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Kohler COMMAND PRO CS10, Service Manual

The Kohler COMMAND PRO CS10 is a powerful engine designed for commercial applications. To ensure proper maintenance and repair, download the free Service Manual from manualshive.com to access detailed instructions and diagrams. Keep your engine running smoothly with the comprehensive manual available for download.

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1.11

Section 1

Safety and General Information

1

Connecting Rod-to-Crankpin Side Clearance

CS4,CS6 ......................................................................................... 0.2/0.6 mm (0.008/0.024 in.)
CS8.5 (spec. 95xxxx) ...................................................................... 0.2/0.6 mm (0.008/0.024 in.)
CS8.5 (spec. 92xxxx) ...................................................................... 0.2/0.65 mm (0.0079/0.0256 in.)
CS10-12 .......................................................................................... 0.2/0.65 mm (0.0079/0.0256 in.)

Connecting Rod-to-Piston Pin Running Clearance ................................ 0.006/0.025 mm (0.0002/0.0001 in.)

Piston Pin End I.D.

New

CS4,CS6 ................................................................................... 16.006/16.020 mm (0.6301/0.6307 in.)
CS8.5 (spec. 95xxxx) ............................................................... 18.006/18.020 mm (0.7089/0.7094 in.)
CS8.5 (spec. 92xxxx) ............................................................... 20.006/20.020 mm (0.7876/0.7882 in.)
CS10-12 ................................................................................... 20.006/20.020 mm (0.7876/0.7882 in.)

Max. Wear Limit

CS4,CS6 ................................................................................... 16.10 mm (0.634 in.)
CS8.5 (95xxxx) ......................................................................... 18.10 mm (0.713 in.)
CS8.5 (92xxxx) ......................................................................... 20.10 mm (0.791 in.)
CS10-12 ................................................................................... 20.10 mm (0.791 in.)

Connecting Rod Journal End I.D.

New

CS4,CS6 ................................................................................... 28.000/28.015 mm (1.1023/1.1029 in.)
CS8.5 (spec. 95xxxx) ............................................................... 32.000/32.015 mm (1.2598/1.2604 in.)
CS8.5 (spec. 92xxxx) ............................................................... 36.000/36.015 mm (1.4173/1.4179 in.)
CS10-12 ................................................................................... 36.000/36.015 mm (1.4173/1.4179 in.)

Max. Wear Limit

CS4,CS6 ................................................................................... 28.115 mm (1.1069 in.)
CS8.5 (95xxxx) ......................................................................... 32.115 mm (1.2644 in.)
CS8.5 (92xxxx) ......................................................................... 36.115 mm (1.4219 in.)
CS10-12 ................................................................................... 36.115 mm (1.4219 in.)

Crankcase
Closure Plate Fastener Torque

CS4,CS6 ......................................................................................... 22 N·m (195 in. lb.)
CS8.5-12 ......................................................................................... 30 N·m (265 in. lb.)

Oil Drain Plugs Torque

CS4,CS6 ......................................................................................... 17 N·m (150 in. lb.)
CS8.5-12 ......................................................................................... 20 N·m (177 in. lb.)

Crankshaft
End Play (Free) ..................................................................................... 0.04 mm (0.0015 in.)

End Play (Threaded Pump Shaft Models Only) ..................................... 0.0/0.2 mm (0.0/0.007 in.)

Summary of Contents for COMMAND PRO CS10

Page 1: ...SERVICE MANUAL COMMAND PRO CS SERIES 4 12 HP HORIZONTAL CRANKSHAFT...

Page 2: ...eshooting Section 4 Air Cleaner and Air Intake System Section 5 Fuel System and Governor Section 6 Lubrication System Section 7 Retractable Starter Section 8 Electrical System and Components Section 9...

Page 3: ...d to notify people of installation operation or maintenance information that is important but not hazard related Hot Parts Engine components can get extremely hot from operation To prevent severe burn...

Page 4: ...ways wear safety goggles when servicing retractable starters and carefully follow instructions in the Retractable Starter Section 7 for relieving spring tension Electrical Shock Never touch electrical...

Page 5: ...xplanation of Engine Identification Numbers NOTE CS8 5 engines have been produced in two different specification series 92xxxx and 95xxxx The design features of 92xxxx spec no engines are identical to...

Page 6: ...al 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...

Page 7: ...2 Service starter motor drive if so equipped 2 Have combustion chamber decarbonized 2 Annually or Every 300 Hours Section 6 Section 4 Section 4 Section 1 Section 5 Section 8 Section 11 Section 5 Secti...

