Kohler K24J Service Manual Download Page 53

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Summary of Contents for K24J

Page 1: ...Single Cylinder Engine SERVICE MANUAL K9J KJ4J KJ6J KJBJ K24J K30J K32J K34J...

Page 2: ...oubleshooting SECTION 5 Air Cleaner And Air Intake System SECTION 6 Fuel System And Governor SECTION 7 Retractable Starters SECTION 8 Electrical Systems And Components SECTION 9 Automatic Compression...

Page 3: ...spilled fuel could ignite if it comes in contact with hot parts or sparks from igni tion Do not start the engine near spilled fuel Never use gasoline as a cleaning agent AWARNING Rotating Parts can ca...

Page 4: ...n the engine in a closed building or confined area A WARNING Spring Under a Tension Retractable starters contain a pow erful flat wire recoil spring that is under tension Do not remove the center scre...

Page 5: ...inder Figure 1 1 Location of Engine Identification Decal Version Code A Special Oil Pan C Clutch Model G Generator Application P Pump Model Q Quiet Model R Reduction Gear S Electric Start T Retractabl...

Page 6: ...posits Shoulder of flange Remove from block Place on shoulder Read level NOTE Using other than Service Class SF or SG oil or extending oil change intervals longer than recommended could cause engine d...

Page 7: ...ts in your fuel system and to insure easy starting Do not add oil to the gasoline Do not overfill the fuel tank Leave room tor the fuel to expand Fuel Type For best results use only clean fresh unlead...

Page 8: ...035 035 035 035 025 025 025 025 025 025 025 018 018 018 018 018 018 018 020 020 020 020 020 020 020 003 010 020 030 Thrust Face f cc ew 11 2 3 71 2 3 6 9 2 9 c29 7 2 9 c28 1 2 92 9 c7 c2 c92 8c 1 3 2...

Page 9: ...16 200ft lb 325ft lb 470ft lb in lbs x 083 ft lbs Conversions ft lbs x 12 in lbs ft lbs x 1383 kgm ft lbs x 1 3558 N m CD Lubricate with engine oil 1 X New 140 ln lba Used 100 ln lbs 200 ln lbs 18 22...

Page 10: ...e job you can service engines easier faster and safer In addition you II increase your service capabilities and customer satisfaction by decreasing engine down time The Special Service Tool Kit No 321...

Page 11: ...KIT Used to pull valve guides with 3222 11838 Stud 3 1 2 slide hammer 12100 Stud 2 1 2 11800 Adapter 0917 Nut 12008 Nut llB ii 3224 VALVE GUIDE INSTALLER KIT Used to install valve guides to 12325 Dri...

Page 12: ...from engine 5108 Bolt 1 4 w washer 3 J J 12505 Bolt 10 24 w washer 2 r 12504 Bolt 3 8 w washer 2 12506 Storage Bag FLYWHEEL STRAP WRENCH Used to hold flywheel for nut 10357 removal OFFSET WRENCH Used...

Page 13: ...nstaller Bearing PTO 12018 Installer Bearing 12019 Installer Bearing 11782 Installer Seal PTO 11783 Installer Seal Flywheel 11784 Installer Seal PTO 11785 Installer Seal PTO 11786 Installer Seal Flywh...

Page 14: ...uple 1 Oil Sump Thermocouple 1 1 4 x 1 8 Bushing 1 318 x 1 8 Bushing 1 1 2 X 1 8 Bushing 1 3 4 X 1 8 Bushing 1 Tube With Fittings 1 Carrying Case 3 Plain Thermocouple The voltmeter tachometer thermome...

Page 15: ...erated under extremely dusty and dirty conditions 250 Hours when leaded gasoline is used WARNING Accidental Starts Before seNicing the engine or equipment always remove the spark plug to prevent the e...

Page 16: ...cleaner every 25 operating hours more often under ex tremely dusty dirty conditions 1 Remove precleaner from paper element Wash the precleaner in warm water with detergent 2 Rinse precleaner thoroughl...

Page 17: ...surfaces as necessary Make sure the cooling shrouds are reinstalled Refer to the Disassembly and Reassembly sections for cooling shroud removal and installation proce dures NOTE Operating the engine w...

