...........................................................................................................

Section 12. Clutch ....................................................................................................................

Summary of Contents for COMMAND CH18-CH26

Page 1: ...6 59 0 18 25 217 5 1 6 7 200 1 ...

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Page 3: ...on 5 Fuel System and Governor Section 5A LPG Fuel Systems Section 5B Electronic Fuel Injection EFI Fuel System Section 6 Lubrication System Section 7 Retractable Starter Section 8 Electrical System and Components Section 9 Disassembly Section 10 Inspection and Reconditioning Section 11 Reassembly Section 12 Clutch 2 1 8 9 10 11 12 4 5 6 7 3 5A 5B ...

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Page 15: ...e Hex Flange Nut Torque in Two Stages first to 16 9 N m 150 in lb finally to 33 9 N m 300 in lb Head Bolt Torque in Two Stages first to 22 6 N m 200 in lb finally to 41 8 N m 370 in lb Max Out of Flatness 0 076 mm 0 003 in Rocker Arm Screw Torque 11 3 N m 100 in lb Fan Flywheel Fan Fastener Torque 9 9 N m 88 in lb Flywheel Retaining Screw Torque 66 4 N m 49 ft lb Governor Governor Cross Shaft to C...

Page 17: ...H22 CH670 674 cc 79 831 mm 3 1430 in CH25 CH26 CH735 CH730 CH740 CH745 CH750 82 841 mm 3 2614 in Piston Thrust Face to Cylinder Bore Running Clearance New CH18 CH620 CH20 CH640 CH22 624 cc 0 014 0 057 mm 0 0005 0 0022 in CH22 CH670 CH23 CH680 674 cc 0 021 0 062 mm 0 0008 0 0024 in CH25 CH26 CH735 CH730 CH740 CH745 CH750 0 001 0 045 mm 0 039 0 0018 in Speed Control Bracket Fastener Torque 10 7 N m ...

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Page 24: ...ing or 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 a used connecting rod from a 10 HP or larger engine Remove and discard the rod cap 2 Remove the studs of a Posi Lock rod or grind off the aligning steps of a Command rod so the joint surface is...

Page 25: ... choke or throttle controls 4 Loose wires or connections that short the kill terminal of ignition module to ground 5 Faulty cylinder head gasket 6 Faulty carburetor 7 Vacuum fuel pump malfunction or oil in vacuum hose 8 Leaking cracked vacuum hose to fuel pump 9 Intake system leak 10 Diode in wiring harness failed in open circuit mode Engine Starts Hard 1 PTO drive is engaged 2 Dirt or water in th...

Page 26: ... Worn valve stems valve guides 7 Crankcase overfilled 8 Blown head gasket overheated Oil Leaks from Oil Seals Gaskets 1 Crankcase breather is clogged or inoperative 2 Breather reed broken 3 Loose or improperly torqued fasteners 4 Piston blowby or leaky valves 5 Restricted exhaust External Engine Inspection Before cleaning or disassembling the engine make a thorough inspection of its external appea...

Page 27: ...t at oil seals gaskets or other available spots Crankcase vacuum is best measured with either a water manometer or a vacuum gauge see Section 2 Complete instructions are provided in the kits To test the crankcase vacuum with the manometer 1 Insert the stopper hose into the oil fill hole Leave the other tube of manometer open to atmosphere Make sure the shut off clamp is closed 2 Start the engine a...

Page 28: ...cket on the flywheel nut screw to hold it in position An assistant may be needed to hold the breaker bar during testing If the engine is mounted in a piece of equipment it may be possible to hold it by clamping or wedging a driven component Just be certain that the engine cannot rotate off of TDC in either direction 4 Install the adapter into the spark plug hole but do not attach it to the tester ...

Page 29: ...aping from carburetor Defective intake valve improper seating Gauge reading in low green zone Piston rings and cylinder in good condition Gauge reading in moderate yellow zone Engine is still usable but there is some wear present Customer should start planning for overhaul or replacement Gauge reading in high red zone Rings and or cylinder have considerable wear Engine should be reconditioned or r...

Page 30: ...3 6 Section 3 Troubleshooting ...

Page 31: ...k the air cleaner daily or before starting the engine Check for and correct any buildup of dirt and debris along with loose or damaged components NOTE Operating the engine with loose or damaged air cleaner components could allow unfiltered air into the engine causing premature wear and failure Figure 4 3 Removing Knob Style Cover Precleaner Service If so equipped wash and reoil the precleaner ever...

Page 32: ...ard Type Every 100 hours of operation more often under extremely dusty or dirty conditions replace the paper element Follow these steps 1 Unhook the latches or loosen the retaining knob and remove the cover 2 Remove the wing nut element cover and paper element with precleaner if so equipped 3 Remove the precleaner if so equipped from the paper element Service the precleaner as described in Preclea...

Page 33: ...ecleaner element cover and wing nut 7 Reinstall the air cleaner cover and secure with the latches or the retaining knob NOTE Make sure the correct depth air cleaner element and rubber seal are used for the engine spec involved Some engines use a deeper or extra capacity air cleaner and a longer rubber seal Figure 4 8 Exploded View of Standard Air Intake System Components ...

Page 34: ...ures 4 9 and 4 10 Remove the bracket 3 Pinch the sealing collar on the breather hose and push it down through the hole in the air cleaner base Carefully feed the upper section of the breather tube down through the base See Figure 4 11 4 Remove the base and gasket 5 Reverse the procedure to reinstall new or serviced components Torque screws to 9 9 N m 88 in lb Heavy Duty Air Cleaner General The hea...

Page 35: ...e 4 12 Removal 1 Remove the upper valve cover screws on each side securing the main bracket and loosen the hose clamp on the adapter inlet or remove the adapter mounting screws 2 Lift the entire air cleaner assembly off the engine Disassemble or service as required Installation 1 Install the main mounting bracket with the center section up and the cutout around the carburetor aligning the mounting...

Page 36: ...conditions remove the blower housing and other cooling shrouds Clean the cooling fins and external surfaces as necessary Make sure the cooling shrouds are reinstalled Figure 4 15 Cleanout Kit Installed on Blower Housing Cleanout kits Kohler Part No 25 755 20 S black or 25 755 21 S gold are recommended to aid inspection and cleanout of the cooling fins See Figure 4 15 NOTE Operating the engine with...

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Page 60: ...ȱ Ğǰȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ Ĵ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱŘǯśȱ ȉ ȱǻŘŘȱ ǯȱ ǯǼǯ 7URXEOHVKRRWLQJ 3URFHGXUH QJLQH VWDUWV EXW ZLOO QRW FRQWLQXH WR UXQ ȱ ŗǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ Ĵ ȱ ǯ ȱ Řǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱǻ ȱ ȱ ȱ ȱ ȱ ȱ ȱ Ǽǯ ȱ řǯȱ ȱ ȱ ȱ ȱ ȱ ȱǻ ȱ Ǽǯ ȱ Śǯȱ ȱ ȱ ȱ ȱǻ ȱ Ǽǯ ȱ śǯȱ ȱ ȱ ȱ ȱ ȱ ǯ QJLQH GRHV QRW UXQ DW WKH H SHFWHG VSHHG ȱ ŗǯȱ ȱ ȱ ȱ ȱ ȱ Ĵ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯ ȱ Řǯȱ ȱ ȱ ȱ ȱ ȱǻ ȱ Ǽǯ ȱ řǯȱ ȱ ȱ ȱ ȱǻ ȱ Ǽǯ ...

Page 61: ...and special equipment Many states require special licensing or certification for LPG repair shops and or technicians Check state and local regulations before attempting any adjustment service or repair of the LPG system or components Faulty repairs by unqualified or underqualified personnel can have very serious ramifications The information in this segment is for the exclusive use of qualified LP...

Page 62: ...opening electrically preventing fuel flow to vaporizer 3 Fuel filter located inside lock off dirty or blocked 4 Insufficient vacuum signal regulator not opening a Vacuum line between carburetor and regulator cracked leaking kinked or pinched b Carburetor loose c Intake manifold loose or leaking d Excessive internal engine wear 5 Faulty regulator a Primary valve not opening b Diaphragm spring adjus...

Page 63: ... Check lines connections and system components for leaks with soapy water Fix any leaks immediately 2 Incorrectly set regulator or leakage from valves in regulator Readjust service or replace regulator as required 3 Dirty air cleaner or precleaner 4 Choke plate in carburetor not opening completely LPG Carburetor Adjustments General The LPG carburetor and regulator are designed to deliver the corre...

Page 64: ...sen or alter the mounted position of the clamping brackets and or stop collar on the throttle shaft Each is preset in correlation to a specific position of the throttle plate shaft or acts as a stop None of these attached components including the throttle plate or shaft requires disassembly or removal for any carburetor servicing All the components on the throttle shaft should be left intact If th...

Page 65: ...oving the three screws See Figure 5A 3 Carefully remove the cover and gasket Discard the gasket 4 The main jet is fixed and nonadjustable but may be accessed for cleaning by removing the rear plug and sealing washer Discard the washer 5 In order to clean the off idle transfer passages and carburetor thoroughly use a good carburetor cleaner and follow the manufacturer s instructions Blow clean comp...

Page 66: ...osition of each before proceeding Follow the complete instructions listed after step 7 then continue with steps 6 and 7 6 Manually move the governor lever toward the carburetor as far as it will go 7 Check that the throttle plate is now fully open or reposition the carburetor slightly on the mounting screws so it is fully open Torque the mounting screws to 9 9 N m 88 in lb Instructions for Checkin...

Page 67: ...y without binding or restriction Throttle Linkage Clamp Bracket Position Carburetor must be assembled to engine with linkage attached to set this position 1 The throttle linkage clamp bracket should be positioned as shown in Figure 5A 13 on the idle speed clamp bracket side of the throttle shaft Figure 5A 13 Throttle Linkage Clamp Bracket Position Figure 5A 10 Tightening Idle Speed Clamp Mounting ...

Page 68: ...the carburetor and new air cleaner base gasket 4 Reconnect the throttle and choke linkages and the fuel and vacuum lines 5 Reinstall the air cleaner base and breather tube Secure base with two mounting nuts Torque nuts to 9 9 N m 88 in lb Install the rest of the air cleaner system 6 Check to be sure all system connections are tight 7 Reset idle RPM and recheck high idle governed speed after starti...

Page 69: ...re and flow of fuel within the LP system It is comprised of both a primary and secondary chamber which are dependent upon one another Two different styles of regulators are used based upon the system involved The Impco Beam regulator is shown in Figure 5A 18 and the Nikki regulator is shown in Figure 5A 19 Although the basic design and operating principles are similar due to system differences the...

Page 70: ...rting adjustment is made with a tamper resistant screw 17 which regulates the whisker wire system not shown opening up the secondary orifice slightly but only when the vacuum diaphragm is drawn down Very little vacuum is needed to start this vacuum diaphragm travel 0 2 in Mercury to start and 0 5 in Mercury for full travel The instant the engine stops rotating loss of vacuum in section D releases ...