Page 8: ...00 14 685 66 00 2 598 162 00 6 378 5 16 24 qty 5 14 mm 551 deep 106 00 4 173 30 00 1 181 347 00 13 661 321 50 Straight PTO 12 657 143 00 5 630 100 00 3 937 162 00 6 378 Spark Plug Oil Fill Oil Drain P...

Page 9: ...146 08 5 751 dia 103 00 4 055 195 50 7 697 90 50 3 563 110 00 4 331 dia 127 00 5 000 dia 133 50 5 256 452 90 17 831 417 50 Straight PTO 16 437 187 50 7 382 118 34 4 659 205 00 8 071 99 00 3 898 Spark...

Page 10: ...103 00 4 055 195 50 7 697 424 00 16 693 70 00 2 756 165 1 6 50 110 4 33 5 16 24 18 mm 709 deep qty 2 5 16 24 18 mm 709 deep qty 4 3 8 16 18 mm 709 deep qty 4 146 08 5 78 380 00 14 961 183 00 7 205 94...

Page 11: ...7 ft lb Bore CS4 56 0 mm 2 20 in CS6 66 0 mm 2 60 in CS8 5 spec 95xxxx 75 0 mm 2 95 in CS8 5 spec 92xxxx 78 0 mm 3 07 in CS10 78 0 mm 3 07 in CS12 85 0 mm 3 35 in Stroke CS4 CS6 50 0 mm 1 97 in CS8 5...

Page 12: ...n lb CS8 5 spec 92xxxx 10 12 N m 88 106 in lb CS10 12 10 12 N m 88 106 in lb Camshaft End Play 0 05 mm 0 0020 in Bore I D Max Wear Limit CS4 CS6 14 95 mm 0 583 in CS8 5 12 15 95 mm 0 627 in Camshaft B...

Page 13: ...imit CS4 CS6 16 10 mm 0 634 in CS8 5 95xxxx 18 10 mm 0 713 in CS8 5 92xxxx 20 10 mm 0 791 in CS10 12 20 10 mm 0 791 in Connecting Rod Journal End I D New CS4 CS6 28 000 28 015 mm 1 1023 1 1029 in CS8...

Page 14: ...CS8 5 spec 92xxxx 72 mm 2 834 in CS10 12 72 mm 2 834 in Max Wear Limit CS4 CS6 52 05 mm 2 0492 in CS8 5 spec 95xxxx 52 05 mm 2 0492 in CS8 5 spec 92xxxx 72 05 mm 2 836 in CS10 12 72 05 mm 2 836 in Co...

Page 15: ...m 0 002 in Cylinder Head Cylinder Head Bolt Torque CS4 CS6 20 N m 177 in lb CS8 5 12 50 N m 36 ft lb Max Out of Flatness 0 1 mm 0 004 in Electric Starter Thru Bolt Case Torque CS8 5 12 5 3 N m 47 7 in...

Page 16: ...imit CS4 CS6 16 03 mm 0 6311 in CS8 5 spec 95xxxx 18 03 mm 0 7098 in CS8 5 spec 92xxxx 20 03 mm 0 7886 in CS10 12 20 03 mm 0 7886 in Piston Pin O D New CS4 CS6 15 995 16 000 mm 0 6297 0 6299 in CS8 5...

Page 17: ...123 84 954 84 998 mm 3 3446 3 3464 in Max Wear Limit CS4 55 900 mm 2 20 in CS6 65 900 mm 2 60 in CS8 5 spec 95xxxx 74 898 mm 2 9487 in CS8 5 spec 92xxxx 77 898 mm 3 0669 in CS10 77 898 mm 3 0669 in CS...

Page 18: ...8 mm 0 002 0 003 in CS8 5 12 0 045 0 072 mm 0 0018 0 0028 in Intake Valve Guide I D New CS4 CS6 5 5 mm 0 22 in CS8 5 12 6 0 6 012 mm 0 2362 0 2367 in Max Wear Limit CS4 CS6 5 60 mm 0 220 in CS8 5 12 6...

Page 19: ...25 M12x1 50 Into Aluminum 17 150 20 177 Model CS4 CS6 CS8 5 CS10 CS12 NOTES 1 Values are in Metric units Values in parenthesis are English equivalents Lubricate threads with engine oil prior to assemb...

Page 20: ...1 18 Section 1 Safety and General Information...

Page 21: ...ssure and for adjusting some gaseous fuel regulators Cylinder Leakdown Tester 25 761 05 S Cylinder Leakdown Tester is a valuable alternate to a compression test on these engines By pressurizing the co...