Page 18: ...dirty with a genuine Kohler filter Refer to Figure 3 5 3 4 Figure 3 5 In line Fuel Filter SERVICE STARTER MOTOR DRIVE Every 500 operating hours or annually whichever occurs first clean and lubricate...

Page 19: ...ther valve cover and check valve to tappet clearance with a flat feeler gauge Refer to Figure 3 8 The engine must be cold when checking this clearance 1 Remove the air cleaner assembly carburetor and...

Page 20: ...e will be out of service for approxi mately two months or more use the following storage procedure 1 Change the oil when engine is still warm from operation Refer to Change Oil 2 Change the oil in red...

Page 21: ...ce 9 Low compression 10 Faulty ACR mechanism Engine Will Not Crank 1 Hydrostatic transmission is not in neutrai PTO drive is engaged 2 Battery is discharged 3 Safety interlock switch is engaged 4 Loos...

Page 22: ...specting the external condition of the en gine clean it thoroughly before disassembling Also clean individual components as the engine is disassembled Only clean parts can be accurately inspected and...

Page 23: ...Test Because these engines are equipped with an auto matic compression release mechanism ACR it is difficult to obtain an accurate compression read ing To check the condition of the combustion chambe...

Page 24: ...e base screws air cleaner base gasket and hose AIR CLEANER SERVICE Precleaner If so equipped wash and re oil the precleaner every 25 operating hours more often under ex tremely dusty or dirty conditio...

Page 25: ...er the air cleaner cover is removed or when servicing the paper element or precleaner check the following components 1 Air Cleaner Base Make sure it is secured tightly to carburetor and is not bent or...

Page 26: ...ets Replace if damaged OIL LEVEL 5 Install base gasket and place filter on air horn 6 Add engine oil to filter and fill to the OIL LEVEL mark 7 Install filter element cover gasket and cover Secure wit...

Page 27: ...l line from inlet fitting at carburetor B Crank engine several times and observe flow chamber where it is compressed then ignited by the spark plug Troubleshooting Use the following procedure to check...

Page 28: ...ankcase Older fuel pumps have a metal body Later mod els have a body made of plastic The plastic body better insulates the fuel from the hot engine mini mizing the chance of vapor lock 6 2 Operation T...

Page 29: ...sually give the best results Adjust the carbu retor as follows 1 With the engine stopped turn the low idle fuel adjusting needle in clockwise until it bottoms lightly NOTE The tip of the low idle fuel...

Page 30: ...edle Now turn the adjusting needle in clockwise The engine speed may increase then it will decrease as the needle is turned in lean Note the position of the needle Set the adjusting needle midway betw...

Page 31: ...holes and other wear or damage 3 Inspect the float for dents or holes Check the float hinge for wear and missing or damaged float tabs 4 Inspect the inlet needle and seat for wear or grooves 5 Inspect...

Page 32: ...48x7 32 l J Y Brass Screws choke Shall I Choke Lever Reused 2 56x7 32 or 3 48x7 32 Brass Screw S J Th ottle Shaft Bushing Throttle Plate Reused Throttle Shaft Bushing Installation Tool Figure 6 8 Thro...

Page 33: ...move and transfer the throttle lever as fol lows Models K91 K181 112 Garb Carefully grind or file away the riveted portion of the throttle shaft Save the throttle shaft as it will be used to install t...

Page 34: ...ll a throttle shaft without throttle lever in carburetor body to use as a pilot Models K91 K181 112 Carb Use the old throttle shaft removed previously Models K141 K341 1 Carb Use one of the remaining...

Page 35: ...lever and check that the throttle plate does not bind in the bore Loosen screws and adjust plate if necessary then tighten screws securely Reassemble Carburetor Refer to the following Reassembly porti...

Page 36: ...djusting needles are tapered to critical dimensions Damage to needles and seats will result if needles are forced 10 Reinstall the carburetor to the engine using a new gasket 11 Adjust the carburetor...

Page 37: ...Fuel Adjusting Needle And Spring Welch Plugs Choke Lever Shaft Assembly Throttle Lever Shaft Assembly Idle Speed Adjusting Screw And Spring c_ Fuel Bowl Retaining Screw And Gasket Fuel Bowl Gasket Thr...