Page 71: ...ce between the secondary valve 11 and the valve seat 12 While the engine is operating and fuel is being drawn from the secondary chamber the secondary diaphragm 14 is raised by atmospheric pressure simultaneously lifting the secondary valve lever 16 opening the secondary valve 11 allowing fuel to flow When the engine is running at idle there may not be enough vacuum created in the carburetor ventu...

Page 72: ... any accumulated deposits See Figure 5A 23 4 Reinstall plug using pipe sealant with Teflon Loctite 592 or equivalent on threads and tighten securely If required a replacement plug is available as Kohler Part No X 75 23 S Regulator Service Every 1500 hours it is recommended that disassembly cleaning and resetting of the regulator be performed using the regulator rebuilding kit available Specific in...

Page 79: ... ȱ ȱ ȱ ȱ ǯ ȱ Řǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ Ĵ ȱ Ȧ ǯ ȱ řǯȱ ȱ ȱ ȱ ȱ ȱ Ǳ ȱ ȱ ǻ ȱ ȱ ȱ ȱś ǯŘŞǰȱś ǯřŗǰȱ ȱś ǯřŘǼǯ ȱ ȱ ȃřśȱ Ȅȱǻ ȱŗǯŝǼȱ Ȭ ȱ Ǳȱ ȱ ǻ Ǽȱ ȱ ȱ ȱǛŗŘȱ ȱ ǰȱ ȱ ȱǻ Ǽȱ ȱ ȱ ȱǛŘŝȱ ȱ ǯ ȱ ȃŘŚȱ Ȅȱǻ ȱŗǯŖǼȱ Ȭ ȱ Ǳȱ ȱ ǻ Ǽȱ ȱ ȱ ȱǛŞȱ ȱ ǰȱ ȱ ȱǻ Ǽȱ ȱ ȱ ȱǛŚȱ ȱ ǯ ȱ ȱ ȃřŘȱ Ȅȱǻ ȱŗǯŗǼȱ Ȭ ȱ Ǳȱ ȱ ǻ Ǽȱ ȱ ȱ ȱǛŞȱ ȱ ǰȱ ȱ ȱǻ Ǽȱ ȱ ȱ ȱǛŚȱ ȱ ǯ ȱ ȱ ȱ Ĵ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱŞŖŖȬŗŘŖŖȱ 7KURWWOH 9DOYH 6KDIW 5HVLVWRU 7UDFN LSHU UP Z ...

Page 80: ...ȃřŘȱ Ȅȱǻ ȱŗǯŗǼȱ Ȭ ȱ Ǳȱ ȱ ȱǛŞȱ ȱǛŚǯ ȱ ǯȱ ȱ ȱ ȱ ȱ ǯ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ Ĵ ǯ ȱ ǯȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ǯ ȱ ŝǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯ ȱ ȱ ǯȱ ȱ ȱ ȱ ǯ ȱ ȱ ǯȱ ȱ ȱ ȱȃ ȱ ȱȱ ȱ Ȅȱ ȱ ȱ ȱ ȱ ȱ ȱȱ ȱ ǯ 736 QLWLDOL DWLRQ 3URFHGXUH ȱ ȃřśȱ Ȅȱǻ ȱŗǯŝǼȱ Ȭ ȱ ȱ ȱ ȃŘŚȱ Ȅȱǻ ȱŗǯŖǼȱ Ȭ ȱ ȱ ȱ ŗǯȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ǰȱ ǰȱ ȱ ǰȱ ȱ Ĵ ȱ ȱ ȱ ȱ ȱ ȱ ę ǯ PSRUWDQW ȱ Řǯȱ Ȧ ȱ ȱ ȱ ȱ ȱ ȱǻ ǰȱ ǰȱ ȱ ȱ ǰȱ ǰȱ ...

Page 81: ... Ĵ ȱ ǯ ȱ ŗŖǯȱ ȱ ȱǻȬǼȱ Ĵ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯ ȱ ŗŗǯȱ ȱ ȱ Ĵ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ Ȃ ȱ ę ȱ Ĵ ȱ ȱ ȱ ȱ Ȭ ǰȱ Ȭ ȱ ȱ Ĵ ǯȱ ȱ ȱ ȱ ǯ 736 QLWLDOL DWLRQ 3URFHGXUH ȱ ȃřŘȱ Ȅȱǻ ȱŗǯŗǼȱ Ȭ ȱ ȱ ȱ ǻȃ Ȭ Ȅȱ Ǽ ȱ ŗǯȱȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ǰȱ ǰȱ ȱ ǰȱ ȱ Ĵ ȱ ȱ ȱ ȱ ȱ ȱ ę ǯ PSRUWDQW ȱ Řǯȱ Ȧ ȱ ȱ ȱ ȱ ȱ ȱ ȱǻ ǰȱ ǰȱ ȱ ȱ ǰ ȱ ȱ ǰȱ ę Ȭ ǰȱ ǯǼǯ ȱ řǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ Ȭ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱǛŘŚȱǻ ȱ Ǽȱ ȱ ȱ Ĵ ȱ ȱ ȱ ȱ ȱ ǻ ȱ Ǽǰȱ ȱ ȱ ȱ ȱ ȱ...

Page 82: ... ǰȱ ȱȱ ȱ ȱ ȱ ȱ Ȭ Ȧ Ȭ ěȱ ȱȱ ȱ ȱ ȱ ȱȃ Ȅȱ ȱ ȱ ȱ ǰȱȱ ȱ ǻ ȱ Ȭ Ȧ Ȭ ěȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱŘǯśȱ ȱ Ǽǯȱ ȱ ȱ ȱȱ ȱ ȱ ȱ ȱ ȱ ȱȃ Ȭ Ȅȱȱ ȱ ȱ ȱ ȱ Ȭ ǯȱ ȱ Ȭ ȱȱ ȱ ȱ ȱ ȱ Ğ ȱ ȱ ȱ ȱ ȱȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱȱ ȱ ȱ ȱ ǯȱ QJLQH 2LO 7HPSHUDWXUH 6HQVRU LJXUH QJLQH 2LO 7HPSHUDWXUH 6HQVRU HQHUDO ȱ ȱǻ Ǽȱ ȱ ȱǻ ȱś Ȭ ŗŖǼȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǰȱǻ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ Ǽǯȱ ȱ ȱ ȱ ȱę ȱ ȱ ǰȱ ȱ ȱ ȱ Ȭ ȱ ȱ ȱ ȱ ȱ ȱ ȱĚ ǯȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ...

Page 83: ...ȱ ȱ ȱ ȱ ȱ ȱ ȱȃ Ŷ ȱ ȱ ǯȄ 6HUYLFH ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ Ȭ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯ Ǳȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǰȱ Ȭ ǰȱ ȱ ȱ ȱ ȱ ȱ ǯ RQQHFWLRQ DEOH LVF 6SULQJ HUDPLF 6XSSRUW 7XEH 3URWHFWLYH 6OHHYH RQWDFW OHPHQW 6HQVRU RXVLQJ FWLYH HUDPLF 6HQVRU 3URWHFWLYH 7XEH LJXUH 2 JHQ 6HQVRU HQHUDO ȱ ȱ ȱ ȱ ȱ ȱ ȱ Ĵ ǰȱ ȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ě ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȃŘŚȱ Ȅȱǻ ȱŗǯŖǼȱ Ȭ ȱ Ǳȱ ȱ ȱ ȱǛŜȱ ȱǛŚȱ ...

Page 86: ...ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ǯ LJXUH 5HOD RQQHFWRU ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱȱ ȱ ȱ ȱ ȱ ǯ ȱ řǯȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱǛřŖȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ŗŘȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯ ȱ Śǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱǛŞśȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱȃ Ȅȱ ǯȱ Ĵ ȱ ȱ ȱ ȱ ǯ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱȱ ȱ ȱ ȱ ȱ ȱ ǯ ȱ ȱ ǯȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱȁȁ ěȂȂȱȱ ȱ ȱ ȱ ȱ ȱśȱ ȱ ȱ ȱ ǯ LJXUH 5HOD 7HUPLQDO HWDLOV ȱ śǯȱ ȱ ȱ ȱǻ ŗȱ Ǽȱ ȱ ȱ ǛŞśȱ ȱǛŞŜȱ ȱ ȱ ȱ ǯȱ ȱ ...

Page 91: ... ȱ ȱȃ Ȅȱǻ ȱ ȱ ȱ ȱ ȱ ȱ Ǽǰȱ ȱ ȱ ȱ ěȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ěȱ Ğ ȱŚȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ǯ 6HUYLFH ȱ ȱ ȱ ȱ Ȭ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱŝǯŖȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ǰȱ ȱ ȱ ȱŝǯŖȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯ LJXUH 3LQ 06 3ODVWLF DVHG 8 RQQHFWRU LJXUH 3LQ 06 3ODVWLF DVHG 8 RQQHFWRU ȱ ȱ ȱ ȱ ǰȱ ...

Page 98: ...HQ FROG ȱ ŗǯȱ ȱ ȱ ȱ ȱ Řǯȱ ȱ ȱ ȱ ȱ řǯȱ Ȧ ȱ ȱ ȱ Śǯȱȱ ȱ ȱ ȱ ȱ śǯȱ ȱ ȱ ȱ ȱ ȱ ȱ Ŝǯȱ ȱ ě ȱ ȱǻ Ǽ ȱ ŝǯȱ ȱ ȱ ȱ Şǯȱ ȱ ȱ ȱ ȱ şǯȱ ȱ ȱ ȱ ŗŖǯȱ ȱ ȱ ŗŗǯȱ ȱ QJLQH VWDUWV KDUG RU IDLOV WR VWDUW ZKHQ KRW ȱ ŗǯȱ ȱ ȱ ȱ ȱ Řǯȱ ȱ ȱ ȱ ȱ řǯȱ ȱ ȱ ȱ ȱ Śǯȱ Ĝ ȱ ȱ ȱ śǯȱ ȱ ě ȱ ȱǻ Ǽ ȱ Ŝǯȱ ȱ ȱ ȱ ȱ ȱ ŝǯȱ ȱ ȱ ȱ Şǯȱ ȱ ȱ ȱ ȱ ȱȱşǯȱ ȱ QJLQH VWDOOV RU LGOHV URXJKO FROG RU ZDUP ȱ ŗǯȱ ȱ ȱ ȱ ȱ Řǯȱ Ĝ ȱ ȱ ȱ ȱ řǯȱ ȱ ě ȱ ȱ Śǯȱ ȱ ȱ śǯȱ ȱ ȱ ȱ ȱ Ŝǯ...

Page 100: ... ş ŗŖ ŗŗ ŗŘ ŗř ŗŚ ŗś ŗŜ ŗŝ ŗŞ ŗş ŘŖ Řŗ ŘŘ Řř ŘŚ Řś ŘŜ Řŝ ŘŞ Řş řŖ řŗ řŘ řř řŚ řś RPSRQHQW ȱ ȱǛŗ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ Ř ȱ ȱ Ĵ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ Ĵ ȱ ȱ ȱ Ĵ ȱ ȱ ȱ ȱǛŘ ȱ ȱ ȱ ȱ ȱ ȱ Ĵ ȱ ȱ ȱ Ĵ ȱ ȱ Ȧ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ 3LQ 0 0HWDO DVHG 8 6 VWHPV ...

