Kohler Command CV17-750 Service Manual Download Page 28 | Manualshive

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3.5

Section 3

Troubleshooting

3

Air escaping from crankcase breather ...................................................... Rings or cylinder worn.
Air escaping from exhaust system ............................................................ Defective exhaust valve/improper seating.
Air escaping 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
replaced.

Leakdown Test Results

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Summary of Contents for Command CV17-750

Page 1: ...SERVICE MANUAL VERTICAL CRANKSHAFT COMMAND CV17 750 ...

Page 2: ...nd Air Intake System Section 5 Fuel System and Governor 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 2 1 4 5 3 5B 8 9 10 11 6 7 ...

Page 3: ...s should be followed at all times Failure to follow these precautions could result in injury to yourself and others Rotating Parts can cause severe injury Stay away while engine is in operation WARNING Rotating Parts Keep hands feet hair and clothing away from all moving parts to prevent injury Never operate the engine with covers shrouds orguardsremoved Hot Parts can cause severe burns Do not tou...

Page 4: ...her 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 ground cable make sure all switches are OFF If ON a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or gasoline vaporsarepresent Explosive Fuel can cause fires and severe bur...

Page 5: ...rs A Model No Version Code S Electric Start C V 18 S Command Engine Vertical Crankshaft Horsepower 17 17 HP 18 18 HP 20 20 HP 22 22 HP 23 23 HP 25 25 HP 26 26 HP Numerical Designation 730 740 745 750 or Identification Decal Variation of Basic Engine B Spec No 61500 Engine Model Code Code Model 72 CV17 61 CV18 65 CV20 67 CV22 624 cc 69 CV25 75 CV22 23 674 cc 79 CV26 CV730 0001 CV740 0001 CV745 0001...

Page 6: ...e gasoline Do not overfill the fuel tank Leave room for the fuel to expand Fuel Type For best results use only clean fresh unleaded gasoline with a pump sticker octane rating of 87 or higher In countries using the Research method it should be 90 octane minimum Unleaded gasoline is recommended as it leaves less combustion chamber deposits and reduces harmful exhaust emissions Leaded gasoline is not...

Page 7: ...hree revolutions 5 On equipment with an EFI engine disconnect the battery or use a battery minder to keep the battery charged during storage 6 Store the engine in a clean dry place Periodic Maintenance Instructions WARNING Accidental Starts Disabling engine Accidental starting can cause severe injury or death Before working on the engine or equipment disable the engine as follows 1 Disconnect the ...

Page 8: ...1 6 Section 1 Safety and General Information Figure 1 4 Typical Engine Dimensions CV Series with Standard Flat Air Cleaner Dimensions in millimeters Inch equivalents shown in ...

Page 9: ...1 7 Section 1 Safety and General Information 1 Figure 1 5 Typical Engine Dimensions CV Series with Commercial Mower Air Cleaner Dimensions in millimeters Inch equivalents shown in ...

Page 10: ...1 8 Section 1 Safety and General Information Figure 1 6 Typical Engine Dimensions CV EFI Series with Heavy Duty Air Cleaner Dimensions in millimeters Inch equivalents shown in ...

Page 11: ... 2800 RPM 54 2 N m 40 0 ft lb CV740 2800 RPM 56 9 N m 42 0 ft lb CV745 2400 RPM 60 0 N m 44 3 ft lb CV750 2600 RPM 63 8 N m 47 1 ft lb Bore CV17 73 mm 2 87 in CV18 CV20 CV22 624 cc 77 mm 3 03 in CV22 23 674 cc 80 mm 3 15 in CV25 CV26 CV730 750 83 mm 3 27 in Stroke CV17 745 67 mm 2 64 in CV750 69 mm 2 7 in Displacement CV17 561 cc 34 cu in CV18 CV20 CV22 624 cc 624 cc 38 cu in CV22 23 674 cc 674 cc...

Page 12: ... 19 962 19 975 mm 0 7859 0 7864 in Max Wear Limit 19 959 mm 0 7858 in Carburetor and Intake Manifold Intake Manifold Mounting Fastener Torque Torque in Two Stages first to 7 4 N m 66 in lb finally to 9 9 N m 88 in lb Carburetor Mounting Nut Torque 6 2 7 3 N m 55 65 in lb Connecting Rod Cap Fastener Torque torque in increments 8 mm straight shank 22 7 N m 200 in lb 8 mm step down 14 7 N m 130 in lb...

Page 13: ...03 0 09 mm 0 0012 0 0035 in Crankshaft Bore In Oil Pan New 40 987 40 974 mm 1 6136 1 6131 in Crankshaft Bore In Oil Pan to Crankshaft Running Clearance New 0 039 0 074 mm 0 0015 0 0029 in Flywheel End Main Bearing Journal O D New 40 913 40 935 mm 1 6107 1 6116 in O D Max Wear Limit 40 84 mm 1 608 in Max Taper 0 022 mm 0 0009 in Max Out of Round 0 025 mm 0 0010 in Oil Pan End Main Bearing Journal O...

Page 14: ... 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 Crankcase Running Clearance 6 mm Shaft...

Page 15: ... I D New 17 006 17 012 mm 0 6695 0 6698 in Max Wear Limit 17 025 mm 0 6703 in Piston Pin O D New 16 995 17 000 mm 0 6691 0 6693 in Max Wear Limit 16 994 mm 0 6691 in Top Compression Ring to Groove Side Clearance CV17 0 040 0 085 mm 0 0016 0 0033 in CV18 CV20 CV22 624 cc 0 040 0 080 mm 0 0016 0 0031 in CV22 23 674 cc 0 030 0 076 mm 0 0012 0 0030 in CV25 CV26 CV730 750 0 025 0 048 mm 0 0010 0 0019 i...

Page 16: ...52 in Max Wear Limit CV22 674 cc 79 831 mm 3 1430 in Max Wear Limit CV25 CV26 CV730 750 82 841 mm 3 2614 in Piston Thrust Face to Cylinder Bore Running Clearance New CV17 0 022 0 065 mm 0 0009 0 0026 in New CV18 CV20 CV22 624 cc 0 014 0 057 mm 0 0005 0 0022 in New CV22 23 674 cc 0 021 0 062 mm 0 0008 0 0024 in New CV25 CV26 CV730 750 0 001 0 045 mm 0 039 0 0018 in Speed Control Bracket Fastener To...

Page 17: ...case Running Clearance 0 0241 0 0501 mm 0 0009 0 0020 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 7 134 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...

Page 18: ...5 0 44 2 0 18 M5 2 5 22 3 2 28 5 8 51 8 1 72 9 7 86 4 0 35 M6 4 3 38 5 7 50 9 9 88 14 0 124 16 5 146 6 8 60 M8 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...

Page 19: ... 67 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 3 175 9 16 18 135 6 100 223 7 165 311 9 230 5 8 11 149 2 110 244 1 180 352 6 260 5 8 18 189 8 140 311 9 230 447 5 330 3 4 10 199 3 150 332 2 245 474 6 350 3 4 16 271 2 200 440 7 325 637 3 470 Tighteni...

Page 20: ...d n E t f a h s m a C y a l p d n e t f a h s m a c g n i k c e h c r o F 5 0 4 2 8 R L K s l o o T E S r e t s e T n w o d k a e L r e d n i l y C n r o w e r a s e v l a v r o s g n i r n o t s i p r e d n i l y c f i d n a n o i t n e t e r n o i t s u b m o c g n i k c e h c r o F S 5 0 1 6 7 5 2 r e l h o K e r a w t f o S c i t s o n g a i D I F E n o i t c e j n I l e u F c i n o r t c e l ...

Page 21: ... o n h c e T n g i s e D 1 3 0 I T D 3 3 0 I T D r e t s e T M A S e l u d o M e c n a v d A k r a p S K R A P S T R A M S h t i w s e n i g n e n o M A S D d n a M A S A M A S e h t t s e t o T S 0 4 1 6 7 5 2 r e l h o K t f i h S d i o n e l o S l o o T g n i d l o H h s u r B r e t r a t S g n i c i v r e s g n i r u d s e h s u r b d l o h o T 6 1 4 2 8 R L K s l o o T E S e v i r D a i t r e...

Page 22: ...c e l E t f i h S d i o n e l o S S 2 0 7 5 3 2 5 r e l h o K t n a l a e S e n o c i l i S V T R e t i t c o L r e s n e p s i d l o s o r e a z o 4 n i y d o B y v a e H 0 0 9 5 e s u r o f d e v o r p p a e r a d e t s i l e s o h t s a h c u s s t n a l a e s V T R t n a t s i s e r l i o d e s a b e m i x o y l n O e t i t c o L s c i t s i r e t c a r a h c g n i l a e s t s e b r o f d e d ...

Page 23: ...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 24: ...ontrols 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 the fuel system 3 Clog...

Page 25: ... 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 26: ...ged or improperly assembled breather can cause oil to be forced out 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 atmo...

Page 27: ...ng tool Leakdown Test Instructions 1 Run the engine for 3 5 minutes to warm it up 2 Remove the spark plug s and the air filter from engine 3 Rotate the crankshaft until the piston of cylinder being tested is at top dead center of the compression stroke Hold the engine in this position while testing The holding tool supplied with the tester can be used if the PTO end of the crankshaft is accessible...

Page 28: ...tive 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 replaced Leakdown Test Resul...

Page 29: ... allow unfiltered air into the engine causing premature wear and failure Precleaner Service Standard and Commercial Mower Types If so equipped wash and reoil the precleaner every 25 hours of operation more often under extremely dusty or dirty conditions To service the precleaner see Figures 4 3 or 4 4 and perform the following steps 1 Loosen the cover retaining knob or unhook the latches and remov...