Page 22: ...g tool must be used to remove and reinstall the flywheel The flywheel holding tool shown below is illustrated in template form on page 2 3 and may be fabricated locally for use in the field The tool i...

Page 23: ...Section 2 Special Tools 2 3 2 Template for Flywheel Holding Tool Material needed 9 mm or 3 8 thick steel 25 mm or 1 wide 14...

Page 24: ...2 4 Section 2 Special Tools...

Page 25: ...ne 4 Loose or faulty wires or connections 5 Faulty choke or throttle controls 6 Faulty spark plug 7 Low compression 8 Faulty ACR mechanism 9 Weak spark ignition Engine Will Not Crank 1 PTO drive is en...

Page 26: ...aces or other damage that could allow unfiltered air into the engine Also note if the element is dirty or clogged These could indicate that the engine has had inadequate or infrequent maintenance Chec...

Page 27: ...isassemble breather clean parts thoroughly reassemble and recheck pressure 2 Replace all worn or damaged seals and gaskets Make sure all fasteners are tightened securely Use appropriate torque values...

Page 28: ...Results Air escaping from crankcase breather Defective rings or worn cylinder walls Air escaping from exhaust system Defective exhaust valve Air escaping from carburetor Defective intake valve Gauge...

Page 29: ...es 4 1 through 4 4 The third design does not use a paper element just the foam See Figure 4 14 Servicing information for the third design is on page 4 5 The heavy duty air cleaner assemblies also cont...

Page 30: ...aces of detergent are eliminated Squeeze out excess water do not wring Allow the precleaner to air dry 4 Saturate the precleaner with new engine oil Squeeze out all excess oil 5 Install the precleaner...

Page 31: ...with precleaner Remove the precleaner from the paper element Service the precleaner Heavy Duty Cyclonic Air Cleaner Unhook the latches and remove the housing assembly from the mounting base Remove the...

Page 32: ...the small end first into the housing so the larger end with the foam seal is out visible Secure with the wing nut if used Secure the cover housing with the latches See Figure 4 11 Air Cleaner Compone...

Page 33: ...with loose or damaged air cleaner components could allow unfiltered air into the engine causing premature wear and failure Every 50 hours of operation wash and reoil the foam air cleaner element more...

Page 34: ...without the air cleaner element excessive piston and or cylinder wear may result Air Intake Cooling System To ensure proper cooling make sure the grass screen cooling fins and other external surfaces...

Page 35: ...ated within the inlet of the fuel tank and the shut off valve Periodically inspect and clean or replace as required Description WARNING Explosive Fuel Gasoline is extremely flammable and its vapors ca...

Page 36: ...r fuel b Make sure the vent in the fuel cap is open c Make sure the fuel valve is open 2 Check for fuel in the combustion chamber a Disconnect and ground the spark plug lead b Close the choke on the c...

Page 37: ...fuel mixture is improperly adjusted Adjust low idle fuel needle b Float level is too low Separate carburetor bowl from carburetor body check float setting against specification Replace float if requi...

Page 38: ...o deliver the correct fuel to air mixture to the engine under all operating conditions The high idle mixture is set at the factory and cannot be adjusted The low idle fuel adjusting needle is also set...

Page 39: ...rain Plug 11 Gasket 12 Bowl Retaining Screw 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 13 Float Pin 14 Clip 15 Needle Assembly 16 Spring 17 Throttle Adjusting Screw 18 Spring 19 Idle Fue...

Page 40: ...from the main body and remove the bowl gasket from the body 8 Place the carburetor in an inverted position Lift up the float so that the tip of the float valve lightly contacts the float arm See Figur...

Page 41: ...s threaded into the tower and can be removed for cleaning but be careful not to damage it as it is not available as a service part a Use a thin flat blade screwdriver to remove the nozzle from the tow...

Page 42: ...ed and the engine speed and governor gear speed decreases the governor spring tension moves the governor lever to open the throttle plate wider This allows more fuel into the engine increasing engine...

Page 43: ...warm up Place the throttle control lever into the fast or high idle position 2 Check the engine speed with a tachometer 3 To increase the high idle speed turn the high idle speed adjusting screw out c...

Page 44: ...16 1 With the engine warm move the throttle lever clockwise until it stops 2 Check the idle speed with a tachometer 3 Turn the adjustment screw in clockwise to increase the idle speed or out counterc...

Page 45: ...temperature at the time of operation as shown in the following table Figure 6 1 Oil Container Logo Check Oil Level The importance of checking and maintaining the proper oil level in the crankcase cann...

