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Kohler K482, Service Manual

The Kohler K482 is a high-performance engine known for its reliability and durability. For easy installation and maintenance, we offer a comprehensive Installation Manual that can be downloaded for free from our website. This essential manual provides step-by-step instructions and valuable information to ensure seamless operation of your Kohler K482 engine.

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ELECTRICAL  SYSTEMS 

Two  b a s i c   t y p e s   of  h a t t e r y   e l e c t r i c a l   s y s t e m s  a r e  u s e d   o n   t h e   2   c y l i n d e r   e n g i n e .   T h e   m a j o r  

c o m p o n e n t s  of  the  c o n v e n t i o n a l   s y s t e m   i n c l u d e s  a  

D. 

C.  g e n e r a t o r ,   a   s t a r t i n g   m o t o r  a n d   a  

c u r r e n t   r e g u l a t o r .  

T h e   o t h e r   s y s t e m ,   t h e  

A l t e r n a t o r   s y s t e m  i n c l u d e s   a   p e r m a n e n t   m a g n e t  

r i n g ,   t h e   a l t e r n a t o r   s t a t o r   a n d   a   r e c t i f i e r - r e g u l a t o r .   A  12  volt  s t o r a g e   b a t t e r y   i s   u s e d   with  both  types 
of  s y s t e m s .   An  e l e c t r i c a l  s y s t e m   u s u a l l y   c o n s i s t s   of  a   c h a r g i n g   c i r c u i t  a n d  

a 

c r a n k i n g  c i r c u i t .  

The 

m a j o r   c o m p o n e n t s   of  e a c h  c i r c u i t  a r e  l i s t e d   i n  t h e   fallowing  c h a r t   u n d e r   the  b a s i c   t y p e   of  e l e c t r i c a l  
s y s t e m s .  

CHARGING  CIRCUIT 

1. 

B a t t e r y  

- 

12  v o l t  

2 .  

V o l t a g e - C u r r e n t  R e g u l a t o r  

3. 

D. 

C.  G e n e r a t o r  

CRANKING  CIRCUIT 

I .  

S t a r t i n g   M o t o r   ( B e n d i x   T y p e )  

CHARGING  CIRCUIT 

1. 

B a t t e r y  

- 

12  volt 

2. 

R e c t i f i e r - R e g u l a t o r  

3. 

A l t e r n a t o r  

CRANKING  CIRCUIT 

1. 

S t a r t i n g   M o t o r   ( B e n d i x  T y p e )  

BATTERY 

S t o r a g e   b a t t e r i e s   u s e d   with  K o h l e r   E n g i n e s   a r e  u s u a l l y   of  the  l e a d - a c i d  t y p e .   M o s t  a r e   12  volt 

b a t t e r i e s - - 6   v o l t  b a t t e r i e s   a r e  u s e d   o n   s o m e  a p p l i c a t i o n s .   L e a d   i s   u s e d   i n  the  c o n s t r u c t i o n  of  the 
p l a t e s   and  s u l f u r i c  a c i d   s e r v e s  a s  t h e   e l e c t r o l y t e .   "Wet" b a t t e r i e s   a r e  f i l l e d  with  e l e c t r o l y t e  a n d  a r e  

s t o r e d   r e a d y  t o  u s e   if  s a t i s f a c t o r y   c h a r g e   h a s  b e e n  m a i n t a i n e d .  

With  " d r y  

b a t t e r i e s ,   t h e  

p l a t e s   a r e   c h a r g e d   b u t  a n  e l e c t r o l y t e   of  s p e c i f i c   g r a d e  m u s t  h e  a d d e d   j u s t   b e f o r e   u s i n g .   Both  t y p e s  
function  i n   the  s a m e  g e n e r a l   way. 

The  t y p i c a l   12  v o l t  b a t t e r y   h a s  a   h a r d   r u b b e r   c a s e  w i t h   s i x  i n d i v i d u a l  c o m p a r t m e n t s   o r  c e l l s .  