Page 30: ...t cover and air cleaner element 3 Remove the precleaner if so equipped from the paper element Service the precleaner as described in Precleaner Service 4 Do not wash the paper element or use pressurized air as this will damage the element Replace a dirty bent or damaged element with a genuine Kohler element Handle new elements carefully do not use if the sealing surfaces are bent or damaged 5 Chec...

Page 31: ...lement Precleaner Air Cleaner Base Rubber Seal Stud Plenum air cleaner system does not use a precleaner Knob Knob Seal Air Cleaner Cover Element Cover Nut Rubber Seal Precleaner Element Cover Element Spitback Cup Gasket Spitback Cup Air Cleaner Base Figure 4 5 Air Cleaner System Components Standard Figure 4 6 Air Cleaner System Components Commercial Mower Type ...

Page 32: ...Figure 4 5 2 Remove the two hex flange nuts securing the bracket or spitback cup with seal and baffle if equipped to base If a plastic intake manifold is used remove the two lower base mounting screws See Figure 4 7 3 Pinch the sealing collar on the breather hose and push it down through the hole in the base Figure 4 8 Removing Base on Commercial Mower Type Air Cleaner Disassembly Reassembly Comme...

Page 33: ...Pull the air cleaner element out of the housing See Figure 4 10 Figure 4 10 Removing Elements 3 After the element is removed check the condition of the inner element It should be replaced whenever it appears dirty typically every other time the main element is replaced Clean the area around the base of the inner element before removing it so dirt does not get into the engine 4 Do not wash the pape...

Page 34: ... blower housing and other cooling shrouds Clean the cooling fins and external surfaces as necessary Make sure the cooling shrouds are reinstalled 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 11 NOTE Operating the engine with a blocked grass screen dirty or plugged cooling fins and or cooling shrou...

Page 35: ...s drawn into the carburetor body There the fuel is mixed with air This fuel air mixture is then burned in the engine combustion chamber Fuel Recommendations General Recommendations Purchase gasoline in small quantities and store in clean approved 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 ...

Page 36: ... certified to meet CARB requirements Standard fuel line may not be used Order replacement hose by part number through a Kohler Engine Service Dealer Figure 5 1 Family Number Location KOHLER CO KOHLER WISCONSIN USA EMISSION COMPLIANCE PERIOD EPA CARB CERTIFIED ON REFER TO OWNER S MANUAL FOR HP RATING SAFETY MAINTENANCE AND ADJUSTMENTS 1 800 544 2444 www kohlerengines com FAMILY 6 KHXS 7252 PH TYPE ...

Page 37: ... pump b Hold the line below the bottom of the tank Open the shut off valve if so equipped and observe flow 3 If fuel does flow from the line check for faulty fuel pump Test 4 If fuel does not flow from the line check the fuel tank vent fuel pickup screen in line filter shut off valve and fuel line Correct any observed problem and reconnect the line 4 Check the operation of fuel pump a Remove the f...

Page 38: ...uoyant force of 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 bowl When demand ceases the buoyant force of the float will again overcome the fuel pressure and stop the flow Figure 5 2 Pulse Pump Connections Performance Minimum fuel delivery rate mus...

Page 39: ...red amount of air is drawn through the slow air bleed jet fuel is drawn through the main jet and further metered through the slow jet Air and fuel are mixed in the body of the slow jet and exit to the transfer port From the transfer port this air fuel mixture is delivered to the idle progression chamber From the idle progression chamber the air fuel mixture is metered through the idle port passage...

Page 40: ...et Float Valve Seat Float Valve Main Jet Float Main Emulsion Hole Idle Speed RPM Adjustment Screw Air Fuel Mixture Main Circuit See Figure 5 4 At high speeds loads the engine operates on the main circuit As a metered amount of air is drawn through the main air bleed jet fuel is drawn through the main jet The air and fuel are mixed in the main nozzle and then enter the main body of airflow where fu...

Page 41: ...starts hard runs roughly or stalls at idle speed 2 Engine runs rich indicated by black sooty exhaust smoke misfiring loss of speed and power governor hunting or excessive throttle opening 2a Clogged air cleaner Clean or replace b Choke partially closed during operation Check the choke lever linkage to ensure choke is operating properly c Low idle fuel mixture is improperly adjusted Adjust low idle...

Page 42: ...vapors present You will also need a 12 volt power source that can be switched on and off 3 Be sure the power source is switched off Connect the positive power source lead to the red lead of the solenoid Connect the negative power source lead to the solenoid body 4 Turn the power source on and observe the pin in the center of the solenoid The pin should retract with the power on and return to its o...

Page 43: ...d as necessary Models with Governed Idle System An optional governed idle control system is supplied on some engines The purpose of this system is to maintain a desired idle speed regardless of ambient conditions temperature parasitic load etc that may change Engines with this feature contain a small secondary spring connected between the governor lever and the lower adjustment tab of the main bra...

Page 44: ...b Hold Throttle Lever Against Screw 5 Slide the carburetor off the retaining studs Remove the fuel bowl retaining screw or fuel shut off solenoid and drain the fuel into a safe container Remove the bowl from the carburetor body Figure 5 9 Proper Float Level 6 Turn the carburetor body upside down and check the float level as shown in Figure 5 9 With the float needle valve fully seated 16 5 mm 0 65 ...

Page 45: ...t damaged while the solenoid is separated from the carburetor 2 Pull the float hinge pin and remove the float with the inlet needle attached 3 Remove the vent plug from the column on fuel solenoid equipped carburetors 4 Remove the screws holding the throttle plate to the throttle shaft pull the throttle shaft from the carburetor body 5 Remove the screws securing the choke plate to the choke shaft ...

Page 46: ...ect the fuel inlet needle and seat for wear or damage Inspect the tip of the low idle fuel adjusting needle if equipped for wear or grooves The choke plate is spring loaded Check to make sure it moves freely 1 Carburetor Body 2 Idle Fuel Adjusting Screw 3 Idle Fuel Adjusting Spring 4 Passage Cover 5 Cover Gasket 6 Cover Retaining Screw 7 Main Jet 8 Ground Lead Solenoid only 9 Fuel Bowl Gasket 10 F...

Page 47: ...ling the carburetor Unseat the clamp and disconnect the accelerator pump hose if so equipped from the upper fitting Remove the four fuel bowl screws and carefully separate the fuel bowl from the carburetor Do not damage the O Ring s Transfer any remaining fuel into an approved container Save all parts See Figure 5 11 Figure 5 12 Removing Float and Inlet Needle 3 Clean the carburetor bowl and inlet...

Page 48: ...O Ring s in place onto the carburetor Secure with the four original screws Torque the screws to 2 5 0 3 N m 23 2 6 in lb Reattach the accelerator pump hose if so equipped and secure with the clip See Figure 5 16 Figure 5 15 Checking Float Height NOTE Be sure to measure from the casting surface not the rubber gasket if still attached Figure 5 16 Installing Fuel Bowl Disassembly Overhaul 1 Clean the...

Page 49: ...ropriate cleaning and installation of the parts in the overhaul kit Further disassembly is not necessary The throttle shaft assembly fuel inlet seat and bowl chamber baffle are non serviceable items and should not be removed The choke shaft assembly is serviceable however it should not be removed unless a Choke Repair Kit 24 757 36 S will be installed 6 Clean the carburetor body jets vent ports se...

Page 50: ...with the new retaining screw See Figure 5 24 Figure 5 24 Installing Float Assembly 12 Hold the carburetor body so the float assembly hangs vertically and rests lightly against the fuel inlet needle The inlet needle should be fully seated but the center pin of the needle on retainer clip end should not be depressed Check the float height adjustment NOTE The inlet needle center pin is spring loaded ...

Page 51: ...ring onto the idle fuel adjusting screw and install it into the carburetor As an initial adjustment set to 1 turn out from lightly seated See Figure 5 28 Figure 5 28 Installing Idle Fuel Adjusting Screw and Spring 18 Place the shorter new spring onto the idle speed adjusting screw and install it into the carburetor Thread in until 3 or 4 threads are exposed as an initial adjustment See Figure 5 29...

Page 52: ...stall the new check valve into the fuel delivery chamber Secure with the new retaining ring See Figure 5 32 Figure 5 32 Check Valve and Retaining Ring Installed 6 Notice the small alignment tab and the small bead on one side of the outer diameter of the new diaphragm Install the diaphragm into the housing so the alignment tab is in the small notch the bead is down in the recessed channel and the d...

Page 53: ...he shaft out of the carburetor body and discard the removed parts Figure 5 35 Choke Details 5 Use a screw extractor easy out and remove the original choke shaft bushing with the old choke lever from the carburetor housing Save the bushing to use as a driver for installing the new bushing Discard the old lever 6 Clean the I D of both choke shaft bores as required 7 Insert the new bushing through th...

Page 54: ...he carburetor function as described following Float Circuit The fuel level in the bowl is maintained by the float and fuel inlet needle The buoyant force of 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 bowl When demand ceases the buoyant force of t...

Page 55: ... low idle or limiter caps on the two idle fuel adjusting needles Step 3 can only be performed within the limits allowed by the cap Do not attempt to remove the limiter caps 1 Start the engine and run at half throttle for 5 to 10 minutes to warm up The engine must be warm before doing steps 2 3 and 4 2 Place the throttle control into the idle or slow position Adjust the low idle speed to 1200 RPM F...