Page 38: ...ke b Idle fuel mixture is improperly adjusted Adjust idle fuel needle misfiring loss of c Float level set too high With fuel bowl removed and carburetor in speed and power governor hunting or verted s...

Page 39: ...warm up The engine must be warm before making final settings Steps 4 5 6 and 7 4 High Idle Fuel Needle Setting This adjustment is required only for adjustable high idle main jet carburetors If the car...

Page 40: ...ns 1 1 4turns 1 1 4 turns 1 turn KT19 1 turn 2 1 2 turns 1 1 4 turns 2 8 DETERMD 2 8 DETERMD K582 1 1 4 turns 3 turns NOT APPL Includes New Look Models Figure 6 20 Preliminary Low Idle And High Idle F...

Page 41: ...or do not attempt to remove the fuel inlet seat as it is not serviceable Replace the carbu retor if the fuel inlet seat is damaged 3 Remove the idle fuel adjusting needle and spring Remove the idle sp...

Page 42: ...moved Do this before removing the throttle shaft from carburetor body 4 Remove the throttle lever shaft assembly with foam dust seal from carburetor body Choke Shaft Removal 1 Because the edges of cho...

Page 43: ...throttle and choke shaft and plate assemblies for wear or excessive play REPAIR Always use new gaskets when servicing and rein stalling carburetors Repair kits are available which include new gaskets...

Page 44: ...nstall the welch plugs A Position the carburetor body securely with the welch plug cavities to the top B Place a new welch plug into the cavity with the raised portion up Use the end of the tool that...

Page 45: ...eedle 3 Remove the existing main fuel jet 4 Install the new high altitude main fuel jet and torque to 12 16 in lb 5 Reinstall the fuel inlet needle float and float pin 6 Install the new bowl gasket fr...

Page 46: ...e ment will result in less choking 3 After adjustment is made tighten adjustment lock screw Electric Thermostatic Type Remove air cleaner from carburetor to observe position of choke plate Choke adjus...

Page 47: ...from starting and to avoid personal in jury Refer to Figure 6 32 CHOKE SPRING l 2 TURN TENSION CHOKE PLATE AUTOMATIC CHOKE UNIT I I I ADJUSTING SLOT I I I I I Figure 6 32 Thermo Electric Automatic Ch...

Page 48: ...t clockwise on the carbu retor viewed from the choke side with a slight pressure until it can no longer be ro tated 4 While holding the choke unit in the above posi tion tighten the two mounting screw...

Page 49: ...a faulty regulator Secondary regulators used on Kohler engines re quire only one adjustment Ensign Models F or F1 regulators have an idle adjustment This adjust ment should be performed while the eng...

Page 50: ...ol of the fuel under pressure as it comes from the fuel sup ply tank The inlet pressure for primary regulators should never exceed 250 psi The primary regula tor is adjusted for outlet pressure of app...

Page 51: ...until the pressure overcomes the spring action on the opposite side of the dia phragm This primary diaphragm spring has suffi cient tension to require approximately 10 psi pres sure on the internal si...

Page 52: ...crease in speed and inward with a decrease As the flyweights move outward they force the regu lating pin of the assembly to move outward The regulating pin contacts the tab on the cross shaft causing...

Page 53: ...le is to be con nected to the engine connect it as follows Refer to Figure 6 41 1 Bend the end of the throttle wire as shown in Figure 6 41 2 Place throttle control in open position Insert throttle wi...

Page 54: ...ng of threads DECREASE SPEED Figure 6 42 Speed Adjustment 6 28 Governor New Look K181 Throttle Linka e Governor Arm Carburetor Throttle Lever Governor Gear Assembly Governor Spring Throttle Control Fi...

Page 55: ...to gov ernor arm and throttle lever on carburetor to en sure proper setting Refer to Figure 6 44 Figure 6 44 Initial Governor Adjustment 1 Pull the governor arm away from the carbure tor as far as it...

Page 56: ...e sensitivity increase the governor spring tension by moving the spring towards the cross shaft To decrease sensitivity and allow broader con trol decrease spring tension by moving the spring away fro...

Page 57: ...or similar tool to loop the end of the throttle wire around the pin Speed Adjustment WARNING Overspeed Is Hazardous The maximum allowable speed for Models K241 through K341 is 3600 RPM no load Never...