Page 46: ...e filter neck Change Oil For a new engine change oil after the first 20 hours of operation Thereafter change oil after every 100 hours of operation For an overhauled engine use 10W 30 weight service c...

Page 47: ...oil level in the crankcase Never operate the engine with the oil level below the low oil level Figure 6 4 CS4 CS6 Right Oil Fill Level Plug Location Figure 6 5 CS4 CS6 Left Oil Fill Level Plug Locatio...

Page 48: ...6 4 Section 6 Lubrication System...

Page 49: ...rter Exploded View To Remove Starter 1 Remove the hex flange screws three on CS4 and CS6 four on CS8 5 12 securing the starter assembly to the blower housing 2 Remove the starter assembly To Install S...

Page 50: ...e Pawls and Tighten Mounting Screws Rope Replacement The rope can be replaced without complete starter disassembly 1 Remove the starter from the engine blower housing 2 Pull the rope out approximately...

Page 51: ...not remove the center screw from starter until the spring tension is released Removing the center screw before releasing spring tension or improper starter disassembly can cause the sudden and potenti...

Page 52: ...cement 2 Unscrew the center screw and lift off the drive plate The screw will be captured within plate by the clip on backside 3 Carefully note the positions of the pawls and pawl springs CS8 5 12 onl...

Page 53: ...nting screws to 5 5 N m 47 7 in lbs See Figure 7 3 3 Carefully install pulley into recoil housing engaging the spring hook with starter housing tab See Figure 7 10 NOTE Rotating pulley counterclockwis...

Page 54: ...7 6 Section 7 Retractable Starter...

Page 55: ...ze 1 2 20 6 mm 13 16 in 3 15 9 mm 5 8 in Spark Plug Service Every 100 hours of operation remove the spark plug check its condition and reset the gap or replace it with a new plug as necessary 1 Before...

Page 56: ...engine operating under normal conditions will have light tan or gray colored deposits If the center electrode is not worn a plug in this condition could be set to the proper gap and reused Carbon Foul...

Page 57: ...e module When the primary voltage is precisely at its peak the module induces a high voltage in its secondary windings This high voltage creates a spark at the tip of the spark plug This spark ignites...

Page 58: ...bare spot on the crankcase ground Turn the ignition switch on crank the engine and observe the red LED indicator lamp a If the indicator lamp was not flashing trace the black manual start models or b...

Page 59: ...meter Test the ignition key switch as follows a On manual start engines trace the two black leads from the on off switch and separate them from any connections Connect the ohmmeter leads to the switc...

Page 60: ...505 941506 941507 941512 941508 941509 941510 941513 941515 941516 941517 941518 8 5 8 5 8 5 8 5 8 5 8 5 8 5 8 8 8 8 8 8 8 8 8 9 8 5 8 10 8 10 8 11 8 15 Page No 8 7 8 7 8 7 8 7 8 7 8 7 8 7 8 9 8 9 8 9...

Page 61: ...Black w White Stripe Red w White Stripe White w Blue Stripe Green w Red Stripe Green w Yellow Stripe Blue w White Stripe Blue w Red Stripe Green w Black Stripe Black with Gray Shielding Ignition Modu...

Page 62: ...ch B L B BW BW Y Y R B R BW W W B B BW Oil Warning Unit Oil Sentry Light Ground Ground Ground Ground Engine Ground Ground Ground Ground Stator Ignition Module Fuse 15 A Battery Rectifier Regulator Sta...

Page 63: ...R RW RW RW BW B R BW R B Y L BW BW Y Y B BW R B B B R R R W W B B M Oil Warning Unit B Ground Wire Lead B B Oil Sentry Gauge Ground Ground Ground Spark Plug Y Y Oil Sentry Light BW BW R BW BW R Igniti...

Page 64: ...Y Y B L R R BW BW B YR YR YR R R R R R RW BW B R RW BW B R RW Wire Color Off On Start BW B R RW BW B R RW Wire Color Off On Start Oil Warning Unit Oil Warning Unit B L BW B Wire Lead Ground Oil Sentr...

Page 65: ...Ground Ground Ground Ground Ground Ground Oil Warning Unit Stator Ignition Module B L BW BW Y Y R BW R BW B Oil Sentry Gauge B L B Wire Lead B Oil Sentry Gauge Y Y BW BW Oil Sentry Light BW R R BW Eng...

Page 66: ...r Fuel Shut Off Solenoid Carb Heater GR B LW LR LR LW GR GB R R B W W W Stator R B W Spark Plug Ignition Module Oil Sentry Gauge Starter Motor Starter Solenoid M Battery B L RW R R R Fuse 15 amp R R B...