E a c h  c e l l  c o n t a i n s   a  s p e c i f i c   n u m b e r   of  s e t s   of  n e g a t i v e  a n d   p o s i t i v e   p l a t e s .   G e n e r a l l y ,   t h e   g r e a t e r   the 

n u m b e r   of  p l a t e s  p e r   c e l l ,   t h e   h i g h e r   the  a m p e r e - h o u r   r a t i n g   of  the  b a t t e r y .   A l l   p l a t e s   of  l i k e   c h a r g e  

a r e  i n t e r c o n n e c t e d   s o  t h a t   the  a c c u m u l a t i v e   c h a r g e s   a r e  p r e s e n t  a t  t h e   p o s i t i v e   a n d   negative  t e r m i n a l s  

of  the  b a t t e r y .   A l l   K o h l e r   E n g i n e s   u s e   n e g a t i v e   g r o u n d   s y s t e m s .   With  t h i s   s y s t e m ,   t h e  n e g a t i v e  

( - )  

t e r m i n a l  of  t h e   h a t t e r y  is  c o n n e c t e d   i n  c o m m o n   ground  t o   t h e   e n g i n e   while  t h e   p o s i t i v e  

t e r m i n a l   i s  

" live"  t e r m i n a l .   When d i s c o n n e c t i n g   b a t t e r y  a l w a y s   r e m o v e   g r o u n d  

t e r m i n a l  f i r s t .  

Voltage  T e s t :   With  a  b a t t e r y  i n  good  c o n d i t i o n ,   e a c h   c e l l   c o n t r i b u t e s  a p p r o x i m a t e l y   1.95  t o  2.08  v o l t s .  
If  l e s s   than  0. 05  v o l t  d i f f e r e n c e  

is 

noted  b e t w e e n  t h e   h i g h e s t  a n d   l o w e s t   c e l l s ,   t h e   b a t t e r y   m a y  be 

r e c h a r g e d .   If  t h e   d i f f e r e n c e   i s  m o r e   t h a n   . 0 5  

t h i s   could  i n d i c a t e  a   c r a c k e d   p l a t e   o r  o t h e r  

d a m a g e   which  could  c a l l  f o r   r e p l a c e m e n t   of  t h e   h a t t e r y .  

S p e c i f i c   G r a v i t y   T e s t :   A s   a   h a t t e r y   d i s c h a r g e s  a n d   t h e   e n e r g y   i s  not  r e p l e n i s h e d ,   s u l f u r i c  a c i d   i s  

c h e m i c a l l y   w i t h d r a w n   f r o m   t h e   e l e c t r o l y t e  a n d   l e a d   s u l f a t e   d e p o s i t s   continue  t o   b u i l d   up  on  the  p l a t e s .  

T h i s   r e s u l t s   i n  a  d i m i n i s h i n g   s p e c i f i c   g r a v i t y   of  t h e  e l e c t r o l y t e .   If  t h e   s p e c i f i c   g r a v i t y   d r o p s   below 

1 . 2 4 0 ,   the  h a t t e r y   m u s t  h e   r e c h a r g e d .   In  f u l l y   c h a r g e d  c o n d i t i o n ,   t h e   s p e c i f i c   g r a v i t y   will  be  in  the 
1 . 2 6 0  

1.280  r a n g e .   S o m e   b a t t e r i e s  a r e  d e s i g n e d   s p e c i f i c a l l y  f o r   u s e   i n  t r o p i c a l   z o n e s - - t h e s e  have  a  

l o w e r   s p e c i f i c   g r a v i t y   t h a n   o t h e r   b a t t e r i e s .   H y d r o m e t e r   r e a d i n g s   m u s t  b e   c o r r e c t  f o r  v a r i a t i o n   in 
t e m p e r a t u r e   of  e l e c t r o l y t e .   Add  , 0 0 4   t o   t h e   r e a d i n g  f o r   e v e r y  

a b o v e   8 0 "  

F. 

a n d  s u b t r a c t  

f o r  

e v e r y   1 0 "   below  8 0 "  

F. 