Page 58: ...g steps 1 Set spark plug point gap to 020 and readjust the carburetor for peak performance See Carburetor Adjustment subsection of this section 6 32 2 Stop the engine and check for free movement of th...

Page 59: ...slip page of the drive cup Refer to Figure 7 1 CENTER NG 19 PIN Operation 1 Be sure starter screen is kept clean when op erating engine or serious engine damage can result from lack of cooling air 2 A...

Page 60: ...ng loop A B 2 Spring holders furnished with replacement springs simplify the assembly procedure Place spring in proper position as shown with the outside loop engaged around the pin Then press the spr...

Page 61: ...ety goggles when servicing retract able starters full face protection is recommended To ensure personal safety and proper starter disas sembly the following procedures must be followed carefully To Re...

Page 62: ...rter To Replace Rope The rope can be replaced without complete starter disassembly Figure 7 4 Starter Pawls 1 Remove the starter from engine 2 Pull the rope out approximately 12 and tie a temporary sl...

Page 63: ...to keep it from re tracting into starter Refer to Figure 7 5 3 Remove the rope retainer from inside handle and untie the knot to remove retainer and han dle 4 Hold the pulley firmly with thumb and unt...

Page 64: ...ubricated with grease Position the spring and keeper assem bly to pulley side opposite pawls The out side spring tail must be positioned opposite rope pocket Refer to Figure 7 9 2 Install the pulley w...

Page 65: ...CAST HOUSING MODELS Sheave Recoil Spring I Rope Retainer Rope 11 Exploded View Figure 7 r 10 I I 7 7...

Page 66: ...se pressure on the pulley and allow it to rotate slowly as the spring tension is released Be sure to keep the rope in the notch Refer to Figure 7 13 7 8 Figure 7 13 Releasing Spring Tension 8 Make sur...

Page 67: ...pulley and sheave Separate the pulley and sheave and remove the old rope Refer to Fig ure 7 16 Figure 7 16 Replacing Rope 4 Position the new rope in the notch in the pulley and around the rope lock po...

Page 68: ...Seal Installer 11791 and Handle 11795 Refer to Special Tools Section 7 10 Hook the spring hook over the post in housing Make sure the spring c ring is centered over the spring pocket in housing Drive...

Page 69: ...eturn spring Make sure the pawls are positioned in the slots of pawl retainer 11 As a test rotate the pawl retainer slightly clockwise Pressure from the return spring should be felt In addition the pa...

Page 70: ...t at the end of rope and install rope retainer into handle Refer to Figure 7 12 19 Untie the slip knot and pull the handle out until the rope is fully extended Slowly retract the rope into the starter...

Page 71: ...15 Amp alternator 4 Battery ignition with 30 Amp alternator Breakerless Ignition System 1 Breakerless ignition with 10 Amp alternator 2 Breakerless ignition with 15 Amp alternator Magneto Ignition Sy...

Page 72: ...r hous ing If a snap button covers the hole pry it out with a screwdriver or similar tool so that the timing marks may be seen Two marks will be present on the flywheel T for top dead center and S or...

Page 73: ...n system operates in a manner similar to the magneto system The major differ ence is that in the battery system energy is pro vided by a battery The battery is maintained at full charge by an engine m...

Page 74: ...spark A trigger module containing solid state electronics performs the same function as the breaker points Refer to Fig ure 8 5 The breakerless system consists of four major components Ignition windin...

Page 75: ...reverse these leads light should come on with leads one way but not the other way If light stays on or off both ways this indicates diodes are faulty replace trigger module SCR Test Turn tester on th...

Page 76: ...ion for a check of its condition At this time the gap should be reset or the spark plug re placed as necessary Refer to Figure 8 9 TO IGNITION SWITCH OR COIL ASSEMBLY 1 TRIGGER MODULE 8 6 BUILD UP ON...

Page 77: ...uses abrasive grit Some grit could remain in recesses and enter the engine causing extensive wear and damage 3 Check the gap with a wire type feeler gauge Set the gap as shown in the following table b...

Page 78: ...sed by overrich carburetor settings weak igni tion or poor compression 8 8 Figure 8 12 Worn Worn On a worn plug the center electrode will be rounded and the gap will be eroded 010 or more beyond the c...