Page 67: ...y voltage There are two different rectifier regulators which are used an 18 amp and a 7 10 amp assembly Although externally similar the internal circuits differ and the two should not be interchanged...

Page 68: ...wiring harness the rectifier module is secured to the equipment with a single mounting screw The rectifier converts the AC voltage coming from the stator to DC voltage only The 3 amp rectifier is sho...

Page 69: ...t increase when load is applied test stator Tests 2 and 3 2 Separate the bullet connectors in the AC white leads Connect an AC voltmeter across the stator leads female terminals With engine running at...

Page 70: ...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...

Page 71: ...engines in this series will use either an inertia drive or a solenoid shift starter Each style has its own respective starter solenoid incorporated into the mounting configuration The inertia drive st...

Page 72: ...d connect the other end to the positve terminal of the battery Connect one end of the negative jumper cable to the negative terminal of the battery Touch the other end of the negative jumper cable to...

Page 73: ...ure and drive pinion This moves the drive pinion out of mesh with the ring gear and into the retracted position When power is removed from the starter the armature stops rotating and the drive pinion...

Page 74: ...tall the drive pinion spring and spring holder collar onto the armature shaft Figure 8 26 Installing Drive Components 8 Install a new retaining ring into the groove of the armature shaft Squeeze it wi...

Page 75: ...arter See Figure 8 30 Figure 8 30 Removing Starter Thru Bolt 5 Remove the commutator end cap and brush plate assembly See Figure 8 31 Figure 8 31 Removing End Cap with Brush Plate 6 Pull the armature...

Page 76: ...utator segments The depth should be 2 mm 0 079 in If less cut scrape the mica to the proper measurement using a hacksaw blade or similar tool ground to fit between the segments See Figure 8 35 NOTE Th...

Page 77: ...nd cap from the inside out Install the O Ring fiber washer metal washer and inner hex jam nut Tighten nut to secure but do not overtighten or damage to the inside plastic support can occur Figure 8 37...

Page 78: ...h a wrench while tightening the top nut to prevent damaging the internal components See Figure 8 44 Reinstall the protective boot over the connection If the solenoid was removed from the starter reins...

Page 79: ...n 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 sta...

Page 80: ...rame from around the armature and drive end cap See Figure 8 48 Figure 8 48 Disassembled Starter 8 Pull outward on the pivot portion of the drive lever and remove the drive lever and armature from the...

Page 81: ...t No 52 351 01 S to lever and shaft Starter Reassembly 1 Install the drive pinion onto the armature shaft 2 Slide the stop collar onto the armature shaft below the retaining ring groove Make sure the...

Page 82: ...tor in Place 9 Stand the armature drive end cap assembly on end so the commutator end is up Place brush armature installation tool over the end of armature shaft until it rests against the commutator...

Page 83: ...d engaging the plunger end with the yoke of the drive lever Check by pulling solenoid towards the rear Mount the solenoid to the starter using the two hex flange nuts Tighten securely See Figure 8 58...

Page 84: ...8 30 Section 8 Electrical System and Components...

Page 85: ...amage There are many commercially available cleaners that will quickly remove grease oil and grime from engine parts When such a cleaner is used follow the manufacturer s instructions and safety preca...

Page 86: ...e Figures 9 5 9 6 and 9 7 Figure 9 5 CS4 CS6 Air Cleaner Base Figure 9 2 Fuel Shut Off Valve Drain Oil From Crankcase 1 Remove one of the oil drain plugs and one of the oil fill caps Figure 9 3 Oil Dr...

Page 87: ...y If the fuel shut off valve is mounted directly to tank close the valve See Figure 9 2 2 Loosen the clamp and disconnect the fuel line from the outlet of shut off valve fuel tank mounted valves on CS...

Page 88: ...engines Figure 9 12 Disconnecting Choke Link and Dampening Spring from CS8 5 CS12 Carburetor 2 Loosen the hex flange screw securing the governor lever to the governor shaft Mark which hole location th...

Page 89: ...tuds Figure 9 16 Removing Carburetor Gaskets and Spacer If you want to remove the carburetor without disturbing the governor lever mounting proceed as follows 1 Gently hold the governor lever in the F...

Page 90: ...loosening or removing the starter cover panel mounting screws will allow easier access to the screw in the upper right hand position Figure 9 21 Cover Panel Mounting Screws Figure 9 22 CS8 5 spec 92xx...

Page 91: ...ounting Bracket Details Electric Start Engines Only 3 On CS8 5 spec 95xxxx remove the two screws securing the control panel and mounting bracket for the electrical components See Figure 9 28 Figure 9...