A s  

a   b a t t e r y   i s  r e c h a r g e d ,   a  r e v e r s e   c h e m i c a l   r e a c t i o n   t a k e s   p l a c e   which  c a u s e s   t h e   l e a d   s u l f a t e  

d e p o s i t s   t o   be  c h a n g e d   b a c k   t o  l e a d ,   l e a d  dioxide  a n d   s u l f u r i c  a c i d .   In  e f f e c t ,   t h i s   r e v e r s e s   t h e   d i s -  
c h a r g e   r e a c t i o n  a n d   r e s t o r e s   m a t e r i a l s   t o  

condition.  If  s u l f a t e   d e p o s i t s   b e c o m e   too  g r e a t   o r   if 

t h e   l e v e l  of  t h e   e l e c t r o l y t e   i s   not  m a i n t a i n e d  a b o v e   the  l e v e l  of  t h e   p l a t e s ,   t h e   b a t t e r y   m a y  be  p e r m a -  
nently  d a m a g e d .  

S a f e t y  P r e c a u t i o n :   A d e q u a t e   v e n t i l a t i o n   m u s t  b e   p r o v i d e d   w h e n  b a t t e r i e s   a r e  being  r e c h a r g e d .   A l s o  

s p a r k s ,   open  f l a m e s   a n d   s m o k i n g   s h o u l d  b e  a v o i d e d   s i n c e   h y d r o g e n   g a s   i s  p r o d u c e d   which,  if  i g n i t e d ,  
c a n   c a u s e  a n  i n t e r n a l   e x p l o s i o n   t h a t  c a n   s h a t t e r   the  b a t t e r y .   T h i s   g a s  

is 

p r o d u c e d  i n  q u a n t i t y   only 

while  the  b a t t e r y   r e c e i v e s   high  r a t e   of  c h a r g e   but  c a n  l i n g e r   f o r   s e v e r a l   h o u r s   i n  a   p o o r l y  v e n t i l a t e d  

a r e a .  

Summary of Contents for K482

Page 1: ...twin cylinder engine SERVICE MANUAL ...

Page 2: ...retors 12 4 Gas Regulators 12 9 MODIFICATIONS ACCESSORIES 13 1 Clutch Wet Type 13 1 Clutch Gear Reduction U n i t 13 2 Air Vac Cooling 13 3 Tool L i s t i n g 13 4 SPECIFICATIONS K482 K532 K662 14 1 Specifications and Tolerances 14 1 Torque Values and Sequences 14 3 General Safety Warnings WARNING ACCIDENTAL STARTS Before s e r v i c i n g the engine o r equipment always remove the spark plug lead...

Page 3: ... LEVEL I I SAE 5W2O USE ONLY GENUINE KOHLERELEMENT MAKE SURE A I R INTAKE CHECK POLARITY F I L L FUEL TANK WITH FRESH REGULAR GRADE NO LEAD OR LEADED GASOLINE D ONOTMIX OIL WITH G A S O L I N E OF FUEL FILTER SERVICE I F NEEDED NEGATIVE GROUND SYSTEM USED 1 1 ...

Page 4: ... STARTS RETURNS TO I G N I T I O N CHOKE CRANK ENGINE HAND I THROTTLE MOVE THROTTLE HALFWAY OPEN I CRANK ENGINE ELECTRIC START ENGINE STARTS starter I MOVE TOGGLE SWITCH TO ON POSITION I GRADUALLY PUSH CHOKE PULL STARTING ROPE KNOB BACK I N AS ENGINE I I N DIRECTION SHOWN USE QUICK STEADY MOTION Ltmiz cranking time continuous PUSH BUTTON DEPRESS t o seconds allow a 60 WHEN I ...

Page 5: ... FUEL FILTER SERVICE SPARK PLUGS CHANGE OIL I N WET TYPE CLUTCH SERVICE CRANKCASE BREATHER CHECK AND SERVICE BREAKER POINTS CHECK IGNITION TIMING CHECK VALVE TAPPET CLEARANCE CHECK CRANKCASE VACUUM CHECK COMPRESSION CHECK SPECIFIC GRAVITY BATTERY SERVICE DC GENERATOR SERVICE STARTING MOTOR AND DRIVE SERVICE CYLINDER HEADS NOTE Intervals stated are for good operating conditions service items more e...