Page 56: ...eturn to the governed idle speed Check it with a tachometer against the equipment manufacturers recommended idle speed Governed Idle Speed RPM is typically 300 RPM approximate higher than the low idle speed If adjustment is necessary bend the adjusting tab on the speed control assembly to set See Figure 5 41 Lean Rich Adjust to Midpoint Lean Rich Adjust to Midpoint Left Side Right Side Governed Id...

Page 57: ...pin and inlet needle See Figure 5 44 Discard all of the parts The seat for the inlet needle is not serviceable and should not be removed Fuel Bowl Bowl Drain Screw Figure 5 46 Installing Float Assembly 7 Hold the carburetor body so the float assembly hangs vertically and rests lightly against the fuel inlet needle The inlet needle should be fully seated but the center pin of the needle on retainer...

Page 58: ...h the four original screws Torque the screws to 2 5 0 3 N m 23 2 6 in lb See Figure 5 48 Figure 5 48 Installing Fuel Bowl 10 Install the carburetor and the heavy duty air cleaner as outlined in Section 11 Reassembly Disassembly Overhaul 1 Clean the exterior surfaces of dirt or foreign material before disassembling the carburetor Remove the four mounting screws and separate the fuel bowl from the c...

Page 59: ... for cracks wear or damage 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 nozzles into the towers of the carburetor body The end of the main nozzles with the two raised shoulders should be out down adjacent to the main jets Make sure the nozzles are comp...

Page 60: ...le Details 13 Install the float and inlet needle down into the seat and carburetor body Install the new pivot pinthrough the float hinge and secure with the new retaining screw See Figure 5 57 Figure 5 54 Installing Main Nozzles and Main Jets 9 Make sure the O Ring near the bottom of each slow jet is new or in good condition Align and insert the two slow jets into the top of carburetor See Figure ...

Page 61: ...ed 7 Insert the new bushing through the new choke lever from the outside and start the bushing in the outer shaft bore Position the choke lever so the protruding boss on the carburetor housing is between the two stops formed in the choke lever See Figure 5 61 Figure 5 59 Installing Fuel Bowl Choke Repair 1 Remove the carburetor from the engine Discard the old mounting gaskets for the air cleaner a...

Page 62: ... formed stops on the end of the choke shaft See Figure 5 63 NOTE Make sure it stays in this location during the following step Figure 5 64 Installing Choke Plate 12 Check for proper operation and free movement of the parts Install the new cap Always use new gaskets when servicing or reinstalling carburetors Repair kits are available which include new gaskets and other components Service repair kit...

Page 63: ...Drain Screw 14 Bowl Screw 4 15 Fuel Solenoid 16 Sealing Washer 17 Float 18 Pin 19 Screw 20 Float Clip 21 Float Valve Inlet Needle 22 Main Nozzle Right Side 23 Main Nozzle Left Side 24 Main Jet Right Side 25 Main Jet Left Side 26 Choke Dust Cap 27 Choke Shaft 28 Spring 29 Bushing 30 Choke Lever 31 Choke Plate 32 Choke Plate Screw 2 1 10 17 20 21 18 19 25 12 23 11 14 13 7 24 9 4 2 3 26 15 16 6 5 31 ...

Page 64: ...he crankcase on the oil pan and is driven off the gear on the camshaft The governor works as follows Centrifugal force acting on the rotating governor gear assembly causes the flyweights to move outward as speed increases Governor spring tension moves them inward as speed decreases As the flyweights move outward they cause the regulating pin to move outward The regulating pin contacts the tab on t...

Page 65: ...eck the RPM speed 2 Loosen the lock nut on the high speed adjusting screw Turn the screw counterclockwise to decrease or clockwise to increase RPM speed Check RPM with a tachometer 3 When the desired RPM speed is obtained retighten the lock nut NOTE When the throttle and choke control cables are routed side by side especially under a single clamp there must be a small gap between the cables to pre...

Page 66: ...d of the spring through the hole in the lever from the left side 2 Rotate the spring 180 until hooked as shown in Figure 5 69 3 Hook the short end of the spring into the appropriate hole in the governor lever Refer to the appropriate chart in Section 11 Reassembly of this manual for the correct hole to use for the speed involved Choke Cable Choke Lever See Detail at Left Clamp Throttle Cable Sprin...

Page 67: ...racket Screw Spring Washer Hex Nut Screw Throttle Control Lever Lock Nut Throttle Cable Bushing Throttle Linkage Fuel Pump Clamp Fuel Throttle Shaft Bushing Throttle Shaft Bracket Deflector If So Equipped Throttle Lever Lock Nut Spacer Washer Governor Spring Governor Lever Linkage Spring Screw Figure 5 69 Governor Controls Assembly CV750 ...

Page 68: ... 10 Oxygen Sensor 5B 10 5B 12 Electrical Relay 5B 12 5B 13 Fuel Injectors 5B 13 5B 16 Ignition System 5B 17 Spark Plugs 5B 18 Wiring Harness 5B 18 Battery Charging System 5B 18 Fuel Components Fuel Pump 5B 18 5B 19 Fuel Pressure Regulator 5B 19 5B 21 Fuel Filter 5B 21 Fuel Rail 5B 21 Fuel Line 5B 21 5B 22 Throttle Body Intake Manifold Assembly 5B 22 Idle Speed Adjustment RPM 5B 22 5B 23 Initial Go...

Page 69: ...ription 2 For plastic cased ECU s below 24 584 28 S the system can be primed by manually cycling the fuel pump a Turn the key switch to the on run position The fuel pump will run for about three seconds and stop Turn the switch off and back on to restart the fuel pump Repeat this procedure until the fuel pump has cycled five times then start the engine 3 The system can also be primed similar to re...

Page 70: ...inject it into the intake ports The ECU controls the amount of fuel by varying the length of time that the injectors are on This can range from 1 5 8 0 milliseconds depending on fuel requirements The controlled injection of the fuel occurs each crankshaft revolution or twice for each 4 stroke cycle One half the total amount of fuel needed for one firing of a cylinder is injected during each inject...

Page 71: ... not use compressed air if the system is open Cover any parts removed and wrap any open joints with plastic if they will remain open for any length of time New parts should be removed from their protective packaging just prior to installation Avoid direct water or spray contact with system components Do not disconnect or reconnect the main ECU wiring harness connector or any individual components ...

Page 72: ...severity of the fault normal operation may continue or limp home operation slowed speed richer running may be initiated A technician can access the stored fault code using a blink code diagnosis flashed out through the MIL An optional computer software diagnostic program is also available see Section 2 The ECU requires a minimum of 7 0 volts to operate The adaptive memory in the ECU is operational...

Page 73: ...or damage or problems 3 Make sure the engine has resistor type spark plugs 4 Disconnect the main harness connector from the ECU 5 Connect an ohmmeter between the 9 and 10 pin terminals See chart on page 5B 26 or 5B 29 according to ECU style A resistance value of 750 1000 Ω Ω Ω Ω Ω at room temperature 20 C 68 F should be obtained If resistance is correct check the mounting air gap toothed ring gear...

Page 74: ... the ECU but leave the TPS mounted to the throttle body manifold 3 a Use an ohmmeter and connect the ohmmeter leads as follows to test See chart on page 5B 26 or 5B 29 24 Pin MSE 1 0 Plastic Cased ECU Red positive ohmmeter lead to 8 pin terminal and Black negative ohmmeter lead to 4 pin terminal 32 Pin MSE 1 1 Plastic Cased ECU Red positive ohmmeter lead to 8 pin terminal and Black negative ohmmet...

Page 75: ...o its original setting c Reconnect connector plugs start engine and retest system operation 7 Remove the two mounting screws from the TPS Save the screws for reuse Remove and discard the faulty TPS Install the replacement TPS and secure with the original mounting screws a Reconnect both connector plugs b Perform the appropriate TPS Initialization Procedure integrating the new sensor to the ECU TPS...

Page 76: ...or function in closed loop operation 7 Watch the MIL When the light starts blinking rapidly 5 blinks per second move the throttle lever to the low idle speed position Check and adjust the idle speed to 1500 RPM using a tachometer The lamp should continue to blink rapidly for another 30 seconds before switching to a slow blink 8 When the MIL blinks slowly do not do anything but wait until the MIL s...

Page 77: ... resistance separately Resistance value should again be 2375 2625 Ω Ω Ω Ω Ω a If the resistance is out of specifications replace the temperature sensor b If it is within specifications proceed to Step 6 6 Check the circuits input ground from the main harness connector to the sensor plug for continuity damage etc Connect one ohmmeter lead to pin terminal 6 in the main harness connector as in step 4...

Page 78: ...2 v and 1 0 v which indicates the oxygen sensor is functioning normally and fuel delivery is within prescribed parameters If the voltage readings show a steady decline rev the engine and check the indicated reading again If the voltage momentarily increases and then again declines without cycling the engine may be running lean due to incorrect TPS initialization Shut off the engine perform TPS ini...

Page 79: ...v 0 35 0 55 v a If the voltage reading is not as specified move the black voltmeter lead to the negative post of the battery to be certain of a good ground If the voltage is still not correct the ECU is probably bad b If the voltage readings are correct clear the fault codes and run the engine to check if any fault codes reappear To Replace Oxygen Sensor 1 Disconnect the oxygen sensor connector fr...

Page 80: ... Ground Terminal 30 Permanent Battery Voltage Terminal 87A Not used Figure 5B 14 Style 1 Fuel Injector 2 Connect the black lead of VOA meter to a chassis ground location Connect the red lead to the 86 terminal in relay connector see Figure 5B 12 Set meter to test resistance Rx1 Turn ignition switch from off to on Meter should indicate continuity ground circuit is completed for 1 to 3 seconds Turn ...