Page 92: ...95xxxx with Control Panel Removed 5 Remove the starter motor wiring harness and control panel housing from the engine Components may be further disassembled if required See Figures 9 31 9 32 and 9 33...

Page 93: ...38 The breather assembly is inside the valve cover Figure 9 38 Valve Cover Gasket and Air Shroud Removed Figure 9 34 CS4 CS6 Left Side Tank Mounting Bracket Details Figure 9 35 CS8 5 spec 92xxxx CS10...

Page 94: ...Mark the push rods so they will be reinstalled in the same location Figure 9 40 Remove Cylinder Head Mounting Screws Figure 9 41 Disassemble Cylinder Head 1 Remove the spark plug 2 Slide the rocker sh...

Page 95: ...arburetor Mounting Studs Remove Flywheel NOTE Whenever possible an impact wrench should be used to loosen the flywheel retaining nut A flywheel strap wrench or an approved holding tool see Special Too...

Page 96: ...External Type Puller to Remove Flywheel on CS4 CS6 3 Remove the flywheel key from keyway Remove Ignition Module 1 Remove the two hex flange screws securing the ignition module to the crankcase See Fig...

Page 97: ...ankcase Place a flat pan or towel under the housing to catch any remaining oil See Figures 9 53 and 9 54 2 Remove the four hex flange shoulder screws securing the stator to the crankcase Remove the st...

Page 98: ...ar assembly See Figure 9 61 Figure 9 57 Removing Screw from Crankshaft on CS4 CS6 Figure 9 58 Removing Screw from Crankshaft on CS8 5 CS12 5 Remove the reduction components a On CS4 and CS6 leave the...

Page 99: ...ion Assemblies CS4 and CS6 1 Remove any drive coupling and the key from the reduction output shaft Clean the shaft and keyway of any burrs damage 2 Remove the four reduction cover mounting screws Use...

Page 100: ...using bearings An arbor press should be used for removal of the others 6 1 Reduction Assemblies CS8 5 CS10 and CS12 1 Remove any drive coupling and the key from the reduction assembly output shaft Cle...

Page 101: ...red use an internal bearing puller to remove the housing bearings An arbor press should be used for removal of the others Remove Closure Plate 1 Remove the hex flange screws securing the closure plate...

Page 102: ...he cutout in the casting and remove the oil sentry gauge Note the routing of the wire 5 Remove the governor gear flyweight assembly by carefully applying upward pressure with two small screwdrivers be...

Page 103: ...tempting to remove the piston 2 Carefully remove the connecting rod and piston assembly from the cylinder bore See Figure 9 84 Figure 9 84 Removing Piston Figure 9 81 Removing Balance Shaft Remove Cam...

Page 104: ...through the inside of the crankcase Figure 9 85 Removing Crankshaft Remove Governor Cross Shaft 1 Remove the hitch pin and plain washer from the governor cross shaft See Figure 9 86 Figure 9 87 Removi...

Page 105: ...2 Remove the front main bearing from the crankcase using an arbor press See Figure 9 89 Figure 9 89 Removing Main Bearing with Press Remove Balance Shaft Bearing 1 Remove the balance shaft bearing usi...

Page 106: ...9 22 Section 9 Disassembly...

Page 107: ...for additional information Measurement Guide TP 2159 B and Engine Inspection Data Record TP 2435 are also available use these to record inspection results Automatic Compression Release ACR These engi...

Page 108: ...ith ACR start much faster in cold weather than engines without ACR 6 Engines with ACR can be started with spark plugs that are worn or fouled Engines without ACR are more difficult to start with those...

Page 109: ...asket fragments Gasket surfaces must also be free of deep scratches or nicks Check the cylinder bore for wear scoring or vertical scratches In severe cases unburned fuel can cause scuffing and scoring...

Page 110: ...should intersect at approximately 20 off the horizontal Too flat an angle could cause the rings to skip and wear excessively too steep an angle will result in high oil consumption See Figure 10 7 Fig...

Page 111: ...the piston pin 3 Piston to bore clearance is the difference between the bore diameter and the piston diameter step 2 minus step 1 Flywheel Inspection Inspect the flywheel for cracks and the flywheel...

Page 112: ...4 in 0 7 mm 0 03 in 1 7 mm 0 067 in Intake 21 0 mm 0 83 in 24 0 mm 0 94 in 5 5 mm 0 22 in 64 5 mm 2 54 in 65 9 mm 2 59 in 0 7 mm 0 0276 in 1 7 mm 0 067 in 90 0 01 mm 0 0004 in 5 5 mm 0 22 in 0 04 0 06...