Page 6: ... s u f f i c i e n t a v a i l a b l e cool a i r 2 D i r t y a i r intake screen shroud o r c o o l i n g f i n s 3 Improper f u e l 4 Fuel mixture too lean 5 Improper i g n i t i o n timing 6 Engine overloaded 7 T i g h t tappet clearance 1 Fuel mixture too lean 2 Improper timing 3 Valve s t i c k i n g 1 Spark plug gap too wide 2 lmproper carburetor s e t t i n g o r l a c k o f f u e l 3 Wrong...

Page 7: ...PI SERVICE SF i n the example The symbol may show additional categories such as SE SF CC CD The center portion shows the viscosity grade such as SAE 30 i n the example Straight 30 weight o i l i s preferred If multiviscosity i s used be aware of the resulting increase i n o i l consumption and combustion deposits when used i n temperatures above 32 F O C CAUTION Using other than Service Class SF o...

Page 8: ...ER LOCATION Cartridge Type Oil Filter On s o m e K482 models it will h e n e c e s s a r y t o remove the a i r baffle on 2 cylinder to gain a c c e s s t o the cartridge on latest K482 and a l l K532 models the cartridge protrudes t h r u the baffle making removal of the a i r baffle unnecessary E a r l i e r models can b e converted for direct a c c e s s with Kit 277577 after this kit i s insta...

Page 9: ...over to the filter body then remove cover 3 Grasp clip on top of filter element and pull element out of filter body slip pan o r rag under element a s it i s removed to prevent oil from dripping on engine Discard old element 4 Thoroughly clean inside of cover and body make s u r e a l l t r a c e of dirty oil i s removed Replace cover gaskets if needed Close drain plug after cleaning 5 Slip new el...

Page 10: ...les Other causes of low oil pressure a r e badly worn bearings and or transfer sleeves If oil pump i s faulty do not attempt to disassemble and r e p a i r the pump they a r e permanently sealed during manu facture Replace faulty pump with new unit An external oil p r e s s u r e adjustment i s provided on the K 5 K482 and K532 but not on K662 models I ACORN NUT SELF LOCKING NUT SCREW have nut I F...

Page 11: ...t only must the r i g h t f i l t e r be used but i t must be properly i n s t a l l e d t o prevent u n f i l t e r e d a i r from entering the engine Check the following when i n s t a l l i n g new o r serviced element 1 Back p l a t e K482 K532 a i r horns and adapters must be securely tightened t o carburetor Replace bent o r cracked back p l a t e when used Gaskets between back p l a t e o r...

Page 12: ...he lips open briefly to dump the accumulation Air cleaned by centrifugal action i s then drawn through the d r y type element and into the carburetor The d r y type element on the multi phase a i r cleaner i s serviceable it c a n be cleaned in water and soap s e e following instructions up to 10 times before replacement i s required Service multi phase cleaner a t the intervals stated in the foll...

Page 13: ... must be replaced Before installing serviced element wipe out inside of filter body Inspect gasket end of element replace element if gasket is damaged o r missing Element should be replaced after 10 washings or after one year of use Also replace automatic dust unloader after one year of use OIL BATH TYPE AIR CLEANERS Oil bath a i r cleaners a r e often used where above normal concentration of dust...

Page 14: ...e copper washer when used then secure with wing nut firmly tighten with fingers only 6 Check to make s u r e cleaner i s properly installed s o that no unfiltered a i r c a n enter carburetor Servicing of the l a r g e capacity type oil bath is essentially the same a s that stated f o r the normal capacity type cleaners The main difference i s that the bowl is removed from the bottom of the unit T...

Page 15: ...e Fuel The other i s a fixed main jet type which has a n external adjustment for the Idle Fuel needle only On fixed jet carburetors main fuel adjustment is possible only by changing to a discharge jet of different size If a n engine with fixed jet carburetor is to be operated at high altitudes above 6000 feet the standard jet should be replaced by a special 6000 jet Another special jet is availabl...

Page 16: ...t the desired idle speed S T E P 6 Final Adjustment Since main fuel and idle fuel adjustment have some effect on each other recheck engine and make final adjustments a s necessary to achieve smoothest operation NOTE If the preceding steps do not remedy problems attributed to carburetor carburetor recon ditioning may be necessary Carburetor Reconditioning Hard starting l o s s of power and rough id...