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Page 103: ...ŗŖ ŗŗ ŗŘ ŗř ŗŚ ŗś ŗŜ ŗŝ ŗŞ ŗş ŘŖ Řŗ ŘŘ Řř ŘŚ XQFWLRQ ȱ Ĵ ȱ ȱ ȱ ȱ Ĵ ȱ ȱ ȱǻ Ǽȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ Ĵ ȱ ȱ ȱǻ Ǽȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱǻ ȱ ȱ ȱ ȱ Ǽ ȱ Ĵ ȱ ȱ ȱ Ĵ ȱ ȱŗȱ ȱŘȱ ȱ ȱ ȱ ȱ ȱ ȱǻ Ǽ ȱ ȱ ȱǻ ȱ ȱ ȱ Ǽ ȱ ȱ ȱ ȱǛŗȱ ȱ ȱǛŘȱ ȱ ȱ 3LQ 06 3ODVWLF DVHG 8 6 VWHPV ...

Page 104: ... ŘŖ Řŗ ŘŘ Řř ŘŚ Řś ŘŜ Řŝ ŘŞ Řş řŖ řŗ řŘ XQFWLRQ ȱ Ĵ ȱ ȱ Ĵ ȱ ȱ ǲȱȃ Ȭ Ȅȱ ȱ Ĵ ȱ ȱ ȱǻ Ǽȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ Ĵ ȱ ȱ ȱǻ Ǽȱ ȱ ȱ ȱǻƸǼ ȱ ȱ ȱǻȬǼ ȱ ȱ ȱ ȱ ȱ ȱ ȱŗȱ ȱŘȱ ȱ ȱ ȱ Ĵ ȱ ȱ ȱ ȱ Ĵ ȱ ȱ ȱ Ĵ ȱ ȱǻ Ǽ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱǻ Ǽ ȱ ȱǛŗȱ ȱ ȱǛŘȱ ȱ ȱ 3LQ 06 3ODVWLF DVHG 8 6 VWHPV ...

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Page 108: ...U LUFXLW 1R FWLYLW H WHFWHG 1 1 1 3 6 VWHP WRR 5LFK 3 2 6HQVRU RQWURO DW 8SSHU LPLW 3 0D LPXP GDSWLRQ LPLW 5HDFKHG 3 0LQLPXP GDSWLRQ LPLW 5HDFKHG 3 7HPSHUDWXUH 6HQVRU LUFXLW 6KRUWHG WR URXQG 3 7HPSHUDWXUH 6HQVRU LUFXLW 2SHQ LUFXLW RU 6KRUW WR DWWHU 1 DLOXUH RPSOHWLQJ XWROHDUQ 736 2IIVHW EHORZ PLQLPXP DOORZDEOH OLPLW 1 1 1 DLOXUH RPSOHWLQJ XWROHDUQ 736 RIIVHW DERYH PD LPXP DOORZDEOH OLPLW 1 1 3 QMH...

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Page 110: ...ȱ ȱ ȱ ȱşȱ Ȧ ȱŗŖȱ ȱȱ ȱ ȱ ȱ ȱ ǯ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱǻ Ĵ ǰȱȱ ȱ ǰȱ ȱ ǰȱ ǰȱ ȱ ǰȱȱ ȱ ȱ Ǽǯ ȱ ȱ ǯȱ ȱ ȱşȱ Ȧ ȱŗŖȱ ȱ ȱ ȱȱ ȱ ȱ ȱǻ ǰȱ ȱ ȱ ǰȱ ȱȱ ȱ Ǽǯ ȱ Śǯȱ Ȧ ȱ ȱ ȱ ǯȱ Ȭ Ȭ ȱ ȱ ǯ ȱ śǯȱ ȱ ȱ ȱ ȱȱ ǯȱ Ȭ ȱ ȱ ǻ Ǽȱ ǯ Ǳȱ ȱ ȱ ŘŘ Ǳȱȱ ȱ Ĵ ȱ ȱ ȱǻ Ǽ Ǳȱ ȱ ȱ ȱ ȱ ȱȱ ȱ ȱ ȱ ȱ ȱǻ ȱ ǰȱ ȱ ǰȱȱ ȱ ȱ ȱ ȱ Ǽǯ ȱ Ǳȱ ȱ ȱȃ Ȭ Ȅȱ ȱ ȱȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱȱȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱȱ ȱ ȱ ȱ ȱ Ĝ ǯȱ ȱ ȱ ȱ ȱ ȱȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱę ȱ ȱȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱǻ ȱȱ ȱ ȱ ȱ Ǽȱȱ ȱ ȱ ȱȃ ...

Page 111: ... ǯ ȱ ȱ ȱ ǻ Ǽȱşȱ Ȧ ȱŗŖȱ ȱȃŘŚȱ Ȅȱǻ ȱŗǯŖǼȱȱ ȱ Ȭ ȱ ǯ ȱ ȱ ȱ ǻ Ǽȱşȱ Ȧ ȱŗŖȱ ȱȃřŘȱ Ȅȱǻ ȱŗǯŗǼȱȱ ȱ Ȭ ȱ ǯ ȱ Śǯȱ Ȧ ȱ ȱ ȱ ǯȱ Ȭ Ȭ ȱ ȱ ǯ Ǳȱ ȱ řŗ Ǳȱȱ ȱ ȱ ȱ ȱ Ǳȱ ȃ ȱ ȱ ǯȄȱ ȱ ȱ ȱȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ Ǳȱ ȱ ȱ ȱȃ ȱ Ȅȱȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱȱȱ ȱ ȱ Ĵ ȱ ǯȱ Ğ ȱ ȱ ȱ ǰȱȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱȱ ȱ ȱ ǯȱ ȱ ȱ ȱ Ĵ ȱ ǰȱȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱȱ ȱ ȱ ȱ ǰȱ ǰȱ ȱ ǯȱȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱȱ ȱ ȱ ǻ ǰȱ ȱ ȱ...

Page 112: ...ȱ ǯ ȱ ȱ ǯȱ ȱ ȱ ǯ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ǯ ȱ ȱ ȱ ȱŗŖȱ ȱȃřśȱ Ȅȱǻ ȱŗǯŝǼȱ Ȭ ȱȱ ȱ ǯ ȱ ȱ ȱ ȱŗŗȱ ȱȃŘŚȱ Ȅȱǻ ȱŗǯŖǼȱ Ȭ ȱȱ ȱ ǯ ȱ ȱ ȱ ȱŘŖȱ ȱȃřŘȱ Ȅȱǻ ȱŗǯŗǼȱ Ȭ ȱȱ ȱ ǯ ȱ řǯȱ ȱ ȱ ȱ ȱ ǯȱ Ĵ ȱ ȱ ȱ ȱ ȱ ȱȱȱ ȱ ȱ ȱȃ ǯȂȂ ȱ ȱ ǯȱ ȱ ȱ ȱ ǯ ȱ Śǯȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ě ȱ ȱ ȱ ȱ ȱ ȱȱ ȱ ǻ ȱ ȱŗŝȱ ȱ Ȭ ȱ ǰȱ ȱȱȱ ȱ ȱŘȱ ȱ Ȭ ȱ Ǽȱ ȱ ȱȱ ȱ ȱ ȱǻ ȱŚśȦŚś Ǽǯȱ ȱ śǯȱ ȱ ȱ ȱ ǯȱ ȱǻ ȱ ǰȱ ȱ ǰȱ ȱ ǯ ȱ ȱ ǯȱ ȱǻ ȱ Ȧ ǰȱ ǰȱ ȱ ǰȱȱ ȱ ȱȱ ǯ ȱ ȱ ǯȱ ȱ ȱǻ ȱ ȱ Ȧ ǰȱȱ ȱ ȱ ǰȱ Ĵ ȱ Ǽǯ...

Page 113: ...ǯ ȱ Řǯȱ ȱ ȱ ȱ ȱ ȃŘŚȱ Ȅȱǻ ȱŗǯŖǼȱ Ȭ ȱ Ǳ ȱ ȱ ǯȱ ȱ ȱŚǰȱŜȱ Ȧ ȱŚ ȱ ȱǻ ǰȱȱ ȱ Ǽȱ ȱ ȱ ȱ ȱ ȱǻ ǰȱȱ ȱ ǰȱ ǯǼǯ ȱ ȱ ǯȱ Ȭ Ȭ ȱ ȱ ǯ ȱ Řǯȱ ȱ ȱ ȱ ȱ ȃřŘȱ Ȅȱǻ ȱŗǯŗǼȱ Ȭ ȱ Ǳ ȱ ȱ ǯȱ ȱ ȱŚǰȱŜȱ Ȧ ȱǻŚ Ǽȱ ȱǻ ǰȱȱ ȱ Ǽȱ ȱ ȱ ȱ ȱ ȱǻ ǰȱȱ ȱ ǰȱ ǯǼǯ ȱ ȱ ǯȱ Ȭ Ȭ ȱ ȱ ǯ ȱ řǯȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱŗŝŜǚ ȱǻřśŖǚ Ǽȱȱ ȱ ȱ ȱ ǯ Ǳȱ ȱ ȱ Śřȱ ȱŚŚȱ ȈřŘȱ Ȉȱǻ ȱŗǯŗǼȱȱ ȱ ȱ ȱ ȱ ȱ Ȭȱ ȱ ȱȱ ȱ ȱ ȱ ȱ ȱ ǯ Ǳȱȱ ȱ ȱȃ Ȭ Ȅȱ ȱȱȱ ȱ ȱ ȱ ȱ ǰȱ Ĵ ȱ ȱ ȱ ȱȱ ȱ ȱ ȱ ȱ ǯ Ǳȱ ȱ ȱ ȱ ȱȃ...

Page 114: ...Ȉȱǻ ȱŗǯŗǼȱ Ȭȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯ Ǳȱȱ ȱ ȱǛŘȱ ȱ ǰȱ ȱ ȱȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ Ĵ ǯ Ǳȱ ȱǛŘȱ ȱ ȱ ȱ ȱȱ ȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ǰȱȱ ȱ ȱ ȱ ȱ ȱ ȱ Ĵ ǯ ȱ Ǳȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱȱ ȱ ȱ ȱ ȱ ȱ ǯ ȱ Ǳ ȱ ŗǯȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ǯ ȱ Řǯȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱȱ ȱ ŗśȱ ȱ ȱ ȱŘǯȱ ȱ ȱŘŞȱ ȱ ȱ ȱȱ ȱ ȱ ȱŞŜǯȱ Ǳȱ Ğ ȱ Ȭ ěȱ ȱ Ȭ ȱȱ ȱ ȱśŜȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱȱ ȱ ȱŞŝȱ ȱ ȱ ȱŗǯ ȱ ȱ ǯȱ ȱ ȱ ȱ ŗǯ ȱ řǯȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ǯ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱřŖȱ ȱ ȱŞŝȱȱ ȱ ȱ ǯ ȱ ȱ...