Page 81: ...he inside The director plate at the tip of the injector see inset contains a series of calibrated openings which directs the fuel into the manifold in a cone shaped spray pattern Figure 5B 16 Fuel Injector Details The injector is opened and closed once for each crankshaft revolution however only one half the total amount of fuel needed for one firing is injected during each opening The amount of f...

Page 82: ...nce should be 4 15 Ω Ω Ω Ω Ω for each circuit 32 Pin MSE 1 1 Plastic Cased ECU Check the resistance between relay terminal 87 and pin 14 in the main connector Then check the resistance between relay terminal 87 and pin 15 Resistance should be 4 15 Ω Ω Ω Ω Ω for each circuit Check all electrical connections connectors and wiring harness leads if resistance is incorrect Injector leakage is very unli...

Page 83: ...Symptoms that could be caused by dirty clogged injectors include rough idle hesitation stumble during acceleration or triggering of fault codes related to fuel delivery Injector clogging is usually caused by a buildup of deposits on the director plate restricting the flow of fuel resulting in a poor spray pattern Some contributing factors to injector clogging include higher than normal operating t...

Page 84: ...sing an ohmmeter set on the Rx1 scale check the resistance in circuits as follows 24 Pin MSE 1 0 Plastic Cased ECU Check between terminal 87 and pin 22 for coil 1 Repeat the test between terminal 87 and pin 23 for coil 2 32 Pin MSE 1 1 Plastic Cased ECU Check between terminal 87 and pin 30 for coil 1 Repeat the test between terminal 87 and pin 31 for coil 2 A reading of 1 8 4 0 Ω Ω Ω Ω Ω in each t...

Page 85: ...ccommodate the combined electrical demands of the ignition system and the specific application Charging system troubleshooting information is provided in Section 8 Fuel Components Fuel Pump Internal External Figure 5B 21 24 Pin MSE 1 0 Plastic Cased ECU Connector Figure 5B 22 32 Pin MSE 1 1 Plastic Cased ECU Connector Figure 5B 23 Fuel Pump Styles General An electric fuel pump is used to transfer ...

Page 86: ...m pressure a If the pressure is too high and the regulator is outside the tank just down line from the pump check that the return line from the regulator to the tank is not kinked or blocked If the return line is good replace the regulator see Regulator Service on page 5B 20 b If the pressure is too low install in line T between the pump and the regulator and retest the pressure at that point If i...

Page 87: ...st the valve holder part of the diaphragm pressing the valve against the valve seat The combination of atmospheric pressure and regulating spring tension equals the desired operating pressure Any time the fuel pressure against the bottom of the diaphragm exceeds the desired top pressure the valve opens relieving the excess pressure returning the excess fuel back to the tank Figure 5B 28 Internal I...

Page 88: ...a substitute filter as operating performance and safety can be affected Relieve system pressure through the safety valve in the fuel rail before servicing Figure 5B 30 Throttle Body Intake Manifold General The fuel rail is a formed tube assembly that feeds fuel to the top of the injectors The tops of the injectors fit into formed cups in the fuel rail When the rail is fastened to the manifold the ...

Page 89: ...ly adjustment that may be performed on the EFI system The standard idle speed setting for EFI engines is 1500 RPM but certain applications might require a different setting Check the equipment manufacturer s recommendation For starting and warm up the ECU will adjust the fuel and ignition timing based upon ambient temperature engine temperature and loads present In cold conditions the idle speed w...

Page 90: ... immediately to Procedure B to perform the initial adjustment A Checking the Initial Adjustment 1 Unsnap the plastic linkage bushing attaching the throttle linkage to the governor lever See Figure 5B 34 Unhook the damper spring from the lever separate the linkage from the bushing and remove the bushing from the lever Mark the hole position and unhook the governor spring from the governor lever Fig...

Page 91: ... procedure as follows Figure 5B 38 Checking Split of Clamp 2 Follow the instructions in Step 2 of Checking the Initial Adjustment then reattach the throttle linkage to the governor lever with the bushing clip It is not necessary to reattach the damper or governor springs at this time 3 Insert a nail into the hole in the top of the cross shaft Using light pressure rotate the governor shaft counterc...

Page 92: ... 1 Fuel pump not running 2 Faulty spark plugs 3 Old stale fuel 4 Incorrect fuel pressure 5 Speed sensor loose or faulty 6 TPS offset incorrect initialization 7 TPS faulty 8 Engine temp sensor faulty 9 Faulty coils 10 Low system voltage 11 Faulty injectors Engine starts hard or fails to start when hot 1 Faulty spark plugs 2 Fuel pump not running 3 Fuel pressure low 4 Insufficient fuel delivery 5 TP...

Page 93: ...nt disconnect the ECU connector and test for continuity between the component connector terminals and the corresponding terminals in the ECU connector using an ohmmeter Little or no resistance should be measured indicating that the wiring of that particular circuit is OK An illustrated listing of numerical terminal locations for each style of ECU connector is provided on pages 5B 26 and 5B 29 NOTE...

Page 94: ......

Page 95: ......

Page 96: ...erature Sensor Input Not Used Throttle Position Sensor TPS Input Speed Sensor Input Speed Sensor Ground Not Used Not Used Not Used Injector 1 Output Injector 2 Output Not Used Diagnostic Line Throttle Position Sensor Supply Voltage Battery Ground Oxygen Sensor Input Battery Ground secondary Not Used Not Used Not Used Safety Switch Input Not Used Not Used Main Relay Output Malfunction Indicator Lig...

Page 97: ...fuel line connections are damaged or broken 6 Test fuel pump and relay operation as described earlier under Fuel Pump Service Fault Codes The ECU continuously monitors engine operation against preset performance limits If the operation is outside the limits the ECU activates the MIL and stores a diagnostic code in its fault memory If the component or system returns to proper function the ECU will ...

Page 98: ...g the chart is a list of the individual codes with an explanation of what triggers them what symptoms might be expected and the probable causes Diagnostic Code Summary Example of Diagnostic Display Long Pause 3 4 5 6 7 k n i l B e d o C 2 D B O e d o C P e l b a c i l p p A n i P 2 3 o t 1 1 E S M t s y S U C E y l n O m e n o i t p i r c s e D e r u l i a F r o n o i t c e n n o C n i P 4 2 0 1 E...

Page 99: ...r i C n e p O 1 r o t c e j n I A N Y 1 5 1 6 2 0 P d n u o r G o t t i u c r i C t r o h S 1 r o t c e j n I A N Y 1 5 2 6 2 0 P y r e t t a B o t t i u c r i C t r o h S 1 r o t c e j n I A N Y 2 5 3 6 2 1 P t i u c r i C n e p O 2 r o t c e j n I A N Y 2 5 4 6 2 0 P d n u o r G o t t i u c r i C t r o h S 2 r o t c e j n I A N Y 2 5 5 6 2 0 P y r e t t a B o t t i u c r i C t r o h S 2 r o t c ...

Page 100: ...ector 4 ECU Harness Related a ECU to harness connection problem 5 Ignition System Related a Non resistor spark plug s used Code 22 Source Throttle Position Sensor TPS Explanation Unrecognizable signal is being sent from sensor too high too low inconsistent Expected Engine Response A limp home operating mode occurs with an overall decrease in operating performance and efficiency Fuel delivery is ba...

Page 101: ...battery voltage After fault is detected performance can vary depending on cause If performance is pretty good the problem is probably with the oxygen sensor wiring or connectors If the engine is still running rich laboring short on power or lean popping or misfiring the fuel mixtureis suspect probably incorrect TPS initialization or low fuel pressure Possible Causes 1 TPS Initialization Incorrect ...

Page 102: ...lem rings valves e Exhaust system leak f Fuel in the crankcase oil g Blocked or restricted fuel return circuit to tank 6 ECU Related a ECU to harness connection problem Code 34 Source Oxygen Sensor Fuel System Components Explanation Long term fuel adaptation control is at the upper or lower limit Expected Engine Response System operates closed loop No appreciable performance loss as long as the te...

Page 103: ...ge to ECU disconnected to clear memory Possible Causes 1 TPS Related a TPS rotated on throttle shaft assembly out of allowable range b TPS bad 2 Engine Wiring Harness Related a Broken or shorted wire in harness ECU pin 18 to TPS pin 1 ECU pin 4 to TPS pin 2 ECU pin 8 to TPS pin 3 3 Throttle Body Related a Throttle shaft inside TPS worn broken or damaged b Throttle plate loose or misaligned c Throt...

Page 104: ...ircuit controlling fuel pump relay damaged Code 55 32 Pin MSE 1 1 Plastic Cased ECU only Source MIL Diagnostic lamp circuit open shorted to ground or shorted to battery Explanation MIL is not functioning because the circuit is open shorted to ground or shorted to battery Expected Engine Response Engine will run normally if no other errors are present Possible Causes 1 MIL diagnostic lamp Related a...

Page 105: ...ooting Flow Chart The following flow chart provides an alternative method of troubleshooting the EFI system The chart will enable you to review the entire system in about 10 15 minutes Using the chart the accompanying diagnostic aids listed after the chart and any signaled fault codes you should be able to quickly locate any problems within the system ...

Page 106: ...5B 39 Section 5B EFI Fuel System 5B Figure 5B 41 Operate for an appropriate period of time based upon original fault codes ...