Page 79: ...are no adjustments in these sys tems Replace if faulty NOTE To prevent damage to the electrical system and components a Make sure the battery polarity is correct A negative ground system is used with...

Page 80: ...te reading If resistance Is high In both directions the diode or stator winding Is open Use Test 4 Reverse the leads and measure resistance again In one direction the resistance should be Infinity ohm...

Page 81: ...att Lighting Breaker Points Spark Plug Blue Diode r Black Condenser Coil I Yellow I I L______J Lights 12 V Battery Flywheel Stator Optional 70 Watt Lighting Stator Figure 8 15 Wiring Diagram Electric...

Page 82: ...voltage B 1 If charge rate Increases B 1 Indicates alternator system OK battery was fully charged B 2 If charge rate does not Increase B 2 Check for defective stator or rectifier regulator TEST C 1 1...

Page 83: ...wheel Alternator fJC Regulator R 0 Starter Ammeter 12 Volt Battery Breaker Points Coil Condenser Figure 8 16 Wiring Diagram Electric Start Engines 15 Amp Regulated Battery Charging System Rectifier Re...

Page 84: ...Is OK Charge With engine running at 3600 RPM measure Rectifier regulator Is faulty Replace the recti To AC voltage across stator leads using an AC tier regulator Battery voltmeter If voltage Is less...

Page 85: ...l Alternator fC Regulator Starter Ammeter 12 Volt Battery Breaker Points Coil Condenser Figure 8 18 Wiring Diagram Electric Start Engines 25 Amp Regulated Battery Charging System Rectifier Regulator F...

Page 86: ...Is OK Charge With engine running at 3600 RPM measure Rectifier regulator Is faulty Replace the recti To AC voltage across stator leads using an AC tier regulator Battery voltmeter If voltage Is less...

Page 87: ...ck Black t Regulator 12 Volt Battery Breaker Points u Swltch r r EL _ Key Start Coil Condenser Figure 8 20 Wiring Diagram Electric Start Engines 30 Amp Regulated Battery Charging System Black Red Figu...

Page 88: ...e three types are Motor Generator This starter also functions as a DC generator In the starting mode it turns the crankshaft through a V belt arrangement The V belt transmits turning force from a smal...

Page 89: ...ock switches are connected to a solid state module that is con nected to the ignition system The module serves two functions It grounds the ignition system until all interlocks have closed and after t...

Page 90: ...tool to keep the brushes in the pockets of commutator end cap Refer to Figure 8 24 4 Install the commutator end cap to armature and starter frame Firmly hold the drive end cap and commutator end cap...

Page 91: ...ISCARD RETIGHTEN NUT TO ORIGINAL 120 INCH LBS Figure 8 26 Bendix Drive Installation BROWN LEADS r RED LEAD TO ENGINE IGNITION CIRCUIT CONNECTOR TO SAFETY SWITCH CIRCUIT NOTE Delta Systems Module Depic...

Page 92: ...use a commutator stone or fine sandpaper NOTE Never use emery cloth to clean a commu tator 8 Carefully insert the armature 8 22 9 Lightly coat the end cap bushing and armature shaft with light engine...

Page 93: ...a number of the following signs 1 The armature wire insulation or coating will ap pear discolored and may be swollen In many cases you may be able to detect an odor from the burnt wire coating or see...

Page 94: ...Charging A WARNING Dangerous Acid Explosive a Gases Batteries contain sulfuric acid To prevent acid burns avoid contact with skin eyes and clothing Batteries produce explosive hydrogen gas while be i...

Page 95: ...ve the exhaust cam lobe This lifts the exhaust valve off its seat during the first part of the compression stroke The reduced compression results in an effective compression ratio of about 2 1 during...

Page 96: ...ed NOTE The tab on the flyweights is hardened and is not adjustable Do not attempt to bend the tab it will break and a new camshaft will be re quired 9 2 COMPRESSION TESTING Because of the ACR mechani...

Page 97: ...es 5 If the valve lift was above 042 hold a wooden dowel or peg on the top of the valve and tap it down carefully to within the 031 042 range If the valve lift was below 031 remove the camshaft cover...