Page 115: ...ȱ ȱ ȱ ȱ ȱ ȱ ěǯ ȱ Ǳ ȱ ŗǯȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ǯ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯ ȱ Řǯȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ǯ ȱ řǯȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ŗȱ ǯ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ǯ ȱ ȱ ȱ ȱ ȱŘŞȱ ȱ ȱ ȱ ȱ ȱŞŜǯ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱŞśǯ ȱ Śǯȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ǯ Ǳȱ ȱ ȱ Ŝŗ Ǳ Ǳȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱȱ ȱ ȱ ȱ ȱę ǰȱ ȱ ȱ ȱ ȱ ȱȱ ȱ ȱ ȱ ǯ 7URXEOHVKRRWLQJ ORZ KDUW ȱ ȱĚ ȱ ȱǻ ȱ ȱś ǯŚŚǼȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱŗŖȬŗśȱ ǯȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱǻ ȱ Ğ ȱ ȱ ...

Page 116: ... 6HFWLRQ XHO 6 VWHP 2SHUDWH IRU DQ DSSURSULDWH SHULRG RI WLPH EDVHG XSRQ RULJLQDO IDXOW FRGHV LJXUH ...

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Page 118: ... Ȭ ȱ Ǳȱ ȱŘŞǰȱ Śŗǰȱ ȱŚŗ ǯȱ ȃŘŚȱ Ȅȱǻ ȱŗǯŖǼȱ Ȭ ȱ Ǳȱ ȱ ŗŞǰȱŞśǰȱřŖǰȱ ȱŞŝǯ ȱ ȱ ȃřŘȱ Ȅȱǻ ȱŗǯŗǼȱ Ȭ ȱ Ǳȱ ȱ ŘŞǰŞśǰȱřŖǰȱ ȱŞŝǯ ȱ řǯȱ ȱ Śǯȱ ȱ ȱ śǯȱ ȱ ȱǛŝȱȃ ȱ Ȅȱǻ ȱ Ǽ ȱ Ǳȱ ȱ ŗǯȱ ȱ ȱ Řǯȱ ȱ ȱ řǯȱ ȱ Śǯȱ ȱ ǻ Ǽ ȱ ȱ ȃřśȱ Ȅȱǻ ȱŗǯŝǼȱ Ȭ ȱ Ǳȱ ȱŗǰȱ ŗşǰȱŚŖǰȱŚŖ ǰȱŚřǰȱ ȱ ǯ ȱ ȱ ȃŘŚȱ Ȅȱǻ ȱŗǯŖǼȱ Ȭ ȱ Ǳȱ ȱ ŘŘǰȱŘřǰȱŜśǰȱŜŜǰȱřŖǰȱ ȱ ǯ ȱ ȱ ȃřŘȱ Ȅȱǻ ȱŗǯŗǼȱ Ȭ ȱ Ǳȱ ȱ řŖǰȱřŗǰȱŜśǰȱŜŜǰȱ ȱ ȱ ȱ ȱřŖǯ ȱ śǯȱ ȱ ȱ Ŝǯȱ ȱ ȱǛŞȱȃ ȱ Ȭ Ȅȱ ǻ ȱ ȱ Ǽ ȱ Ǳ ȱ ...

Page 124: ... 6HFWLRQ XEULFDWLRQ 6 VWHP ...

Page 125: ...ng leaving the five hex flange screws slightly loose 2 Pull the starter handle out until the pawls engage in the drive cup Hold the handle in this position and tighten the screws securely Rope Replacement The rope can be replaced without complete starter disassembly 1 Remove the starter from the blower housing 2 Pull the rope out approximately 12 in and tie a temporary slip knot in it to keep it f...

Page 126: ...ide the starter handle Untie the single knot and remove the rope retainer and handle 4 Hold the pulley firmly and untie the slipknot Allow the pulley to rotate slowly as the spring tension is released 5 When all spring tension on the starter pulley is released remove the rope from the pulley 6 Tie a single knot in one end of the new rope 7 Rotate the pulley counterclockwise when viewed from pawl s...

Page 127: ...ositions of the pawls and pawl springs before removing them Remove the pawls and pawl springs from the starter pulley Figure 7 5 Brake Spring and Washer Pawls and Pawl Springs 5 Rotate the pulley clockwise 2 full turns This will ensure the spring is disengaged from the starter housing 6 Hold the pulley in the starter housing Invert the pulley housing so the pulley is away from your face and away f...

Page 128: ...ll a new spring and keeper assembly 4 Clean all old grease and dirt from the starter components Generously lubricate the spring and center shaft with any commercially available bearing grease Reassembly 1 Make sure the spring is well lubricated with grease Place the spring and keeper assembly inside the pulley with spring towards pulley See Figure 7 7 2 Install the pulley assembly into the starter...

Page 129: ...clean dry and free of grease and oil 6 Apply a small amount of Loctite No 271 to the threads of the center screw Install the center screw with the washer and retainer to the center shaft Torque the screw to 7 4 8 5 N m 65 75 in lb 7 Tension the spring and install the rope and handle as instructed in steps 6 through 12 under Rope Replacement on page 7 2 8 Install the starter to the engine blower ho...

Page 130: ...7 6 Section 7 Retractable Starter ...

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Page 137: ... RU ODFN 6SDUN 3OXJ H 6ZLWFK RU µµ2II 3RVLWLRQ RI H 6ZLWFK 6SDUN GYDQFH 0RGXOH 9ROW DWWHU JQLWLRQ 0RGXOH O ZKHHO 0DJQHW PP LQ LU DS 6SDUN 3OXJ UHHQ KLWH LJXUH ORFN LDJUDP 6SDUN GYDQFH 0RGXOH Ǳȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱę ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱǻ Řǰȱ ȱŞȬśǼȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱǻ ȱŞȬŝǼǯȱ LJXUH DSDFLWLYH LVFKDUJH JQLWLRQ 6 VWHP ZLWK 6SDUN GYDQFH ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱĚ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯ ...

Page 138: ... ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯ ȱ ȱ ȱ ȱ ȱ Ğ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ Ȭ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ę ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯ Ǳȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ǰȱ ȱ ę ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ǯ 7HVW 3URFHGXUH IRU 60 57 63 5 70 JQLWLRQ 6 VWHPV ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ Ȭ Ȝȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǻ Ǽǯ 6SHFLDO 7RROV 5HTXLUHG ȱ Ȋȱ ȱ ȱ Ȋȱ Șȱǻ ȱ ȱŘǼ ȱ Ȋȱ ȱ ȱ ȱ ...

Page 142: ... ȱ ȱǻ Ǽȱ ȱ ǯȱŘŚȱśŞŚȱŗŞȱ ȱ ǯȱ ȱ Ȭ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱǻ Ǽȱ ȱ ȱ ȱŘśȱŝŜŗȱŚŖȬ ȱ ȱ ȱ ǯȱ ȱ ȱ ǯȱ ȱ ȱ ȱ Ĵ ȱ ȱ ȱ ȱ ǯȱȱ ȱ Ğ ȱ ȱ ȱ ǰȱ ȱȱ ȱ ȱ ȱ ȱ ȱ ȱ ǰȱȱ ȱ ȱ ȱŗȱ ȱŘȱ ȱ ȱ ȱȱŞȱ ȱȱ ȱ şǰȱ ȱ ȱ ȱ Ĵ ȱȃ Ȅȱǻ Ǽȱ ȱȃ Ȅȱǻ Ǽǯȱȱ ȱ ȱ ȱŞȬŗŗȱ ȱŞȬŗŘǯȱ ȱ ȱ ȱȱ ȱ ȱ ȱ Ĵ ȱ ȱ ȱ ȱ ȱ ȱȱ ȱ ȱ ȱ ȱ ȱ ěȘǯȱ ȱ ȱ ȱ ȱȃȬȄȱ ȱȱ ȱ ȱ ȱ ȱ ȱ ǰȱ Ȧ ȱȱ ȱ ȱȱȃ Ȅȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ǰȱȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ Ĵ ȘȘȱ ȱȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱȃȬȄ ȱ Ȧ ȱȱ ȱ ȃ...

Page 148: ...RUV DWWHU KDUJLQJ 6 VWHP HQHUDO ȱ ȱ ȱ ȱ ȱ ȱŗśȱ ȱŘŖȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱŘśȱ ȱ ȱ ȱ ǯȱ ȱ ȱŞȬŘřǰȱŞȬŘŚȱ ȱŞȬŘśȱ ȱ ȱŗśȦŘŖȦŘśȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱřȱ ȱ ȱ ȱ ȱ ȱŝŖȱ Ĵȱ ȱ ǯȱ ȱ ȱ ȱŞȬŘŜǯ Ǳȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ Ǳ Ȋȱ ȱ ȱ ȱ ȱ Ĵ ȱ ȱ ȱ ǯȱ ȱ ȱǻȬǼȱ ȱ ȱ ȱ ǯ ȱ Ȋȱ ȱ ȱ ę Ȭ ȱ ȱ Ȧ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯ ȱ Ȋȱ ȱ ȱ ȱǻ Ǽȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ǯ PS 5HJXODWHG KDUJLQJ 6 VWHP ...

Page 149: ... 6HFWLRQ OHFWULFDO 6 VWHP DQG RPSRQHQWV LJXUH LULQJ LDJUDP PS 5HJXODWHG DWWHU KDUJLQJ 6 VWHP ZLWK L HG 7LPLQJ ...

Page 150: ... 6HFWLRQ OHFWULFDO 6 VWHP DQG RPSRQHQWV LJXUH LULQJ LDJUDP PS 5HJXODWHG DWWHU KDUJLQJ 6 VWHP ZLWK 6PDUW 6SDUN ...

Page 151: ... 6HFWLRQ OHFWULFDO 6 VWHP DQG RPSRQHQWV LJXUH LULQJ LDJUDP PS 5HJXODWHG DWWHU KDUJLQJ 6 VWHP ZLWK 6 JQLWLRQ DQG H 6ZLWFK ...

Page 152: ...Q 0RGXOHV 6SDUN 3OXJ 5HG OXH 5 6 1 LJKW 2SWLRQDO XVH 2SWLRQDO PPHWHU 6SDUN 3OXJ LJKWLQJ HDG HOORZ KDUJLQJ HDG ODFN LRGH LJKWLQJ 6WDWRU PS KDUJLQJ 6WDWRU PS 8QUHJXODWHG KDUJLQJ 6 VWHP LJXUH LULQJ LDJUDP PS 8QUHJXODWHG DWWHU KDUJLQJ 6 VWHP DWW LJKWLQJ LJXUH PS DWW 6WDWRU 6WDWRU ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱĚ ǯȱ ȱ ȱ ȱ ȱ ȱşȱȬȱȃ Ȅȱ ȱ ȱŗŗȬȃ Ȅȱ ȱ ȱ ȱ ȱ ǯ 5HFWL HU 5HJXODWRU ȱ ę Ȭ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱŞȬŘŞǯȱ ȱ ȱ ǰȱ ȱ ȱ ǻ...