Page 107: ...Injector 2 32 Pin MSE 1 1 Plastic Cased ECU only 13 Code 55 MIL Light 32 Pin MSE 1 1 Plastic Cased ECU only 14 Code 56 Pump Relay 32 Pin MSE 1 1 Plastic Cased ECU only 15 Code 61 End of Fault Blink Code Transmission Diagnostic Aid 3 RUN ON MIL remains on while engine is running Possible causes 1 Fault codes which turn on MIL when engine is running a Code 21 Engine Speed Synchronization b Code 22 T...

Page 108: ... s 24 Pin MSE 1 0 Plastic Cased ECU Circuits 22 23 65 66 30 and relay 32 Pin MSE 1 1 Plastic Cased ECU Circuits 30 31 65 66 relay and relay circuit 30 5 ECU grounds 6 ECU Diagnostic Aid 8 FUEL SYSTEM ELECTRICAL no fuel delivery Possible causes 1 No fuel 2 Air in fuel rail 3 Fuel valve shut off 4 Fuel filter line plugged 5 Injector circuit s 24 Pin MSE 1 0 Plastic Cased ECU Circuits 16 17 45 and 45...

Page 109: ...elect the viscosity based on the air temperature at the time of operation as shown in the following table Figure 6 1 Oil Container Logo The top position 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 shows the viscosity grade such as SAE 10W 30 If the bottom portion shows Energy Conserving it means ...

Page 110: ... off Reinsert the dipstick into the tube and rest the oil fill cap on the tube Do not thread the cap onto the tube See Figure 6 2 NOTE To prevent extensive engine wear or damage always maintain the proper oil level in the crankcase Never operate the engine with the oil level below the low mark or above the full mark on the dipstick Changing Oil and Oil Filter Changing Oil Change the oil after ever...

Page 111: ...cement filter in a shallow pan with the open end up Pour new oil of the proper type in through the threaded center hole Stop pouring when the oil reaches the bottom of the threads Allow a minute or two for the oil to be absorbed by the filter material 6 Apply a thin film of clean oil to the rubber gasket on the new oil filter 7 Install the new oil filter to the filter adapter Hand tighten the filt...

Page 112: ... through the range of 3 0 5 0 psi the tester should indicate a change to no continuity switch open The switch should remain open as the pressure is increased to 90 psi maximum 3 Gradually decrease the pressure through the range of 3 0 5 0 psi The tester should indicate a change to continuity switch closed down to 0 psi 4 Replace the switch if it does not operate as specified Figure 6 8 Cleaning Bl...

Page 113: ... the retractable starter onto the blower housing leaving the five hex flange screws slightly loose Figure 7 2 Removing Starter Handle 3 Remove the rope retainer from inside 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 t...

Page 114: ...ed Slowly retract the rope into the starter When the spring is properly tensioned the rope will retract fully and the handle will stop against the starter housing Pawls Dogs Replacement To replace the pawls follow disassembly steps 1 4 and reassembly steps 3 8 on the following pages A pawl repair kit is available which includes the following components Description Qty Pawl Retainer Center Screw Pa...

Page 115: ...ousing so the pulley is away from your face and away from others in the area 7 Rotate the pulley slightly from side to side and carefully separate the pulley from the housing See Figure 7 6 If the pulley and the housing do not separate easily the spring could be engaged in the starter housing or there is still tension on the spring Return the pulley to the housing and repeat step 5 before separati...

Page 116: ...into the starter housing See Figure 7 8 Make sure the pulley is fully seated against the starter housing Do not wind the pulley and recoil spring at this time Figure 7 9 Installing Pawls and Pawl Springs 4 Place the brake washer in the recess in the starter pulley over the center shaft 5 Lubricate the brake spring sparingly with grease Place the spring on the washer Make sure the threads in the ce...

Page 117: ...Spark Plug Service Remove the spark plugs after every 200 hours of operation Check their condition and either reset the gap or replace with new plugs as necessary To service the plugs perform the following steps 1 Before removing a spark plug clean the area around the base of the plug to keep dirt and debris out of the engine 2 Remove the plug and check its condition See Inspection following this ...

Page 118: ...amber is usually caused by a restricted air cleaner a breather problem or worn piston rings cylinder walls or valve guides Carbon Fouled Soft sooty black deposits indicate incomplete combustion caused by a restricted air cleaner over rich fuel mixture weak ignition or poor compression Worn On a worn plug the center electrode will be rounded and the gap will be greater than the specified gap Replac...

Page 119: ...lication and starting temperatures The cranking requirements increase as temperatures decrease and battery capacity shrinks Refer also to the operating instructions for the piece of equipment for specific battery requirements Battery Size Recommendations If the battery charge is not sufficient to turn over the engine recharge the battery Battery Maintenance Regular maintenance is necessary to prol...

Page 120: ...tem For Customer Connected Tractor Applications Oil Pressure Safety Input Rectifier Regulator B and Carburetor Solenoid Input Ignition Module Input Carburetor Solenoid Oil Pressure Safety Red Green White Ignition Modules Spark Plugs B Violet Red Starter and Carburetor Solenoid Input White Red Red Spark Advance Module Optional Operation of CD Ignition Systems A Capacitive Discharge with Fixed Timin...

Page 121: ...etic field induces energy into the input coil L1 The resultant pulse is rectified by D1 and charges capacitor C1 As the magnet assembly completes its pass it activates the triggering device L2 which causes the semiconductor switch SCS to turn on With the device switch ON the charging capacitor C1 is directly connected across the primary P of the output transformer T1 As the capacitor discharges th...

Page 122: ...ch mounts to the engine shrouding Figure 8 7 A 12 volt battery which supplies current to the spark advance module A kill switch or key switch which grounds the spark advance module to stop the engine Two spark plugs Figure 8 7 Block Diagram Spark Advance Module Figure 8 6 Capacitive Discharge Ignition System with Spark Advance The timing of the spark is controlled by the location of the flywheel m...

Page 123: ...oblem CAUTION High Energy Electric Spark The CD ignition systems produce a high energy electric spark but the spark must be discharged 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 Reported ignition problems are most often due to poor connections Before beginning the test procedure che...

Page 124: ... lead terminal so it cannot touch ground Try to start the engine to verify whether the reported problem is still present a If the problem is gone the electrical system on the unit is suspect Check the key switch wires connections safety interlocks etc b If the problem persists the condition is associated with the ignition or electrical system of the engine Leave the kill lead isolated until all te...

Page 125: ...vendor numbers MA 2C or MA 2D Kohler Part No 24 584 11 or the larger style modules 24 584 15 S and 24 584 36 S use a digital ohmmeter to check the resistance values and compare them to the table following When testing resistance to the laminations touch the probe to the laminations inside the screw hole as some laminations have a rust preventative coating on the surface which could alter the resis...

Page 126: ...ector and connect the red lead of a DC voltmeter to the harness terminal Trace the ground lead from the SAM black on singles green on twins to the grounding screw Connect the black voltmeter lead to the eyelet terminal of the ground lead or the ground screw bolt Check the voltage with the key switch in both the START and RUN positions A minimum of 7 25 volts must be present 5 Check and or adjust t...

Page 127: ...heck the fit 4 Seal the base of the ignition module connections with GE Novaguard G661 see Section 2 or Fel Pro Lubri Sel dielectric compound The beads should overlap between the two connections to form a solid bridge of compound Do not put any compound inside the connectors The 24 584 15 S ignition modules have a separator barrier between the terminals On these modules seal the base of the termin...

Page 128: ...e reading may be displayed in the form of a or a faint 8 3 Disconnect the yellow and brown tester leads from the long module leads Connect the brown tester lead to the short brown module lead Connect the yellow tester lead to the short yellow or pink module lead See Figure 8 13 Leave the red and green leads connected Repeat step 2 Figure 8 13 The tester is powered by a 9 volt battery Most SAMs are...

Page 129: ...k white lead with the bullet connector or a Fail test result will occur regardless of actual condition Caution Do not allow alligator clip leads to touch each other 2 Recheck the SAM part number noting the last two digits Refer to the table below or on the tester faceplate to determine the test number to be used To Test Using 25 761 40 S Tester DSAM ASAM Test Procedure NOTE The SAM must be at room...

Page 130: ...gines are equipped with a 15 or 20 amp regulated charging system Some have a 25 amp regulated charging system See Figure 8 17 and 8 18 for the 15 20 25 amp charging system diagram Some engines utilize a 3 amp unregulated system with optional 70 watt lighting circuit Refer to Figure 8 23 NOTE Observe the following guidelines to avoid damage to the electrical system and components Make sure the batt...

Page 131: ...8 15 8 Section 8 Electrical System and Components 15 20 25 Amp Regulated Charging System Figure 8 17 Wiring Diagram 15 20 25 Amp Regulated Battery Charging System with Fixed Timing ...

Page 132: ...m and Components Figure 8 19 15 Amp Stator and Rectifier Regulator Figure 8 20 20 Amp Stator and Rectifier Regulator Figure 8 18 Wiring Diagram 15 20 25 Amp Regulated Battery Charging System with Variable Ignition Timing SMART SPARK ...

Page 133: ... V Battery Solenoid Starter Lights Yellow Black 3 Amp 70 Watt Flywheel Stator Ignition Modules Spark Plug Red Blue R A S B GND Light Optional Fuse Optional Ammeter Spark Plug Figure 8 21 25 Amp Stator and Rectifier Regulators 3 Amp Unregulated Charging System 1st Style 2nd Style 25 Amp Stator Figure 8 22 Wiring Diagram 3 Amp Unregulated Battery Charging System 70 Watt Lighting ...

Page 134: ...regulator may be performed as follows using the appropriate Rectifier Regulator Tester see Section 2 To Test NOTE 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 clarity Repeat the applicable test procedure two or three times to determine the condit...