Page 98: ...nnect spark plug lead 2 Drain oil from crankcase 3 Remove air cleaner 4 Remove muffler 5 Remove throttle linkage and carburetor 6 Remove external governor components and throttle control 7 Remove fuel...

Page 99: ...or and fuel system Gasoline is extremely flammable and it can explode if ignited Keep sparks open flames and other sources of ignition away from the engine Dis connect and ground the spark plug lead t...

Page 100: ...ls 1 Remove the grass screen retainer and wire mesh grass screen from rope pulley 2 Hold the flywheel with a strap wrench and loosen the hex cap screw Remove the hex cap screw plain washer rope pulley...

Page 101: ...rotator on both valves REMOVE OIL PAN NOTE Make sure the piston is at top dead center in bore to prevent damage to oil dipper on con necting rod 1 Remove the hex cap sems screws oil pan and gasket 10...

Page 102: ...ess crankshaft out of cylinder block Bearing plate should be removed first if this is done NOTE If the repair does not require separating the bearing plate from crankshaft the crankshaft and bearing p...

Page 103: ...ccur the bearing case should be greased and the needles reset There are 27 indi vidual needles in each bearing Figure 10 11 Removing Balance Gears REMOVE GOVERNOR GEAR AND CROSS SHAFT 1 Remove the sto...

Page 104: ...plug gap when flywheel keyshearing oc curs Spark plug gap on battery ignition engines must be set as specified If improperly gapped a maverick spark can occur which can cause improper igni tion of un...

Page 105: ...ne proceed as fol lows 1 Lower hone into bore and after centering ad just so that stones are in contact with the cyl inder wall Use of a commercial cutting cool ing agent is recommended 2 With the low...

Page 106: ...he bottom of the skirt Figure 11 4 Measuring Piston Diameter 2 Use an inside micrometer telescoping gauge or bore gauge and measure the cylinder bore Take the measurement approximately 2 1 2 below the...

Page 107: ...y be symptoms of faulty valves lthough these symptoms could also be attributed to worn rings remove and check valves first After re moval clean valve head face and stem with power Normal Even after lo...

Page 108: ...r may result in valve damage because deposits can become hard enough to cut the valve Cleaning of the cylinder head at proper intervals could prevent such damage Stem Corrosion Moisture from the fuel...

Page 109: ...11 6 Pulling Valve Guide 1 Install 5 16 18 NC nut on coarse threaded end of 2 1 2 long stud K161 and K181 or 3 1 2 long stud K241 K301 K321 and K341 11 6 2 Insert other end of stud through valve guid...

Page 110: ...e Fig ure 11 Sb 6 Use slide hammer to remove valve seat insert Install Valve Seat Insert To install valve seat insert proceed as follows 1 Make sure valve seat insert bore is clean and free of nicks o...

Page 111: ...ersize are stamped on the cylinder head gasket surface with 003 It is essential that 003 oversize pistons are used in these blocks to prevent possible fail ure such as a noisy engine or eventual pisto...

Page 112: ...ht through the piston dome Pre ignition is caused by a hot spot in the combustion chamber from sources such as glowing carbon Stuck Broken Rings Abrasive Scratched Rings deposits blocked fins improper...

Page 113: ...s of service ring sets are available Std 01 0 020 030 only two sizes of oil rings are supplied Std and 020 oversize When using 010 and 030 oversize ring sets the oil rings appear to have excessive end...

Page 114: ...crankcase The gears and spacers are held on the shafts with snap ring retainers The gears are timed with and driven by the engine crankshaft Inspection and Repair Use a micrometer and measure the stu...

Page 115: ...racked teeth If one 11 12 or more of these problems is noted replace the governor gear CAMSHAFT AND CRANKSHAFT Inspection and Service Inspect the gear teeth on both the crankshaft and camshaft If the...

Page 116: ...ter applications but may be found on other applications Therefore use the drive cup to identify which washer should be used 2 Required for drive cups with 5 8 mounting hole Figure 11 17 Gear Reduction...

Page 117: ...2 Tape or paper should be wrapped around the shaft to prevent the keyway from damaging 11 14 the cover oil seal Install the gasket s and reduction gear cover and tighten cap screws 3 Adjust shaft end...

Page 118: ...mbly 20 Install side air baffles and cylinder head baffle 21 Install dipstick 22 Install fuel tank 23 Install electric starter 24 Install retractable starter 25 Install fuel pump 26 Install external g...