Page 17: ...worn o r damaged replace carburetor 6 Thoroughly clean carburetor p e r instructions in reconditioning paragraph Reassembly Side Draft Carburetor A 277061 1 Install new fuel inlet needle s e a t gasket and fuel inlet needle 2 Install float and float pin Invert casting s o that float lip r e s t s lightly against fuel inlet needle There should be 11 64 plus o r minus 1 32 clearance between machined...

Page 18: ...onditioning paragraph Reassembly Fixed J e t Type Side Draft Carburetor 1 Position s e a l and install main discharge tube 2 Install gasket and fuel inlet needle seat and fuel inlet needle 3 Invert carburetor body and install float and float pin Hold i n inverted position and measure distance between machined surface no gasket and top of floats This should be 31 32 plus o r minus 1 32 a t highest ...

Page 19: ...ace discharge tube Be s u r e s e a l i s i n place 2 P l a c e bowl gasket in position 3 Install needle float and float in Set float level with carburetor body inverted and float resting lightly against needle in its seat There should be 1 1 4 between machined sur face of casting no gasket and top of float Float should be level f r o m one side to the other Adjust by bending float lever close to ...

Page 20: ...assembly Lift a i r intake assembly off use c a r e to avoid bending float a s assembly i s removed Remove and dis card gasket 2 Remove capscrews and separate fuel bowl assembly from throttle assembly Service each assembly separately p e r the following instructions Air Intake Assembly 1 Remove float pin and float Inspect float discard if dented cracked o r leaking 2 Remove and discard fuel valve ...

Page 21: ... r t s where required r e a s s e m b l e a s follows 1 After installing new gasket place large venturi in throttle body 2 Position bowl assembly on throttle body and s e c u r e with capscrews 3 J u s t before final assembly s e t float level Turn intake assembly upside down s o that float r e s t s lightly against fuel valve Measure distance between machined surface of assembly and top of float ...

Page 22: ...en screws on outside of cover plate then shift cover in clockwise direction arrow f o r richer set ting o r in counterclockwise direction for leaner setting Tighten cover screws a f t e r final adjustment Exhaust Manifold Mounted Unit Remove a i r cleaner from carburetor to observe position of choke plate Choke adjustment must be made on cold engine If starting in extreme cold choke should be in f...

Page 23: ...sket 4 Clean fuel head thoroughly with solvent and a fine wire brush 5 Holding pump cover with diaphragm surface up place new valve gasket into the cavity Now a s s e m b l e the valve spring and valves into the cavity and reassemble valve retainer and lock in position by inserting and tightening fuel pump valve retainer screw 6 Place pump cover assembly in a clean place and rebuild the lower diap...

Page 24: ... turn fuel off a t valve located on top of filter assembly then loosen retaining bail a t bottom of fuel bowl remove and clean bowl If filter element i s used swish element in clean solvent After reinstalling and opening fuel valve u s e p r i m e r if s o equipped on fuel pump to pump fuel back into bowl ...

Page 25: ... a constant speed setting o r a t a variable speed setting a s determined by the engine application Make s u r e the proper procedure i s followed for the particular engine involved K482 K532 GOVERNORS On the K482 and K532 the b r e a k e r points a r e mounted on the governor and a r e activated by the b r e a k e r rod which rides on a c a m on the governor drive shaft F o r this reason it i s n...

Page 26: ...t readjustment of speed is possible with constant speed governors T o increase speed loosen the inside speed adjusting locking nut and tighten the outside nut to d r a w the eye of the holt closer t o the bracket to a e c r e a s e speed loosen the outside nut and tighten the inside nut After speed i s correct tighten the nut that was loosened t o lock the eye bolt a t the new setting Governor Sen...

Page 27: ...tighten locknut after adjustment SENSITIVITY ADJUSTMENT If governor control is too sensitive speed surging o r hunting will occur with chaneine load An excessive droo in soeed when load i s aoolied indicates that the governor L A v should be s e t for g r e a t e r sensitivity Recheck speed after making sensitivity adjustment a s changing this will affect speed On variable speed type governors s e...