Page 135: ...rily one of the four status lights will illuminate indicating the condition of the part 20 25 Amp Rectifier Regulators 1 Connect the single lead adapter in between the B center terminal of the rectifier regulator being tested and the squared single end of the tandem adapter lead See Figure 8 28 Figure 8 28 2 Connect the tester ground lead with spring clamp to the body of the rectifier regulator 3 ...

Page 136: ...e not location specific 4 Connect the remaining black lead from tester to one of the black AC outside leads from rectifier regulator See Figure 8 31 Figure 8 31 5 Plug the tester into the proper AC outlet power supply for tester being used Turn on the power switch The POWER light should be illuminated and one of the four status lights may be on as well See Figure 8 26 This does not represent the c...

Page 137: ...epresent the condition of the part 4 Press the TEST button until a click is heard and then release See Figure 8 27 Momentarily either the HIGH LOW or SHORT light will flash a If the HIGH light flashes on off the part is good and may be used b If any other light is displayed the rectifier is faulty and should not be used NOTE A flashing LOW light can also occur as a result of an inadequate ground l...

Page 138: ... battery charges at too high a rate the problem can usually be found somewhere in the charging system or with the battery NOTE Always zero ohmmeter on each scale before testing to ensure accurate readings Voltage tests should be made with the engine running at 3600 RPM no load The battery must be good and fully charged 2 Remove connector from rectifier regulator With engine running at 3600 RPM mea...

Page 139: ...onnect 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 from lighting lead to ground using an ohmmeter Conclusion 1 If voltage is more than 12 5 volts charging system is OK If voltage is 12 5 volts or less the stator or diode are probably faulty Test th...

Page 140: ...ce the faulty components Solenoid Shift Starters Perform individual solenoid test procedure See pages 8 39 and 8 40 1 Check the specific gravity of battery If low recharge or replace battery as necessary 1 Check for excessively dirty or worn brushes and commutator Clean using a coarse cloth not emery cloth 2 Replace brushes if excessively or unevenly worn 1 Make sure the clutch or transmission is ...

Page 141: ...rive components Style A Drive Service 1 Remove the starter from the engine and remove the dust cover 2 Hold the drive pinion in a vice with soft jaws when removing or installing the stop nut The armature will rotate with the nut until the drive pinion stops against internal spacers NOTE Do not over tighten the vise as this can distort the drive pinion 3 Remove the stop nut stop gear spacer anti dr...

Page 142: ... Retaining Ring Anti Drift Spring Drive Pinion Drive Nut Collar Dust Cover Spacer Spring Retainer Figure 8 35 Drive Components Bonded Inertia Drive Starter 2 Disassemble the snap ring removal tool see Section 2 3 Again referring to Figure 8 35 grasp the spring retainer and push it toward the starter compressing the anti drift spring and exposing the retaining ring 4 Holding the spring retainer in ...

Page 143: ...cate the small raised line on the edge of the drive end cap On starters with Style A commutator end caps it will be aligned with a pre marked line on the starter frame The frame is not pre marked on starters with Style B end caps Place a piece of masking tape on the frame and mark a line on the tape in line with the raised line on the end cap See Figure 8 41 3 Remove the thru bolts 4 Remove the co...

Page 144: ...1 2 1 1 3 4 2 1 2 2 Insert the armature into the starter frame Make sure the magnets are closer to the drive shaft end of the armature The magnets will hold the armature inside the frame 3 Install the drive end cap over the drive shaft Make sure the match marks on the end cap and starter frame are aligned See Figure 8 41 Figure 8 41 Starter Assembly Match Marks For Style A Commutator End Caps 4 In...

Page 145: ...er is covered first and the Delco Remy starter servicing follows Operation Solenoid Shift Starter When power is applied to the starter the electric solenoid moves the drive pinion out onto the drive shaft and into mesh with the flywheel ring gear When the pinion reaches the end of the drive shaft it rotates the flywheel and cranks the engine When the engine starts and the start switch is released ...

Page 146: ...rrs on the post 4 The replacement brushes have a solid portion 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 the brush holder Reinstall the springs Starter Service Every 500 hours of operation or annually whichever comes first solenoid shift starters must be disassembled cleaned and relubricated Apply s...

Page 147: ... mounted with external Torx head screws the plunger is part of the solenoid unhook the plunger pin from the drive lever Remove the gasket from the recess in the housing See Figures 8 46 and 8 47 NOTE Test procedure for checking starter solenoid on pages 8 39 and 8 40 Figure 8 47 Removing Plunger 4 Remove the two thru larger bolts See Figure 8 48 Figure 8 46 Solenoid Removed from Starter Phillips H...

Page 148: ... Plate Assembly 6 Remove the frame from the armature and drive end cap See Figure 8 50 Figure 8 52 Armature and Lever Removed 10 Push the stop collar down to expose the retaining ring See Figure 8 53 Figure 8 50 Starter Frame Removed 7 Remove the drive lever pivot bushing and backing plate from the end cap See Figure 8 51 Figure 8 51 8 Take out the drive lever and pull the armature out of the driv...

Page 149: ...mature or use solvent when cleaning Wipe clean using a soft cloth or use compressed air Figure 8 53 Retaining Ring Detail 11 Remove the retainer from the armature shaft Save the stop collar NOTE Do not reuse the old retainer Lever Solenoid CE Frame Bolt Ring Stop Drive Armature Washer Screw Plunger Spring Plate Collar Tube Screw Plug Frame Field Brush Holder Nut Figure 8 55 Delco Remy Starter ...

Page 150: ...e Rx1 scale Touch the probes between two different segments of the commutator and check for continuity See Figure 8 58 Test all the segments Continuity must exist between all or the armature is bad Wear limit length 7 6 mm 0 300 in Commutator O D Mica Insulation Continuity Check Armature Coil Insulation Check Inspection Drive Pinion Check and inspect the following areas a The pinion teeth for abno...

Page 151: ...d 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 other starter parts for wear or damage as required Starter Reassembly 1 Apply drive lubricant see Section 2 to the armature shaft splines Install the drive pinion onto the armature shaft 2 Install and assemble the stop collar retainer assembly...

Page 152: ...w the machined surface of the housing which receives the backup washer See Figure 8 63 Figure 8 63 Installing Armature and Pivot Lever Figure 8 64 Installing Backup Washer and Grommet 8 Install the frame with the small notch forward onto the armature and drive end cap Align the notch with the corresponding section in the rubber grommet Install the drain tube in the rear cutout if it was removed pr...

Page 153: ...th the I D of the brush holder assembly Insert the Brush Installation Tool with extension or use the tube described above from a prior brush installation through the brush holder assembly so the holes in the metal mounting clips are up out c Install the brush springs and snap on the four retainer caps See Figure 8 69 Figure 8 67 Installing Brush Holder Assembly with Supplied Tube Starter reassembl...

Page 154: ...ting screws to 2 5 3 3 N m 22 29 in lb See Figures 8 71 and 8 72 Figure 8 72 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 the drive end cap Use these to hold the solenoid gasket in position then mount the solenoid Torque the screws to 4 0 6 0 N m 35 53 in lb 14...

Page 155: ...o the solenoid for any time over what is necessary for performing each of the individual tests Internal damage to the solenoid may otherwise occur Figure 8 74 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 leads to the two large post terminals Perform the preceding test 1 and ...

Page 156: ...t to the audible or Rx2K scale and connect the two ohmmeter leads to the two large post terminals Perform the preceding test 3 and check for continuity See Figure 8 77 The meter should indicate continuity if no continuity is indicated the solenoid should be replaced Repeat test several times to confirm condition Figure 8 77 Testing Hold In Coil Solenoid Contact Continuity ...

Page 157: ...odate options or special equipment 1 Disconnect spark plug leads 2 Shut off fuel supply 3 Drain oil from crankcase and remove oil filter 4 Remove oil cooler 5 Remove muffler 6 Remove air cleaner assembly 7 Remove control panel 8 Remove fuel pump 9 Remove throttle controls 10 Remove external governor controls 11 Remove carburetor 12 Remove electric starter motor 13 Remove outer baffles and blower h...

Page 158: ...te the filter adapter from the oil pan leaving the oil lines attached Remove the two hex flange screws mounting the oil cooler to the blower housing Remove the cooler lines and filter adapter as an assembly Remove Muffler 1 Remove the exhaust system and attaching hardware from the engine On engines equipped with a port liner remove it now Remove Air Cleaner Assembly Standard Air Cleaner 1 Unhook t...

Page 159: ...uring the spitback cup baffle or bracket and air cleaner base See Figure 9 7 Two additional lower screws must be removed if the engine contains a lower air cleaner support bracket Figure 9 9 Disconnect Breather Hose from Base 5 Disconnect the breather tube from the nipple on the underside or the hose from the base as equipped See Figure 9 9 6 Remove the base and gasket while carefully pulling the ...

Page 160: ...See Figure 9 14 4 Remove the panel from the blower housing See Figure 9 15 4 Remove the two upper screws securing the air cleaner mounting bracket to the blower housing and remove the air cleaner assembly See Figures 9 12 and 9 13 Figure 9 10 Removing Breather Hose Hex Nuts and Adapter Elbow Two Barrel Model Pictured 2 Pull the adapter elbow and gasket off the mounting studs 3 Remove the four scre...

Page 161: ...r and at the in line fuel filter Figure 9 17 Pulse Fuel Pump Details 2 Disconnect the pulse vacuum hose from the crankcase See Figure 9 16 3 Remove the two hex flange mounting screws from the blower housing and remove the fuel pump and lines as an assembly See Figure 9 17 Remove Throttle Controls 1 Remove the four hex flange screws securing the throttle control bracket and lower air cleaner bracke...