Page 113: ...rolled 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 combinat...

Page 114: ...m Corrosion Moisture in the fuel or condensation are the most common causes of valve stem corrosion Condensation occurs from improper preservation during storage and when engine is repeatedly stopped...

Page 115: ...stem or the guide is responsible for the excessive clearance The valve guides are not replaceable Valve Seat Inserts The valve seats are not replaceable If the seats become badly pitted worn or disto...

Page 116: ...nder wall under this condition Oil control is also lost when ring gaps are not staggered during installation When cylinder temperatures get too high lacquer and varnish collect on the piston causing t...

Page 117: ...STD pistons and for 0 25 mm 0 010 in and 0 50 mm 0 020 in oversized pistons Always use new piston rings when installing pistons Never reuse old rings The cylinder bore must be deglazed before service...

Page 118: ...st 2 Middle Compression Ring Locate and identify the compression ring with the R marking Using a piston ring expander install this ring in the middle groove with the R up towards the top of the piston...

Page 119: ...wo small screwdrivers and carefully applying upward pressure from beneath the gear and against the bosses in the closure plate Do not pry against or nick damage the gasket surface of the closure plate...

Page 120: ...components for wear and damage Remove the housing gasket and dowel pins then clean the gasket surfaces with a cleaning solvent or aerosol type gasket remover Do not nick or scrape the sealing surface...

Page 121: ...10 Figure 10 25 Inspect for Binding 5 Check to see that the closure plate oil passages to the reduction assembly are open and not restricted See Figures 10 26 and 10 27 Figure 10 26 CS4 CS6 Oil Passa...

Page 122: ...10 16 Section 10 Internal Components...

Page 123: ...dels 10 Install stator and wire shield 11 Install flywheel 12 Install ignition module 13 Assemble and install cylinder head 14 Install push rods rocker arms studs and rocker shaft 15 Install valve cov...

Page 124: ...the lower flat section faces to the right 3 o clock position and insert the hitch pin so the end of the clip comes in contact with the raised section of the housing boss limiting the inward movement...

Page 125: ...bearing and seal Install Connecting Rod with Piston and Rings 1 If the piston and or connecting rod has been changed or removed make sure the following is correct before installing Figure 11 6 CS4 CS...

Page 126: ...pin and piston rings with engine oil Compress the rings using a piston ring compressor 4 Lubricate the crankshaft journal and connecting rod bearing surfaces with engine oil 5 Make sure stamping on p...

Page 127: ...Aligning Balance Shaft and Crankgear Timing Marks Install Governor Assembly The governor gear assembly is located inside the closure plate If servicing was performed or the governor was removed reasse...

Page 128: ...0 1 mm 0 0039 in 0 2 mm 0 007 in 0 3 mm 0 011 in and 0 4 mm 0 015 in for CS8 5 12 When proper end play has been established install all screws and torque in the sequence shown in Figure 11 22 or 11 2...

Page 129: ...nto the cover to a depth of 2 mm 0 08 in See Figure 11 26 Apply a light coating of lightweight lithium grease to lip of seal 1 8 4 6 2 7 3 5 Figure 11 24 CS4 CS6 Installing Bearing Torque Screws to 30...

Page 130: ...the keyway of the crankshaft Install the crankshaft gear onto the engine crankshaft Secure with the flat washer and hex flange screw See Figure 11 32 Torque the screw to CS8 5 spec 92xxxx CS10 CS12 60...

Page 131: ...tall the dowel pins into their respective locations in the closure plate and install a new gasket dry onto the dowel pins See Figures 11 34 and 11 35 Figure 11 35 CS8 5 12 Installing Dowel Pins and Ga...

Page 132: ...ing Washer Bolt Washer Shaft 2 Idle Sprocket Chain Washer Straight Key C Oil seal installation depth 2 mm 0 08 in 30 N m 265 in lbs 65 N m 48 ft lbs No Description 1 2 3 4 5 6 7 8 9 Chain Case Cover G...

Page 133: ...ation Depth 3 Pre lube all bearing surfaces with engine oil 4 Install a new gasket between the reduction housing and closure plate 5 Install the reduction housing to the closure plate as shown and sec...

Page 134: ...hole on side Capacity 0 15 liter 5 02 fl oz 9 Install the level plug and fill plug into their respective locations The fill plug contains a vent hole and must be installed on top See Figure 11 46 Torq...

Page 135: ...gear on crankshaft Figure 11 49 Installing Counter Gear Assembly 5 Lubricate the bearing surfaces with oil and install the output shaft gear assembly into the cover See Figure 11 50 Figure 11 50 Inst...