Page 119: ...guide Intake and exhaust tappets are interchangeable on other models 2 Install the camshaft one 005 shim spacer and the camshaft pin from bearing plate side Do not drive the camshaft pin into its fin...

Page 120: ...timing tool to simplify this pro cedure refer to the Special Tools section in this manual If the balance gears must be timed with out using the tool do not install the lower balance gear closest to t...

Page 121: ...ed balance gear as semblies are being used in the K241 K301 K321 and K341 single cylinder engines These new bal NEW ance gear assemblies Part No 45 043 03 are being used in engines with a Serial No of...

Page 122: ...and wiring harness between the bearing plate and crankcase before pressing the crankshaft all the way in 3 Remove the balance gear timing tool and align the primary timing mark on the crank shaft with...

Page 123: ...he primary timing mark on the crank shaft will now be aligned with the secondary timing mark on the lower balance gear Refer to Figures 12 9 and 12 17 4 Install one 1 020 shim spacer and retaining rin...

Page 124: ...bearing until the crankshaft gear is just above the camshaft gear but not in mesh with it Do not remove the balance gear timing tool at this time 4 Align the fifth 5th land marked on camshaft gear wit...

Page 125: ...ckwise direction Mark the sev enth land Refer to Figure 12 26 12 8 Upper Balance Gear J Secondary Timing M Figure 12 26 Marking Land On Upper Balance Gear 2 Lubricate the rear bearing surface of crank...

Page 126: ...k end play of lower balance gear as instructed in INSTALL BALANCE GEARS Figure 12 30 Crankshaft Gear Lower Balance Gear Alignment 7 Check the timing of the crankshaft camshaft and balance gears The pr...

Page 127: ...nd install the remaining two hex cap sems screws and hand tighten 4 Tighten the screws evenly drawing bearing plate to crankcase Torque K91 K181 to 115 in lb Torque K241 K341 to 35ft lb 5 Check cranks...

Page 128: ...RING NOTE For detailed piston inspection and piston ring installation procedures refer to the Inspec tion And Repair Reconditioning section INSTALL PISTON TO CONNECTING ROD Style A Piston 1 Install w...

Page 129: ...NSTALL OIL PAN 1 Install the gasket oil pan and oil drain plug 12 12 Figure 12 37 Installing Connecting Rod Cap 5 Torque the capscrew to 20 over the nominal torque value listed below Loosen cap screws...

Page 130: ...as neces sary On Models K91 K141 K161 and K181 If clearance is too small grind end of valve stems until correct clearance is obtained Make sure stems are ground perfectly flat and smooth If clearance...

Page 131: ...y which is also secured to the bearing plate Permanent magnets are af fixed to the inside rim of the flywheel except in rotor type magneto systems On these the magnet or rotor has a keyway and is pres...

Page 132: ...cure the flywheel The new crankshaft design has an internally threaded end and uses a woodruff key washer and or bushing hex cap screw or hex nut 1 Position key properly in keyway as shown in Figure 1...

Page 133: ...gasket and cylinder head Always use a new gasket when head has been re moved for service work 2 Torque the hex cap screws and hex nuts in increments in the sequence and torques shown in Figure 12 44...

Page 134: ...K241 Breather Assembly 2 Install the gasket breather cover and palnut INSTALL SIDE AIR BAFFLES AND CYLINDER HEAD BAFFLE 1 Install the starter side air baffle plain washer and hex cap sems screws Leave...

Page 135: ...rews Refer to Figure 12 47 Fuel Pump Camshaft Figure 12 47 Mechanical Fuel Pump 12 18 NOTE Make sure the fuel pump lever is positioned above the camshaft Damage to the fuel pump and subsequent severe...

Page 136: ...engine is now completely reassembled Before starting or operating the engine be sure to do the following 1 Make sure all hardware is tightened securely 2 Make sure the oil drain plugs oil sentry press...

Page 137: ...S AND SERVICE INFORMATION IN U S AND CANADA CALL 1 800 544 2444 This publication replaces ENS 575 KOHLER UD OUD ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 ISSUED 4 90 REVISED 11 92 MAILED LITHO...

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Kohler K24J, Service Manual

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