Page 162: ... Leave the lever attached to the throttle linkage Figure 9 20 Removing Governor Lever Remove Carburetor WARNING Explosive Fuel Gasoline may be present in the carburetor and fuel system Gasoline is extremely flammable and its vapors can explode if ignited Keep sparks and other sources of ignition away from the engine 1 Disconnect the fuel shut off solenoid lead if so equipped Control Bracket Air Cl...

Page 163: ...r throttle linkage and governor lever can be separated Reattach the bushings to the linkage following separation to avoid losing them Remove Electric Starter Motor 1 Disconnect the leads from the starter 2 Remove the two hex flange screws See Figure 9 25 Figure 9 25 Removing Electric Starter Motor 3 Remove the starter assembly and lift bracket Some inertia drive starters use a separate starter cov...

Page 164: ...th SMART SPARK remove the mounting screws from the spark advance module SAM See Figure 9 27 The module will hang loose as part of the wiring harness 3 Remove the three each side hex flange screws securing the outer baffles Note the location of any lifting strap and the position of the two short screws one each side on bottom for reassembly See Figure 9 28 Remove Outer Baffles and Blower Housing 1 ...

Page 165: ...ex flange screws from the breather cover 4 Pry under the protruding edge of the breather cover with a screwdriver to break the RTV or gasket seal See Figure 9 35 Do not pry on the sealing surfaces as it could cause damage resulting in leaks Most engines use a formed gasket rather than RTV sealant Remove Oil Sentry 1 Disconnect the lead from the Oil Sentry switch 2 Remove the Oil Sentry switch from...

Page 166: ...nt between the cover and sealing surface of the cylinder head The second type had a black O Ring installed in a groove on the underside of the cover and may have metal spacers in the bolt holes The latest design uses a yellow or brown O Ring and the bolt hole spacers are molded in place 1 Remove the four hex flange screws securing each valve cover Note valve cover differences for proper location i...

Page 167: ...o 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 Ring plastic intake manifolds See Figure 9 40 3 Leave the wiring harness attached to the manifold Figure 9 40 Removing Intake Manifold Remove Spark Plugs 1 Remove the spark plug from each cylinder head See Figure 9 41 Figure 9 41 Removing Spark P...

Page 168: ...using either 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 42 Discard the screws or nuts and washers once removed Do not reuse Studs if present should only be removed ...

Page 169: ...em seals on the intake valves Use a new seal whenever the valve is removed or if the seal is deteriorated or damaged in any way Never reuse an old seal 4 Repeat the above procedure for the other cylinder head Do not interchange parts from one cylinder head to the other Remove Grass Screen and Fan 1 On engines with a flat plastic screen small metal retainers are typically attached on three of the s...

Page 170: ... the four screws securing the backing plates and stator wire bracket if so equipped See Figure 9 53 Remove the backing plates and stator wire bracket Figure 9 49 Removing Plastic Grass Screen 2 Remove the four hex flange screws or hex studs and washers Remove the plastic fan from the flywheel See Figure 9 50 Figure 9 50 Removing Fan Remove Flywheel 1 Use a flywheel strap wrench or holding tool see...

Page 171: ...her from the governor cross shaft See Figures 9 57 and 9 58 2 Locate the splitting tabs cast into the perimeter of the oil pan Insert the drive end of a 1 2 breaker bar between the splitting tab and the crankcase and turn it to break the RTV seal See Figure 9 55 Do not pry on the sealing surfaces as this can cause leaks Governor Gear Assembly The governor gear assembly is located inside the oil pa...

Page 172: ...s to mark each end cap connecting rod and piston for reassembly Do not mix end caps and connecting rods Remove Connecting Rods with Pistons and Rings 1 Remove the two hex flange screws securing the closest connecting rod end cap Remove the end cap See Figure 9 60 Figure 9 61 Removing Connecting Rod and Piston Assembly Figure 9 58 Removing Governor Cross Shaft Retainer 8 mm Shaft Design 2 Remove th...

Page 173: ...er connecting rod and piston assembly Remove Crankshaft 1 Carefully pull the crankshaft from the crankcase See Figure 9 62 Figure 9 62 Removing Crankshaft Figure 9 63 Removing Oil Seal Remove Flywheel End Oil Seal 1 Remove the oil seal from the crankcase See Figure 9 63 ...

Page 174: ...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 175: ...ntal planes Use an outside micrometer to measure the outside diameter of the crankshaft main bearing journals Subtract the journal diameters from their respective bore diameters to get the running clearances Check the results against the specifications in Section 1 If the running clearances are within specification and there is no evidence of scoring grooving etc no further reconditioning is neces...

Page 176: ...l It washes the necessary lubricating oils off the piston and cylinder wall As raw fuel seeps down the cylinder wall the piston rings make metal to metal contact with the wall Scoring of the cylinder wall can also be caused by localized hot spots resulting from blocked cooling fins or from inadequate or contaminated lubrication If the cylinder bore is badly scored excessively worn tapered or out o...

Page 177: ...should be taken perpendicular to each other at each of the three locations Clean Cylinder Bore After Honing Proper cleaning of the cylinder walls following boring and or honing is very critical to a successful overhaul Machining grit left in the cylinder bore can destroy an engine in less than one hour of operation after a rebuild The final cleaning operation should always be a thorough scrubbing ...

Page 178: ...lve heads faces and stems with a power wire brush Then carefully inspect each valve for 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 EXHAUST VALVE E G F H D D C A B A B A F E G H INTAKE VALVE EXHAUST INSERT INTAKE INSERT A B C D E F G H Seat Angle I...

Page 179: ...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 180: ...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 181: ... 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 182: ...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 183: ...ing pistons Never use old rings Some important points to remember when servicing piston rings 1 The cylinder bore must be deglazed before service ring sets are used 2 If the cylinder bore does not need reboring and if the old piston is within wear limits and free of score or scuff marks the old piston may be reused 3 Remove the old rings and clean up the grooves Never reuse old rings 4 Before inst...

Page 184: ...eck the 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 p...

Page 185: ...all molded tabs in the gear When the gear is removed from the shaft these tabs are destroyed and the gear must be replaced Therefore remove the gear only if absolutely necessary 1 Remove the regulating pin and governor gear assembly See Figure 10 13 Figure 10 14 Governor Shaft Press Depth Figure 10 15 Removing Oil Pump 3 Remove the oil pump rotor If a plastic pickup is used See Figures 10 15 and 1...

Page 186: ... worn See Figure 10 18 Figure 10 18 Oil Pressure Relief Valve Piston and Spring Reassembly 1 Install the pressure relief valve piston and spring 2 Install the oil pickup to the oil pump body Lubricate the O Ring with oil and make sure it remains in the groove as the pickup is being installed 3 Install the rotor 4 Install the oil pump body to the oil pan and secure with the two hex flange screws To...

Page 187: ...the lifter bores See Figure 10 19 When the pistons move downward air is pushed past the reeds into the cylinder head cavities On the 2 cylinder the upper end of the head is completely sealed by the rocker cover so a low positive pressure is created in the head cavity The 1 rocker cover has a hole in it for venting The bottom nipple of an oil separator canister is fitted into the hole with a gromme...

Page 188: ...options or special equipment Detailed procedures follow 1 Install flywheel end oil seal 2 Install governor cross shaft 3 Install crankshaft 4 Install connecting rods with pistons and rings 5 Install camshaft 6 Install oil pan assembly 7 Install stator and backing plates 8 Install flywheel 9 Install fan and grass screen 10 Install hydraulic lifters 11 Install cylinder heads 12 Install push rods and...

Page 189: ...or cross shaft See Figures 11 3 and 11 4 8 mm Governor Shaft Install the nylon washer onto the governor cross shaft then start the push on retaining ring Hold the cross shaft up in position place a 0 50 mm 0 020 in feeler gauge on top of the nylon washer and push the retaining ring down the shaft to secure Remove the feeler gauge which will have established the proper end play See Figures 11 5 and...

Page 190: ... with a rubber grip and gently tap the piston into the cylinder as shown in Figure 11 9 Be careful that the oil ring rails do not spring free between the bottom of the ring compressor and the top of the cylinder Install Crankshaft 1 Carefully slide the flywheel end of the crankshaft through the main bearing in the crankcase See Figure 11 7 Figure 11 8 Proper Piston Connecting Rod Orientation Cylin...

Page 191: ...kshaft gear at the 12 o clock position 3 Turn the governor cross shaft clockwise until the lower end of the shaft contacts the cylinder Make sure the cross shaft remains in this position while installing the camshaft See Figure 11 13 4 Slide the camshaft into the bearing surface of the crankcase positioning the timing mark of camshaft gear at the 6 o clock position Make sure the camshaft gear and ...

Page 192: ...lay Oil Pump Assembly The oil pump is mounted inside the oil pan If service was required and the oil pump was removed refer to the assembly procedures under Oil Pump Assembly in Section 10 Determining Camshaft End Play 1 Install the shim removed during disassembly onto the camshaft 2 Position the camshaft end play checking tool on the camshaft See Figure 11 14 Governor Gear Assembly The governor g...

Page 193: ...ealing surfaces have been cleaned and prepared as described at the beginning of Section 10 or in Service Bulletin 252 2 Check to make sure that there are no nicks or burrs on the sealing surfaces of the oil pan or crankcase 3 Apply a 1 5 mm 1 16 in bead of sealant to the sealing surface of the oil pan on CV17 23 engines See Figure 11 17 for the sealant pattern On CV25 750 engines use a new gasket ...