Page 155: ...ȱŞȬřŖǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯ ȱ Ŝǯȱ ȱ ȱȁȁ ȂȂȱ Ĵ ȱ ȱ ȱȃ Ȅȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱŞȬřŗǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯ ȱ ȱ ǯȱ ȱ ȱȃ Ȅȱǻ Ǽȱ ȱ ȱ ǰȱ ȱȱ ȱ ȱ ȱ ȱ ȱ Ĵ ȱ ȱ ȱ ȱ ǰȱȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱȱ ȱ ȱ ȱ ǯȱ ȱ ȱȃ Ȅȱ ȱǻ Ǽȱ ȱȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ Șȱ ȱ ȱ ȱ ȱȱ ȱ ǰȱ ȱ ę Ȭ ȱ ȱ ȱ ȱȱ ȱ ȱ ȱ ȱ ȱ ǯ Ș Ǳȱ ȱĚ ȱȃ Ȅȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯ PS 8QUHJXODWHG 5HFWL HUV ȱ ŗǯȱ ȱ ȱ ȱ ȱ ȱǻ ȱ ȱ Ǽǰȱ...

Page 156: ... PPHWHU DWWHU ȱ Śǯȱ ȱ ȱȁȁ ȂȂȱ Ĵ ȱ ȱ ȱȃ Ȅȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱŞȬřŗǯȱ ȱ ȱ ȱ ȁȁ ȂȂǰȱȁȁ ȂȂǰȱ ȱȁȁ ȂȂȱ ȱ ȱĚ ǯ ȱ ȱ ǯȱ ȱ ȱȃ Ȅȱ ȱĚ ȱ Ȧ ěǰȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ Șȱ ȱ ę ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯ Ș Ǳȱ ȱĚ ȱȃ Ȅȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯ LJXUH RQQHFWLRQV IRU 7HVWLQJ KDUJLQJ 6 VWHP ...

Page 157: ...ȱŘŞȱ ȱ ȱ ǰȱ ȱ ȱ ǯȱ ę Ȭ ȱ ȱ ǯȱ ȱ ȱ ę Ȭ ǯ ȱ ȱ ȱ ȱ ȱ ȱ ȱŘŞȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱǻ ȱřǼǯ 1R KDUJH WR DWWHU ȱř ǯȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯ ȱř ǯȱ ȱ ȱ ȱŖǯŖŜŚȦŖǯŘȱ ǰȱ ȱ ȱ ȱ ǯ ȱ ȱ ȱ ȱ ȱ ȱ ę ȱ ǰȱ ȱ ȱ ǯȱ ȱ ǯ ȱř ǯȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯ ȱř ǯȱ ȱ ȱ ȱ ȱ ę ȱ ȱǻ ȱ Ǽǰȱ ȱ ȱ ȱ ȱǻ ȱ ȱ ȱ Ǽǯ ȱ ȱ ȱ ȱǻ ȱ Ǽȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ǯ ȱ ŗǯȱ ȱ ȱ ȱ ȱŗŚǯŝȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ Ĵ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ Ĵ ȱ ȱ ȱ ȱ ǯ ȱ ...

Page 158: ...ǰȱ ȱ ȱ ȱ ǯ ȱ ȱ ȱ ȱ ȱŗŘǯśȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ǻ ȱŘǰȱřȱ ȱŚǼǯ ȱ Řǯȱ ȱ ȱ ȱŘŞȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ǯ ȱ ȱ ȱ ȱ ȱ ȱ ȱŘŞȱ ǰȱ ȱ ȱ ȱ ȱ ȱǻ ȱřȱ ȱŚǼǯ ȱ řǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ǯ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱǻ ȱ ȱŚǯǼ ȱ Śǯȱ ȱ ȱ ȱ ȱŗǯŖŝȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ǯ ȱ ȱ ȱ ȱ ȱŖȱ ǰȱ ȱ ȱ ȱ ǯȱ ȱ ǯ ȱ ȱ ȱ ȱ ȱ ę ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ǯ ȱ ŗǯȱ ȱ ȱ ȱ ǯ ȱ Řǯȱ ȱ ȱ ȱŗśȱ ȱ ȱ ǰȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯ ȱ ȱ ȱ ȱ ȱ ȱ ȱŗśȱ ǰȱ ȱ ȱ...

Page 163: ... 6WXG 7HUPLQDO ZLWK 3RVLWLYH UXVKHV UXVK 6SULQJV UXVK ROGHU 1HJDWLYH UXVK 6HOI 7DSSLQJ 6FUHZ 6KHHW 0HWDO UXVK ROGHU 7RRO UXVK ROGHU 7RRO QVWDOOHG 2YHU UXVKHV DQG QG DS Ǳȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ŞȬŚŚǯ LJXUH 6W OH µµ RPPXWDWRU QG DS ZLWK UXVKHV LJXUH UXVK ROGHU 7RRO 6W OH µµ QG DS 6W OH µµ QG DS UXVK 5HSODFHPHQW ȱ ȱ ȱȁȁ ȂȂȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ...

Page 164: ...XVKHV ȱ Ŝǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯ ȱ ŝǯȱ ȱ ȱ ȱ Ğȱ ȱ ȱ ȱ ȱ ȱ ȱǻ ȱ ȱŘǼǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯ 6ROHQRLG 6KLIW OHFWULF 6WDUWHUV ȱ ȱ ȱ ȱ ȱ ȱ Ğȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ Ȭ ȱ ȱ Ğȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱę ǰȱ ȱ ȱ Ȭ ȱ ȱ ȱ ǯ 2SHUDWLRQ 6ROHQRLG 6KLIW 6WDUWHU ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ Ğȱ ȱ ȱ ȱ ȱ ȱĚ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ Ğȱ ȱ ȱ ȱĚ ȱ ȱ ȱ ȱ ǯ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ǰ...

Page 166: ...5HPRYLQJ 6ROHQRLG 6FUHZV ȱ řǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ŞȬśŖȱ ȱŞȬśŗǯ Ǳȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱŞǯŚŚȱ ȱŞǯŚśǯ LJXUH 6ROHQRLG 5HPRYHG IURP 6WDUWHU LJXUH 5HPRYLQJ 3OXQJHU ȱ Śǯȱ ȱ ȱ ȱ ȱǻ Ǽȱ ǯȱ ȱ ȱȱ ŞȬśŘǯ ...

Page 167: ... ȱ ȱ ȱ ȱ ȱ ȱ ȱ Ğǯȱ ȱ ȱŞȬśŜǯ LJXUH UPDWXUH DQG HYHU 5HPRYHG LJXUH 5HPRYLQJ 7KUX ROWV ȱ śǯȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ǰȱ ǰȱ ǰȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱŞȬśřǯ LJXUH 5HPRYLQJ RPPXWDWRU QG 3ODWH VVHPEO ȱ Ŝǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱŞȬśŚǯ LJXUH 6WDUWHU UDPH 5HPRYHG ȱ ŝǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱŞȬśśǯ ...

Page 168: ...H 3OXJ 6ROHQRLG UDPH LHOG UXVK ROGHU 1XW UDPH 6FUHZ ROW 7XEH ŗŖǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱŞȬśŝǯ LJXUH 5HWDLQLQJ 5LQJ HWDLO ȱ ŗŗǯȱ ȱ ȱ ȱ ȱ ȱ ȱ Ğǯȱ ȱ ȱ ȱ ǯ Ǳȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯ LJXUH 5HPRYLQJ 5HWDLQLQJ 5LQJ ŗŘǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯ ŗřǯȱ ȱ ȱ ȱ ȱ ǯ Ǳȱȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ Ğȱ ǰȱ ȱ ȱ ȱ ǯ LJXUH HOFR 5HP 6WDUWHU ...

Page 170: ... ȱ ǰȱ ȱ ǰȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ǯ 6WDUWHU 6HUYLFH ȱ ȱ ȱ ȱ ȱ ȱ Ğǯȱ ȱ ȱ ȱ ȱ ȱ ȱǻ ȱ ȱŘǼȱ ǻ ȱ řŘŘ ȱ ȱ ȱ ȱ ȱřŘǼȱ ȱ ȱ ȱ ȱ Ğǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯ 6WDUWHU 5HDVVHPEO ȱ ŗǯȱ ȱ ȱ ȱǻ ȱ ȱŘǼȱ ȱ ȱ ȱ Ğȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ Ğǯ ȱ Řǯȱ ȱ ȱ ȱ ȱ ȱ Ȧ ȱ ǯ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱȱ ȱ Ğȱ ȱ ȱ ȱ ȱǻ Ǽȱ ǯ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱǻ Ǽȱȱȱ ȱ ȱ ȱ ȱ ȱ Ğǯȱ ȱ ȱ ȱȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱȱ ȱ ȱ ȱ ǯȱ ȱ ...

Page 172: ... ȱ ȱ ȱ ȱ ȱȱ ȱ ȱ ǯ LJXUH QVWDOOLQJ UXVK ROGHU VVHPEO ZLWK 6XSSOLHG 7XEH ȱ ȱ ȱ ȱ ȱ ȱ Ȧ ȱ ȱ Ǳ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ǯ LJXUH 5HPRYLQJ 5HWDLQLQJ OLSV ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱĚ ȱ ȱ ȱ ǯ ǯȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱǻ ȱ Ǽǰȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱȃ Ȧ ǯȄ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱŞȬŝřǯ LJXUH UXVK QVWDOODWLRQ 7RRO ZLWK WHQVLRQ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ...

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Page 177: ...anufacturer s instructions 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 the lubricating properties of engine oil Typical Disassembly Sequence The following sequence is suggested for complete engine disassembly The sequence can be varied to accom...

Page 178: ...9 3 Removing Oil Fill Cap from Cover Figure 9 6 Removing Oil Filter Adapter Nipple Figure 9 4 Removing Oil Drain Plug 2 Allow ample time for the oil to drain from the crankcase and oil filter Figure 9 5 Removing Oil Filter 3 Remove and discard the oil filter See Figure 9 5 ...

Page 179: ...Assembly Standard Air Cleaner 1 Unhook the latches or loosen the knob and remove the cover Refer to Section 4 2 Remove the wing nut from the element cover 3 Remove the element cover the air cleaner element with precleaner and the stud seal Figure 9 8 Removing Air Cleaner Base Retainer Figure 9 9 Rear Air Cleaner Bracket Screws 5 Remove the bracket then remove the base and gasket while carefully pu...

Page 180: ...ipped Do not lose any of the hardware See Figure 9 13 Mounting Nuts Breather Hose Figure 9 13 Air Cleaner Bracket Mounting Screws Two Barrel Model Pictured 4 Remove the heavy duty air cleaner as an assembly from the engine See Figure 9 14 Mounting Screws Figure 9 14 Removing Heavy Duty Air Cleaner Assembly Two Barrel Model Pictured Remove Fuel Pump WARNING Explosive Fuel Gasoline is extremely flam...