Page 136: ...ubricants The presence of lubricants can cause the flywheel to be over stressed and damaged when the flange screw is torqued to specifications Figure 11 53 Torquing Mounting Screws Install Stator and...

Page 137: ...ey is properly seated and parallel with taper of shaft Figure 11 58 Clean and Dry Flywheel Hub 2 Install the flywheel onto the crankshaft being careful not to shift the woodruff key 3 Install the driv...

Page 138: ...orth checking to make sure the magnet does not strike the module Connect the kill lead to the terminal Figure 11 63 Intake Valve Stem Seal NOTE The engine utilizes a valve stem seal on the intake valv...

Page 139: ...bolt holes 4 Install a new cylinder head gasket Figure 11 65 Installing Dowel Pins and New Head Gasket 5 Install the cylinder head and start the four hex flange screws Torque the screws in several inc...

Page 140: ...CS8 5 spec 95xxxx Assembled Rocker Arms in Position CS8 5 spec 92xxxx CS10 CS12 Install the rocker arms and adjuster assemblies into their original locations Seat the push rods into the cupped end of...

Page 141: ...he compression stroke b Insert a flat feeler gauge between the rocker arm and the valve stem The recommended valve to rocker arm clearance for both intake and exhaust is 0 1 mm 0 004 in Figure 11 74 C...

Page 142: ...acket off the two right side valve cover locations or to the cylinder head boss locations based upon the model involved using the two longer screws Torque all the screws to 10 12 N m 88 106 in lb See...

Page 143: ...5 spec 92xxxx CS10 CS12 Mounting Left Fuel Tank Support 2 Assemble the right fuel tank support and attached electrical components to the crankcase bosses Mount the throttle control bracket off the fl...

Page 144: ...the two hex flange head screws Torque the screws to 10 12 N m 88 106 in lb 3 Check that the ground leads are secured at the bracket locations as shown in Figures 11 83 through 11 85 CS8 5 12 Reattach...

Page 145: ...rom the top down into the hole s in long end of governor lever as shown in Figures 11 86 11 87 and 11 88 Figure 11 90 CS8 5 spec 92xxxx CS10 CS12 Spring Hole Position 1 2 3 Figure 11 88 CS8 5 spec 95x...

Page 146: ...m 265 in lb See Figure 11 95 Figure 11 92 CS8 5 spec 92xxxx CS10 CS12 Installing Electric Starter 2 Connect the electrical leads for the Oil Sentry ignition module keyswitch solenoid and starter Attac...

Page 147: ...ex flange screws On CS4 and CS6 engines secure the ground lead with the silver screw in the upper right hand location See Figures 11 96 11 97 and 11 98 Torque the screws to 7 N m 62 in lb Figure 11 98...

Page 148: ...he hole s of the throttle lever See Figures 11 101 and 11 102 Figure 11 101 CS4 CS6 Assembling Linkage Figure 11 102 CS8 5 12 Assembling Linkage 3 CS8 5 12 Connect Z end of choke link and dampening sp...

Page 149: ...x flange nuts to CS4 CS6 5 8 N m 44 71 in lb CS8 5 12 10 12 N m 88 106 in lb Torque hex flange screw s to 5 8 N m 44 71 in lb Seal Seal Figure 11 104 CS4 CS6 Installing Air Cleaner Base Figure 11 105...

Page 150: ...re 11 109 CS8 5 12 Adjusting Governor Install Fuel Tank CS4 CS6 CS8 5 spec 92xxxx CS10 CS12 1 If the fuel shut off valve was removed or serviced separately install and secure with the flange nut so th...

Page 151: ...rburetor inlet Secure with the clamps Install Outer Air Cleaner Cover 1 Install the outer air cleaner cover onto the stud over the element Secure with the knob Figure 11 113 CS8 5 spec 95xxxx Shut Off...

Page 152: ...3 Fill the crankcase with the correct oil Refer to the oil recommendations and procedures in the General Information and Lubrication System sections 4 Reconnect the rectifier regulator if so equipped...

Page 153: ...11 31 Section 11 Reassembly 11 Figure 11 118 CS4 CS6 High Speed Stop Screw Figure 11 119 CS8 5 spec 92xxxx CS10 CS12 High Speed Stop Screw Figure 11 120 CS8 5 spec 95xxxx High Speed Stop Screw...

Page 154: ...ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 LITHO IN U S A FORMNO TP 2503 A ISSUED 12 99 REVISED 8 00 MAILED 9 00...

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