Page 194: ... taper and 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 torqued to specifications Figure 11 22 Installing Backing Plates and Stator Wire Bracket Figure 11 20 Torquing Stator Screws 4 Route the stator leads in the crankcase channel then install the backing plates and st...

Page 195: ...igure 11 24 3 Install the hex flange screw and washer 4 Use a flywheel strap wrench or holding tool to hold the flywheel Torque the hex flange screw securing the flywheel to the crankshaft to 66 4 N m 49 ft lb See Figure 11 25 Figure 11 25 Installing and Torquing Flywheel Fastener Install Fan and Grass Screen 1 Install the fan onto the flywheel using the four hex flange screws engines with plastic...

Page 196: ... 31 NOTE Hydraulic lifters should always be installed in the same position as before disassembly The exhaust lifters are located on the output shaft oil pan side of the engine while the intake lifters are located on the fan side of the engine The cylinder numbers are embossed on the top of the crankcase and each cylinder head See Figure 11 32 Figure 11 29 Torquing Supports for Metal Screen Some Mo...

Page 197: ...iners Valve spring keepers Figure 11 35 Valve Components Figure 11 33 Installed Breather Reed Valve Stem Seals These engines use valve stem seals on the intake valves and occasionally on the exhaust valves Use a new seal whenever the valve is removed or if the seal is deteriorated or damaged in any way Never reuse an old seal See Figure 11 34 Figure 11 32 Match Numbers on Cylinder Barrel and Head ...

Page 198: ... NOTE Match the numbers embossed on the cylinder heads and crankcase See Figure 11 32 3 Install the cylinder head and start the four new hex flange screws NOTE When installing cylinder heads new screws should always be used Figure 11 37 Torquing Cylinder Head Fasteners 4 Torque the hex flange screws in two stages first to 22 6 N m 200 in lb then finally to 41 8 N m 370 in lb following the sequence...

Page 199: ...from the crankcase surface is achieved See Figure 11 39 When threading in the studs use a steady tightening motion without interruption until the proper height is obtained Otherwise the frictional heat from the engaging threads may cause the locking compound to set up prematurely The studs closest to the lifters must have an exposed height of 75 mm 2 15 16 in The studs furthest from the lifters mu...

Page 200: ... module bosses Figure 11 45 Installing Ignition Modules 2 On engines equipped with SMART SPARK both modules are installed the same way with the two tabs out See Figure 11 46 and 11 52 On engines not equipped with SMART SPARK the modules are installed with the spark plug lead wire from module always away from the cylinder On 1 cylinder the single kill tab should be towards you See Figure 11 45 On 2...

Page 201: ...he cylinder heads Slide any wiring harness clips onto the appropriate bolts before installing Make sure the gaskets are in the proper orientation See Figures 11 47 and 11 48 Using the sequence shown in Figure 11 49 torque the four screws in two stages first to 7 4 N m 66 in lb then to 9 9 N m 88 in lb Figure 11 48 Installing Intake Manifold with Wiring Harness Aluminum Manifold Shown 4 Rotate the ...

Page 202: ... lead to the tab terminal on standard ignition modules See Figure 11 51 Figure 11 53 Breather Cover and Gasket RTV sealant was used on early models between the breather cover and the crankcase A gasket with imprinted sealant beads is now used and recommended See Figure 11 53 Install as follows 1 Be sure the sealing surfaces of the crankcase and breather cover are clean of old gasket material or RT...

Page 203: ...5 Installing Inner Baffles Figure 11 54 Installing Screws Locations 3 and 4 4 Install the inner baffles using the remaining two hex flange screws see Figures 11 55 and 11 56 and finger tighten Do not torque the screws at this time they will be tightened after the blower housing and outer baffles are installed Figure 11 56 Finger Tighten Two Remaining Cover Screws Figure 11 58 Wires on Oil Filter S...

Page 204: ...l of the shrouding fasteners Torque the blower housing screws to 6 2 N m 55 in lb in a new hole or to 4 0 N m 35 in lb in a used hole Torque the shorter M5 side baffle screws to 4 0 N m 35 in lb See Figure 11 61 Torque the M5 side baffle screws into cylinder head to 6 2 N m 55 in lb in a new hole or to 4 0 N m 35 in lb in a used hole Torque the two lower M6 baffle mounting screws to 10 7 N m 95 in...

Page 205: ...ier regulator in the blower housing if removed previously then connect the rectifier regulator ground lead with the washer and the silver screw through the eyelet as shown If a grounding bracket is used secure with the mounting screw and washer against the outer side of the rectifier regulator See Figure 11 64 Install Oil Sentry If So Equipped 1 Apply pipe sealant with Teflon Loctite No 59241 or e...

Page 206: ...h then apply a second bead of sealant on the top surface of the gaskets For O Ring type covers install a new O Ring in the groove of each cover Do not use gaskets or RTV sealant 4 Position the covers on the cylinder heads Locate the cover with the oil separator hole on the 1 cylinder If loose spacers were used insert a spacer in each of the screw holes Install the four hex flange screws in each co...

Page 207: ...ernal Governor Controls Install External Governor Controls 1 Install the governor lever onto the governor cross shaft See Figure 11 70 Figure 11 71 Installing External Governor Controls One Barrel Carburetor Two Barrel Carburetor Models Move the control panel into position on the blower housing and connect the choke linkage into the bushing lever from the backside Make certain that the control sha...

Page 208: ...wire to the fuel shut off solenoid if so equipped 6 Install the lower support control bracket if equipped with a control panel See Figure 11 74 Figure 11 72 Choke Linkage Details Two Barrel Models Figure 11 75 Installing Control Panel 8 Assemble the throttle control shaft to the control bracket 9 Assemble the choke control to the control bracket Figure 11 74 Installing Lower Support Control Bracke...

Page 209: ...Sentry Indicator light wires Attach governor spring to governor lever See Figure 11 76 and appropriate charts on pages 11 23 through 11 25 Figure 11 77 Standard Control Bracket 2 One Barrel Carburetor Models Install the standard throttle control bracket and the air cleaner support bracket if used to the cylinder heads using the four hex flange screws Torque the screws to 10 7 N m 95 in lb into new...

Page 210: ...Clear 3301 3450 3 Clear 3101 3300 5 Purple 2951 3100 4 Purple 2800 2950 3 Purple 3750 4 Clear 3150 4 Purple Governed Idle Hole 6 5 4 3 2 1 5 Regulation others 10 6 mm Governor Lever and Hole Position RPM Chart Figure 11 78 Throttle Choke Control Bracket Detail Item Description 1 Bracket speed control 2 Clamp cable some applications 3 Kill Switch some applications 4 Lever choke top position 5 Lever...

Page 211: ...t Spring Color Hole No Standard Throttle Control High Idle WOT Intended Maximum RPM Spring Color Hole No Purple Black Red Purple Black Red Clear Red Green 4 4 4 3 3 3 3 2 1 3888 3780 3672 3564 3456 3348 3240 3132 3024 3600 3500 3400 3300 3200 3100 3000 2900 2800 Green Blue Orange Clear Red Purple Blue Orange Black 4 4 3 4 3 2 2 1 1 CV17 CV20 740 Engines Without Throttle Limiter Engine Mounted Thro...

Page 212: ...lack Red Green Red Green Blue Clear Clear 3 3 3 2 2 1 1 1 1 Standard Throttle Control With WAWB Wide Area Walk Behind Throttle Control Spring Color Hole No Red Purple Blue Orange Green Red Purple Blue Clear 3 3 3 2 2 1 1 1 1 8 mm Governor Lever and Hole Position RPM Charts cont Figure 11 79 Installing Starter and Lift Bracket Lift Bracket Dipstick Tube Support Starter CV750 Engines Governor Shaft ...

Page 213: ...ased Pulse Fuel Pump Metal Cased Pulse Fuel Pump Install Fuel Pump WARNING Explosive Fuel Gasoline may be present in the carburetor and fuel system Gasoline is extremely flammable and its vapors can explode if ignited Keep sparks and other sources of ignition away from the engine 1 Install the fuel pump and lines as an assembly Connect the pulse line to the crankcase vacuum fitting See Figures 11 ...

Page 214: ... two lower M5 mounting screws when applicable to 4 0 N m 35 in lb See Figures 11 85 and 11 86 Lower Screws Figure 11 86 Tightening Lower Base Bracket Screws Some Models 4 Install the air cleaner components as described in Section 4 Heavy Duty Air Cleaners 1 Install a new air cleaner base gasket 2 Attach the main support bracket to the four inboard valve cover screw locations Make sure each of the ...

Page 215: ...ding on style used reverse the removal procedure from Section 9 2 Secure the cooler or adapter to the oil pan with the oil filter nipple Torque the oil filter nipple to 27 N m 20 ft lb Install Oil Filter and Fill Crankcase with Oil 1 Prefill a new oil filter following the instructions in Section 6 2 Apply a thin film of clean oil to the rubber gasket on the oil filter and thread the filter onto th...

Page 216: ...ne It is recommended that the engine be operated on a test stand or bench prior to installation in the piece of equipment 1 Set the engine up on a test stand Install an oil pressure gauge Start the engine and check to be certain that oil pressure 20 psi or more is present Run the engine at idle for 2 3 minutes then 5 6 minutes more between idle and midrange Adjust the carburetor mixture settings a...

Page 217: ...LITHO IN U S A FORMNO TP 2450 C ISSUED 3 94 REVISED 3 06 ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 FOR SALESAND SERVICE INFORMATION IN U S AND CANADA CALL 1 800 544 2444 ...

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