Page 181: ...acket or to the blower housing See Figure 9 18 The fuel pump body may be metal or plastic Figure 9 18 Removing Screws Holding Fuel Pump Metal Bodied Pump Shown 4 Note or mark the orientation of the fuel pump then remove the fuel pump with lines attached as shown in Figure 9 19 Figure 9 19 Remove Fuel Pump and Lines Mechanical Fuel Pump The mechanical style fuel pump is part of the valve cover asse...

Page 182: ...ing Choke Linkage from Actuator Lever Figure 9 21 Removing Control Bracket Figure 9 20 Mechanical Fuel Pump Remove Control Panel If So Equipped 1 Disconnect the Oil Sentry Indicator Light wires 2 Disconnect the choke control cable from the control bracket 3 Disconnect the throttle control cable or shaft 4 Remove the panel from the blower housing Remove Throttle Choke Controls 1 Remove the four hex...

Page 183: ...oline as a cleaning agent 1 Disconnect the fuel shut off solenoid lead and ground lead if equipped See Figure 9 26 Figure 9 28 Removing Carburetor Assembly with Governor Lever Attached 4 Remove the carburetor gasket Figure 9 26 Remove Ground Lead Two Barrel Model Pictured Ground Lead 2 One Barrel Carburetor Models Only Remove the two carburetor mounting screws See Figure 9 27 Two Barrel Carburetor...

Page 184: ... two hex flange screws See Figure 9 30 5 If necessary the carburetor throttle linkage and governor lever can be separated Reattach the bushings to the linkage following separation to avoid losing them Remove Oil Sentry If So Equipped 1 Disconnect the lead from the Oil Sentry switch 2 Remove the Oil Sentry switch from the breather cover See Figure 9 29 Figure 9 31 Disconnecting Plug from Rectifier ...

Page 185: ...gure 9 35 6 On engines equipped with a metal grass screen remove the screen before removing the blower housing See Figure 9 36 Plastic grass screens can be removed after the blower housing is removed Figure 9 34 Note Location of Two Short Screws Figure 9 36 Removing Metal Grass Screen 7 Remove the lower blower housing screw and washer securing the rectifier regulator ground lead or grounding strap...

Page 186: ...it could cause damage resulting in leaks Most engines use a formed gasket rather than RTV sealant Figure 9 38 Removing Blower Housing Remove Inner Baffles and Breather Cover The inner valley baffles are attached at one corner using the same fasteners as the breather cover See Figure 9 39 1 Remove the two hex flange screws securing the inner baffles Figure 9 37 Debris Shield Details Two Barrel Carb...

Page 187: ...latest design uses a brown O Ring and the bolt holes spacers are molded in place 1 Remove the four hex flange screws securing each valve cover Note the position of any attached brackets or lifting straps 2 Remove the valve covers valve cover gaskets or O Rings and any brackets or lifting straps Note which side of the engine has the oil fill and or fuel pump valve cover See Figure 9 45 Figure 9 41 ...

Page 188: ...ng the intake manifold to the cylinder heads Note which screws hold the wiring clamps 2 Remove the intake manifold and the intake manifold gaskets aluminum intake manifolds or O Rings plastic intake manifolds See Figure 9 48 Figure 9 48 Removing Intake Manifold Aluminum Intake Manifold Plastic Intake Manifold Remove Ignition Modules 1 Disconnect the lead s from each ignition module See Figure 9 46...

Page 189: ... hex flange screws or hex flange nuts and washers on studs Do not interchange or mix components as the cylinder heads may have different machining unique to each fastening method 1 Remove the four hex flange screws or hex nuts and washers securing each cylinder head See Figure 9 51 Discard the screws or nuts and washers once removed Do not reuse Studs if present should only be removed if damaged o...

Page 190: ...Hydraulic lifters should always be reinstalled in the same position See Figures 9 53 and 9 54 NOTE The exhaust lifters are located on the output shaft side of the engine while the intake lifters are located on the fan side of the engine The cylinder head number is embossed on the outside of each cylinder head See Figure 9 55 Figure 9 54 Mark Position of Hydraulic Lifters Figure 9 55 Match Marks on...

Page 191: ...lves mark position Valve stem seals intake valve only Valve Retainer Spring Keepers Cap Valve Seal Figure 9 59 Intake Valve Seal Location NOTE These engines use valve stem seals on the intake valves Use a new seal whenever valve is removed or if the seal is deteriorated in any way Never reuse an old seal 4 Repeat the above procedure for the other cylinder head Do not interchange parts from one cyl...

Page 192: ...ywheel to become cracked or damaged Figure 9 62 Removing Flywheel Fastener Using Strap Wrench 2 Remove the hex flange screw and washer 3 Use a puller to remove the flywheel from the crankshaft See Figure 9 63 NOTE Always use a flywheel puller to remove the flywheel from the crankshaft Do not strike the crankshaft or flywheel as these parts could become cracked or damaged Striking the puller or cra...

Page 193: ...See Figure 9 65 Note the routing of the stator lead in the channel Figure 9 65 Removing Stator Remove Closure Plate Assembly 1 Remove the ten hex flange screws securing the closure plate to the crankcase See Figure 9 66 2 Locate the three splitting tabs that are cast into the perimeter of the closure plate Insert the drive end of a 1 2 breaker bar between the top splitting tab and the crankcase Ho...

Page 194: ... end cap Remove the end cap See Figure 9 70 Figure 9 71 Mark End Cap with Cylinder Number Before Removal NOTE The cylinders are numbered on the crankcase Use the numbers to mark each end cap connecting rod and piston for reassembly Do not mix end caps and connecting rods Figure 9 72 Removing Piston Connecting Rod Assemblies 2 Carefully remove the connecting rod and piston assembly from the cylinde...

Page 195: ...shaft from the crankcase See Figure 9 73 Note thrust washers and shims if used Figure 9 75 Removing Governor Cross Shaft Retainer 8 mm Shaft Design 2 Pull the cross shaft with small washer out through the inside of the crankcase See Figure 9 76 Figure 9 74 Removing Governor Cross Shaft Hitch Pin 6 mm Shaft Design Figure 9 76 Pulling Governor Cross Shaft Remove Flywheel End Oil Seal 1 Remove oil se...

Page 196: ...9 20 Section 9 Disassembly ...

Page 197: ...easurement Guide TP 2159 B and Engine Inspection Data Record TP 2435 are also available use these to record inspection results Automatic Compression Release ACR Some engines are equipped with the optional Automatic Compression Release ACR mechanism The ACR lowers compression at cranking speeds to make starting easier Operation The ACR mechanism consists of a flyweight spring and pivoting control p...

Page 198: ... with a flat washer into the drilled hole The flat washer must be large enough to seat against the shoulder of the plug bore See Figure 10 2 3 Tighten the self tapping screw until it draws the plug out of the crankshaft Procedure to Install New Plug 1 Use a single cylinder camshaft pin Kohler Part No 47 380 09 S as a driver and tap the plug into the plug bore until it seats at the bottom of the bo...

Page 199: ... a drill speed of about 250 RPM and 60 strokes per minute After installing coarse stones in hone proceed as follows 1 Lower hone into bore and after centering adjust so the stones are in contact with the cylinder wall Use of a commercial cutting cooling agent is recommended 2 With the lower edge of each stone positioned even with the lowest edge of the bore start drill and honing process Move the ...

Page 200: ...eter and the piston diameter step 2 minus step 1 Flywheel Inspection Inspect the flywheel for cracks and the flywheel keyway for damage Replace the flywheel if it is cracked Replace the flywheel the crankshaft and the key if flywheel key is sheared or the keyway is damaged Inspect the ring gear for cracks or damage Kohler does not provide the ring gear as a serviceable part Replace the flywheel if...

Page 201: ... 2987 1 2997 in 6 5 mm 0 2559 in 7 038 7 058 mm 0 2771 0 2779 in 29 37 29 63 mm 1 1563 1 1665 in 45 1 5 mm 0 0591 in 6 970 6 988 mm 0 2744 0 2751 in Figure 10 6 Valve Details Hard starting or loss of power accompanied by high fuel consumption may be symptoms of faulty valves Although these symptoms could also be attributed to worn rings remove and check the valves first After removal clean the val...

Page 202: ...t 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 excessive hours or a combination of poor operating conditions Leakage A poor grind on face or seat of valve will allow leakage resulting in a burned valve on one side only Coking Coking is normal on intake ...

Page 203: ...g 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 is repeatedly stopped before it has a chance to reach normal operating temperatures Replace corroded valves Overheating An exhaust valve subject to overheating will have a dark discoloration in the...

Page 204: ... an 89 cutter as specified for the valve seat angle in Figure 10 6 Cutting the proper 45 valve face angle as specified in Figure 10 6 and the proper valve seat angle 44 5 half of the full 89 angle will achieve the desired 0 5 1 0 full cut interference angle where the maximum pressure occurs on the outside diameters of the valve face and seat Figure 10 7 Typical Valve Seat Cutter Lapping Valves Reg...

Page 205: ...sive material such as carbon dirt or pieces of hard metal Detonation damage occurs when a portion of the fuel charge ignites spontaneously from heat and pressure shortly after ignition This creates two flame fronts which meet and explode to create extreme hammering pressures on a specific area of the piston Detonation generally occurs from using low octane fuels Preignition or ignition of the fuel...

Page 206: ... 4 Before installing the new rings 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 10 9 Compare the ring gap to the specifications listed in Section 1 Figure 10 9 Measuring Piston Ring End Gap 5 After installing the new compression top and middle rings on the piston check the piston to ring side clearance Compare the clea...

Page 207: ...he base surface of the hydraulic lifters for wear or damage If the lifters need to be replaced apply a liberal coating of Kohler lubricant see Section 2 to the base of each new lifter before it is installed Bleeding the Lifters To prevent a possible bent push rod or broken rocker arm it is important to bleed any excess oil out of the lifters before they are installed 1 Cut a 50 75 mm 2 3 in piece ...

Page 208: ... pump body 5 If the relief valve is like that shown in Figure 10 15 drive out the pin to remove the oil pressure relief valve piston and spring Refer to the following inspection and reassembly procedures If the relief valve is a one piece style staked to the oil pump housing See Figure 10 16 removal should not be attempted nor is internal servicing possible If a problem with the relief valve is en...

Page 209: ...essure relief valve piston It should be free of nicks or burrs Check the spring for wear or distortion The free length of the spring should be approximately 47 4 mm 1 8 in Replace the spring if it is distorted or worn See Figure 10 17 Pickup Relief Valve Figure 10 17 Oil Pressure Relief Valve Piston and Spring Reassembly 1 Install the pressure relief valve piston and spring 2 Install the oil picku...

Page 210: ... seal is damaged and or leaks replace it using the following procedure Remove the oil seal from the crankcase and replace it with a new one Install the new seal to the depth shown in Figure 10 18 using a seal installer 2 0 mm 0 0787 in Governor Cross Shaft Seal Figure 10 18 Installing Cross Shaft Oil Seal ...

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Page 215: ...ŝśȱ ǯǼ Ǳȱ ŖǯŞşśřśȦŖǯşşřŚśȱ ȱǻŖǯŖřśŘśȦŖǯŖřŜŝśȱ ǯǼ Ǳȱ ŖǯşŚŜŗśȦŖǯşŞŚŘśȱ ȱǻŖǯŖřŝŘśȦŖǯŖřŞŝśȱ ǯǼ Ǳȱ ŖǯşşŜşśȦŗǯŖřśŖśȱ ȱǻŖǯŖřşŘśȦŖǯŖŚŖŝśȱ ǯǼ LJXUH KDQJH 6KLP WR 2EWDLQ RUUHFW QG 3OD ȱ śǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯ 2LO 3XPS VVHPEO ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ȱȃ ȱ ȱ Ȅȱ ȱ ȱŗŖǯ RYHUQRU HDU VVHPEO ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ȱȃ ȱ ȱ Ȅȱ ȱ ȱŗŖǯ 7KUXVW HDULQJ DVKHU DQG 6KL...

Page 216: ... ȱȱ ȱ ǻŖǯŞŝśŖȱ ȦŖǯŖřŚȱ ǯȱ Ǽ ȱ ŗǯŖŜśŘȬŗǯŗŚŗŚȱ ȱȱ ȱ ǻŗǯŗŖřřȱ ȦŖǯŖŚřȱ ǯȱ Ǽ ȱ ŗǯŘşřŞȬŗǯřŝŖŖȱ ȱȱ ȱ ǻŗǯřřŗşȱ ȦŖǯŖśŘȱ ǯȱ Ǽ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱȃ ȱ ȱ ȱ ǯȄ QVWDOO ORVXUH 3ODWH 2LO 6HDO ȱ ŗǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ Ğȱ ȱ ȱ ȱ ȱ ǯ ȱ Řǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯ ȱ řǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱŗŗȬŗŞǯ LJXUH 2LO 6HDO HSWK LQ ORVXUH ...

Page 217: ... ǯȱ ȱ ȱŗŗȬŘŖǯ LJXUH 8VLQJ 6SDQQHU UHQFK WR 7XUQ UDQNVKDIW ȱ Ŝǯȱ ȱ ȱ ȱ ȱĚ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱŗŗȬŘŗȱ ȱŘŚǯŚȱ ȉ ȱǻŘŗŜȱ ǯȱ ǯǼǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱǛŜȱ ȱ ȱ ȱ ȱ ŗŗȬŘŗǯ LJXUH ORVXUH 3ODWH DVWHQHU 7RUTXH 6HTXHQFH LJXUH 7RUTXLQJ ORVXUH 3ODWH DVWHQHUV QVWDOO 6WDWRU DQG DFNLQJ 3ODWHV ȱ ŗǯȱ ȱ ȱ ȱ ȱ Ě ț ȱǻ ț ȱ ȱ śşŘŚŗȱ ȱ Ǽȱ ȱ ȱ ȱ ȱ ǯ ȱ Řǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ Ĵ ǰȱ ȱ ȱ ǯ...

Page 218: ...UH QVWDOOLQJ DFNLQJ 3ODWHV DQG 6WDWRU LUH UDFNHW QVWDOO O ZKHHO 51 1 DPDJLQJ UDQNVKDIW DQG O ZKHHO DQ DXVH 3HUVRQDO QMXU ȱ ȱ ȱ ȱ ȱ ȱĚ ȱ ȱ ȱ ȱ ȱ ȱ Ğȱ Ȧ ȱĚ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱĚ ǯ Ǳȱ ȱ ȱ ȱĚ ȱ ȱ ȱ ȱ Ğȱ ȱ ȱ ȱĚ ȱ ȱ ȱ ǰȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱĚ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱĚ ȱ ȱ ȱ ȱ ȱ ę ǯ LJXUH OHDQ DQG U 7DSHU RI UDQNVKDIW LJXUH OHDQ DQG U O ZKHHO XE ...

Page 219: ...ȱ ȱĚ ȱ ȱ ȱ Ğȱ ȱ ŜŜǯŚȱ ȉ ȱǻŚşȱĞǯȱ ǯǼǯȱ ȱ ȱŗŗȬŘşǯ LJXUH QVWDOOLQJ DQG 7RUTXLQJ O ZKHHO DVWHQHU QVWDOO O ZKHHO DQ ȱ ŗǯȱ ȱ ȱ ȱ ȱ ȱĚ ȱ ȱ ȱ ȱ ȱĚ ȱ ǯ Ǳȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ Ě ǯȱ ȱ ȱŗŗȬřŖǯ LJXUH QVWDOOLQJ DQ RQ O ZKHHO ȱ Řǯȱ ȱ ȱ ȱ ȱşǯşȱ ȉ ȱǻŞŞȱ ǯȱ ǯǼǯ QVWDOO 3ODVWLF UDVV 6FUHHQ ȱ ŗǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱŗŗȬřŗǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ě ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ȱŗřȱ ...

Page 220: ...RUTXLQJ 6XSSRUWV IRU 0HWDO 6FUHHQ 6RPH 0RGHOV QVWDOO GUDXOLF LIWHUV ȱ ŗǯȱ ȱȁȁ ȱ ȱ Ğ ȂȂȱ ȱ ȱŗŖȱ ȱ Ğ ȱ ȱǻ ȱ Ǽȱ ǯ ȱ Řǯȱ ȱ Ğȱ ȱǻ ȱ ȱŘǼȱ ȱ ȱ Ĵ ȱ ȱ ȱ ȱ Ğ ǯȱ ȱ ȱŗŗȬřŚǯȱ ȱ ȱ ȱ Ğ ȱ ȱ ȱ Ğ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯ LJXUH SSO LQJ DPVKDIW XEULFDQW WR RWWRP RI LIWHUV ȱ řǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ Ğ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ŗȱ ȱ ȱŘǯȱ ȱ ȱ ȱ Ğ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱŗŗȬřśǯ Ǳȱ ȱ Ğ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ Ğ ȱ ȱ ȱ ȱ ȱ ȱ Ğȱ ȱ ȱ ȱ ȱ...

Page 221: ... ȱ ȱ ǯȱ ȱŗŗȬřŝǯ VVHPEOH OLQGHU HDGV ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ Ĵ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱŗŗȬřŞȱ ȱŗŗȬřşǯ ȱ Ȋȱ ȱ ȱ ȱ ȱ Ȋȱ ȱ ȱ ȱ Ȋȱ ȱ ȱ Ȋȱ ȱ ȱ ȱ Ȋȱ ȱ ȱ LJXUH 9DOYH RPSRQHQWV LJXUH QVWDOOLQJ 9DOYHV ZLWK 9DOYH 6SULQJ RPSUHVVRU QVWDOO OLQGHU HDGV Ǳȱ ȱ ȱ ȱ ȱ Ĵ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱĚ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ě ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ǯ ȱ ŗǯȱ ȱ...

Page 222: ...HUV LJXUH OLQGHU HDG DVWHQHU 7RUTXH 6HTXHQFH HDGV VHFXUHG ZLWK PRXQWLQJ VWXGV QXWV DQG ZDVKHUV ȱ ŗǯȱ ȱ ȱ ȱ ȱ ȱ ȱ Ğȱ ǰȱ ȱ ȱ ȱŜǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱřǯȱ ȱ ȱ Ȧ ȱ ȱ ȱ ȱ ȱ ǯ ȱ Řǯȱ ȱ ȱ ȱ ǻ Ǽȱ ȱ ȱ ǯ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱȱ ȱ ȱ ȱ ȱ ȱ ȱȱ ȱ ȱ ȱ ȱ ȱ ę ȱ ȱ ȱ ȱȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱȱ ȱ ŗŗȬŚřǯȱ ȱ ȱ ȱ ȱ ǰȱ ȱȱȱ ȱ ȱ ȱ ȱ ȱ ȱȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱȱ ȱ ȱ ȱ ǯȱ ǰȱ ȱ ȱ ȱȱ ȱ ȱ ȱ ȱ ȱ...

Page 227: ...HQ 7ZR 5HPDLQLQJ RYHU 6FUHZV HEULV 6KLHOG QVWDOO ORZHU RXVLQJ DQG 2XWHU DIÀHV Ǳȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ Ğ ȱ ȱ ȱ ǯ ȱ ŗǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱǻ ȱ ȱ Ǽǯ ȱ Řǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ĝ ǯȱ ȱ ȱ ŗŗȬŜŗǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ Ȭ ȱ ȱ ǰȱ Ğȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱŗŗȬŜŗȱ ȱŗŗȬŜŘǯ LJXUH QVWDOOLQJ ORZHU RXVLQJ LJXUH 5RXWLQJ LULQJ DUQHVV DQG HDGV 7ZR DUUHO...

Page 228: ...G HDGV ȱ Śǯȱ ȱ ȱ ę Ȭ ȱ ȱ ȱ ǰȱ Ĵ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ę Ȭ ǰȱ ȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱŗŗȬŜŚǯ LJXUH URXQG HDG HWDLOV ȱ śǯȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱŜǯŘȱ ȉ ȱǻśśȱ ǯȱ ǯǼȱ ȱ ȱ ȱ ǰȱ ȱ ȱŚǯŖȱ ȉ ȱǻřśȱ ǯȱ ǯǼȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ śȱ ȱ ĝ ȱ ȱ ȱ ŚǯŖȱ ȉ ȱǻřśȱ ǯȱ ǯǼǯȱ ȱ ȱŗŗȬŜśǯȱ ȱ ȱ ȱ śȱ ȱ ĝ ȱ ȱǻ ȱ ȱ Ǽȱ ȱŜǯŘȱ ȉ ȱǻśśȱ ǯȱ ǯǼȱ ȱ ȱ ȱ ǰȱ ȱ ȱŚǯŖȱ ȉ ȱ ǻřśȱ ǯȱ ǯǼȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ Ŝȱ ĝ ȱ ȱ ȱ ȱŗŖǯŝȱ ȉ ȱǻşśȱ ǯȱ ǯǼȱ ȱ ȱ ȱ ǰȱ ...

Page 229: ...ŘǯŘȱ ȉ ȱǻŘŖȱ ǯȱ ǯǼǯ LJXUH QVWDOOLQJ 0HWDO 7 SH UDVV 6FUHHQ ȱ ŝǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱŝǯřȱ ȉ ȱ ǻŜśȱ ǯȱ ǯǼȱ ȱ ȱ ȱ ȱ ȱ ȱŗŗȬŜŞǯ LJXUH UHDWKHU RYHU DVWHQHU 7RUTXH 6HTXHQFH 5HFRQQHFW 5HFWL HU 5HJXODWRU ȱ ŗǯȱ ȱ ȱ ę Ȭ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ę Ȭ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱŗŗȬŜşǯȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ȱ ę Ȭ ǯȱ ȱ ȱŗŗȬŝŗǯ LJXUH RQQHFWLQJ URXQG HDG ȱ Řǯȱ ȱ ȱ Ƹȱ Ȧ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ę Ȭ ȱ ȱ ȱ ȱ ȱ ȱ ...

Page 230: ...W DQG WWDFKHG RQQHFWRU 60 57 63 5 0RGXOH ȱ ŗǯȱ ȱ ȱ ȱ Ȭ Ȝ ǰȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ĝ ǯȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱŗŗȬŝŘǯ LJXUH 5HLQVWDOOLQJ 6 0 0RGXOH QVWDOO OHFWULF 6WDUWHU 0RWRU ȱ ŗǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱĚ ȱ ǯȱ ȱ ȱŗŗȬŝřǯȱ ȱ Ȭ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯ ȱ Řǯȱ ȱ ȱ ȱ ȱĚ ȱ ȱ ȱŗśǯřȱ ȉ ȱ ǻŗřśȱ ǯȱ ǯǼǯ URXQGLQJ UDFNHW LJXUH QVWDOOLQJ OHFWULF 6WDUWHU 0RWRU ...

Page 232: ...ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ Řǯȱ ȱ ț ȱŘŚŘȱ ȱ ȱ ȱǻ Ǽȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ řǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱĚ ȱ ȱĚ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ Ĵ Ȧ ǯȱ ȱ ȱŗŗȬŝŞǯ LJXUH QVWDOOLQJ 6WXGV DQG DUEXUHWRU 7ZR DUUHO DUEXUHWRU ȱ Śǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱŗŗȬŝşǯ LJXUH RQQHFWLQJ URXQG HDG 7ZR DUUHO DUEXUHWRU QVWDOO WHUQDO RYHUQRU RQWUROV ȱ ŗǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ Ğǯȱ ȱ ȱŗŗȬŞŖǯ LJXUH QVWDOO RYHUQRU HYHU WR 6KDIW ...

Page 233: ... ȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ȱŜǯŞȱ ȉ ȱ ǻŜŖȱ ǯȱ ǯǼǯȱ ȱ ȱŗŗȬŞŘǯȱ LJXUH ROGLQJ DQG 7LJKWHQLQJ RYHUQRU UP ȱ śǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ Ȭ ěȱ ȱ ȱ ȱ ǯ QVWDOO 7KURWWOH KRNH RQWUROV ȱ ŗǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱŗŗȬŞřǯ LJXUH RQQHFWLQJ KRNH LQNDJH ȱ Řǯȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱǻ ȱ Ǽȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱĚ ȱ ǯȱ ȱ ȱ ȱ ȱŗŖǯŝȱ ȉ ȱǻşśȱ ǯȱ ǯǼȱ ȱ ȱ ǰȱ ȱ ŝǯřȱ ȉ ȱǻŜśȱ ǯȱ ǯǼȱ ȱ ȱ ǯȱ ȱ ȱ ŗŗȬŞŚǯ LJXUH 7RUTXLQJ 0DLQ RQWURO UDFNHW ...

Page 234: ... 6SULQJ RORU RGH ś Ś ř Ř Ś ř Ř ř ř ȘśƖȱ ȱǻ ȱŗŖƖǼ RYHUQHG GOH ROH RYHUQRU HYHU RORUHG RQ QG 2QO RORUHG RPSOHWHO ȱ řǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱȱ ŗŗȬŞśȱ ȱŗŗȬŞŜǰȱ ȱ ȱ ȱ ǯ LJXUH RQQHFWLQJ 6SULQJ WR RYHUQRU HYHU PP RYHUQRU HYHU DQG ROH 3RVLWLRQ 530 KDUW LJXUH RYHUQRU 6SULQJ RORU 0DUNLQJV ...

Page 235: ...ŗ Ś ř ř ř Ř Ř ŗ Ř ŗ 6WDQGDUG 3DUHQW 0DWHULDO řŞŞŞ řŝŞŖ řŜŝŘ řśŜŚ řŚśŜ řřŚŞ řŘŚŖ řŗřŘ řŖŘŚ řŜŖŖ řśŖŖ řŚŖŖ řřŖŖ řŘŖŖ řŗŖŖ řŖŖŖ ŘşŖŖ ŘŞŖŖ Ȭ ř ř ř Ř Ř ŗ ŗ ŗ Ȭ PP RYHUQRU HYHU DQG ROH 3RVLWLRQ 530 KDUWV QJLQHV RYHUQRU 6KDIW RQ JXUDWLRQ 1HHGOH HDULQJ 6WDQGDUG 3DUHQW 0DWHULDO 1RQ FFHOHUDWRU 3XPS DUEXUHWRU FFHOHUDWRU 3XPS DUEXUHWRU LJK GOH 27 QWHQGHG 0D LPXP 530 řŝŚŚ řŗŘŖ řŜŖŖ řŖŖŖ 6SULQJ RORU ROH 1R 6SUL...

Page 236: ...ȱ ȉ ǻŚŖȱ ǯȱ ǯǼǯ ȱ Řǯȱ ȱ ȱ ȱ ȱǻ Ǽȱ ȱ ȱ ȱ Ȝȱ ǯ QVWDOO RQWURO 3DQHO I 6R TXLSSHG ȱ ŗǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯ ȱ Řǯȱ ȱ ȱ Ĵ ȱ ȱ ȱ ȱ Ğǯ ȱ řǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯ ȱ Śǯȱ ȱ ȱ ȱ Ȝȱ ȱ ȱ ǯ WHP HVFULSWLRQ ȱ ŗȱ ǰȱ ȱ ȱ Řȱ ǰȱ ȱǻ ȱ Ǽ ȱ řȱ ȱ ȱǻ ȱ Ǽ ȱ Śȱ ǰȱ ȱǻ ȱ Ǽ ȱ śȱ ǰȱ Ĵ ȱ ȱǻ Ǽ ȱ Ŝȱ ǰȱ ȱ ȱ ŝȱ ǰȱ Ĵ ȱ ȱǻ Ĵ Ǽ ȱ Şȱ ǰȱ ś ŖǯŞ ŘŖ ȱ şȱ ǰȱ ȱ ŗŖȱ ǰȱĚ ȱǻřǼ ȱ ŗŗȱ ǰȱ ȱ ȱ ŗŘȱ ǰȱ ś ŖǯŞȱ LJXUH QVWDOOLQJ 2LO 6HQWU 6ZLWFK ...

Page 238: ... řǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱĚ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ śȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ Ŝȱ ȱ ȱŜǯŘȬŝǯřȱ ȉ ȱǻśśȬŜśȱ ǯȱ ǯǼȱ ȱ ȱ ȱ ȱ śȱ ȱ ȱǻ ȱ Ǽȱ ȱ ŚǯŖȱ ȉ ȱǻřśȱ ǯȱ ǯǼǯȱ ȱ ȱŗŗȬşŚȱ ȱŗŗȬşśǯ LJXUH 7RUTXLQJ DVH 6FUHZV LJXUH 7LJKWHQLQJ 5HDU DVH UDFNHW 6FUHZV 6RPH 0RGHOV ȱ Śǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯ ȱ śǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱŚǯ HDY XW LU OHDQHU ȱ ŗǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱęĴ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ...

Page 239: ...ȱǻ Ȭ ȱ ȱ Ǽȱ ȱşǯşȱ ȉ ȱ ǻŞŞȱ ǯȱ ǯǼǯ ȱ Śǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ŗŗȬşŞǯ LJXUH VVHPEOHG HDY XW LU OHDQHU 7ZR DUUHO DUEXUHWRU QVWDOO 0XIÀHU ȱ ŗǯȱ ȱ ȱ ȱ ȱǻ ȱ Ǽǯȱ ȱ ȱ ĝ ȱ ȱ Ĵ ȱ ȱ ȱ ȱ ĝ ȱ ǯȱ ȱ ȱ ȱşǯşȱ ȉ ȱǻŞŞȱ ǯȱ ǯǼǯ ȱ Řǯȱ ȱ ȱ ȱĚ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱĚ ȱ ȱ ȱŘŚǯŚȱ ȉ ȱǻŘŗŜȱ ǯȱ ǯǼǯ QVWDOO 2LO RROHU ȱ ŗǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱǻ ȱ Ǽǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱŘŝȱ ȉ ȱǻŘŖȱĞǯȱ ǯǼǯȱ ȱ ȱŗŗȬ...

Page 240: ...ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱę ȱ ȱ ȱ ȱę ȱ ȱ ȱ ȱ ǯȱ ȱ ȱŗŗȬŗŖŗǯ LJXUH QVWDOOLQJ 1HZ 2LO LOWHU ȱ řǯȱ ȱ ȱ ȱ ȱę ȱ ȱ ȱę ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱę ȱ ȱ ȱ ǯȱ LJXUH QVWDOO 2LO LOWHU ȱ Śǯȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱŗŗȬŗŖřǯȱ ȱ ȱ ȱ ȱŗřǯŜȱ ȉ ȱǻŗŖȱĞǯȱ ǯǼǯ Ǳȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ę ȱ ȱ ȱ ȱ ǯ LJXUH 5HLQVWDOO DQG 7RUTXH RWK 2LO UDLQ 3OXJV ȱ śǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱȃ Ȅȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱŗŗȬŗŖŚǯ 0RXQWLQJ RFDWLRQV ...

Page 241: ...ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ǯ ȱ ŗǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯ ȱ Řǯȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱę ȱ ȱ ǯ ȱ řǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ǰȱ ǰȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱȁȁ ȱ ȱ ȱ ȂȂȱ ȱȁȁ ȱ ȂȂȱ ǯ ȱ Śǯȱ ȱ ȱ ǰȱ ȱ ȱ ǰȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱśǰȱ ȱȃ ȱ ȱ ȱ Ȅǯ 7HVWLQJ WKH QJLQH ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯ ȱ ŗǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱ ȱǻŘŖȱ ȱ ȱ Ǽȱ ȱ ǯȱ ȱ ȱ ȱ ȱ ȱ ȱŘȬřȱ ǰȱ ȱśȬŜȱ ȱ ȱ ȱ ȱ ȱ ǯȱ ȱ ȱ ...

Page 242: ... 6HFWLRQ 5HDVVHPEO ...

Page 243: ... view of clutch Figure 12 1 Wet Type Clutch Exploded View Nameplate Gasket Shifting Lever Seal Shaft Yoke Clutch Housing Key Yoke Roll Pin Ball Bearing Power Shaft Adjusting Ring Driven Member Clutch Assembly Pilot Bearing Pressure Plate Release Sleeve Clutch Assembly Adjusting Lock Bearing Release Assembly Oil Seal Retaining Rings Snap Ring ...

Page 244: ...ll clutch assembly off 6 To replace clutch simply turn adjusting collar off and remove plate Reverse procedure for reassembly Adjust and lubricate following previous instructions Adjustment Slight readjustment may be needed after a few hours on a new clutch to accommodate normal run in wear Firm pressure should be required to engage clutch 40 45 pounds pull at lever handle Readjust if clutch slips...

Page 245: ......

Page 246: ... 7 2 1 8 6 250 12 5HY 668 5 9 6 1 1 9 6 21 2 5 2 2 5 6 216 1 25 6 6 1 6 59 1 250 7 21 1 8 6 1 1 RKOHU QJLQHV FRP ...

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Kohler COMMAND CH18-CH26, Service Manual

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