Page 28: ...on to this type of equipment Briefly this device places a slight tension on the throttle rod to stabilize governor control with sudden change in load The compensator spring is adjusted with engine running at high speed 3000 R P M To adjust turn hex nuts in proper direction until there i s just enough tension on the spring s o that it floats without any end play Lock nuts a f t e r readjustment is ...

Page 29: ...82 K582 B a t t e r y Standard resistor plug BREAKER POINTS K662 Engine operation is greatly affected by b r e a k e r point condition and adjustment of the gap If points a r e burned o r badly oxidized little o r no current will pass and a s a result the engine may not operate a t all o r if it does run it i s likely to m i s s particularly a t full throttle Adjusting breaker point gap affects th...

Page 30: ...inals the lamp will not light if the circuit is grounded To check the secondary circuit connect one test point to the high tension terminal and the other point to either of the p r i m a r y terminals In this c a s e the lamp will not light but tiny sparks should be noted a s the test points a r e rubbed a c r o s s the terminals If the secondary i s opened no sparks will occur If the tests show t...

Page 31: ...l and a hub connected together by a strong spring One half of the coupling the shell i s fitted to a drive member on the engine drive shaft while the other half the hub i s keyed to the magneto rotor shaft In operation a t slow speeds a pawl on the magneto half of the coupling engages a stop pin mounted on the magneto f r a m e which acts to prevent further movement of the rotor while the engine h...

Page 32: ...contact s c r e w then b r e a k e r a r m lock and washer 2 Lift b r e a k e r a r m off pivot discard a r m 3 Remove the two breaker plate contact s c r e w s then remove and discard the fixed contact plate 4 Position and secure new contact plate and b r e a k e r a r m then adjust b r e a k e r point gap p e r instructions stated in the foregoing 5 Replace old c a m wick with new wick lubricate...

Page 33: ...n while holding g e a r in timing position attained in Step 2 carefully guide magneto gear into engagement with c a m gear 4 After securing magneto to housing test by turning flywheel in clockwise direction until impulse coupling trips loud click DC m a r k on flywheel should be just past center m a r k in sight hole I I 1 FIGURE 6 5 INSTALLING AND TIMING MAGNETO TO ENGINE Use timing light to time...

Page 34: ... r e w and gear 2 To remove breaker a r m remove spring clamp screw a r m lock and washer then slip a r m off pivot Discard old breaker a r m 3 Breaker plate is removed after spacer washer and two clamp screws a r e removed Discard old breaker plate 4 Reverse procedure to install new breaker plate and a r m which include new contacts then adjust contact point gap p e r previous instructions Remove...

Page 35: ... s s u r e and should move freelv in its holder Replace b r u s h if unevenly o r excessively worn U s e the following procedure to replace breaker contacts 1 To remove breaker a r m remove breaker a r m terminal screw which releases coil con denser and ground leads and breaker a r m spring then remove snap ring on fulcrum pin and lift b r e a k e r a r m off pin Discard old breaker a r m 2 To rem...

Page 36: ... he used with timing lights Rotating the governor advances o r r e t a r d s the timing depending on which way the unit i s turned 1 If boot type lead i s used remove hoot a t l cylinder nearest flywheel then wrap one end of a short piece of fine wire around s p a r k plug terminal Reconnect boot to terminal s o that f r e e end of the wire can protrude under the boot Step 1 applies to timing ligh...

Page 37: ...is s y s t e m the negative terminal of the hattery is connected in common ground to the engine while the positive t terminal i s the live terminal When disconnecting battery always remove ground terminal f i r s t Voltage Test With a battery in good condition each cell contributes approximately 1 95 to 2 08 volts If l e s s than 0 05 volt difference is noted between the highest and lowest cells t...

Page 38: ...a simple cleaning of the contact points plus possible readjustment The flat point always develops a slight cavity and is the point that requires most attention It is not n e c e s s a r y to have a perfectly flat surface on this point hut cleaning the surface down to pure metal with a fine cut riffel file will insure long periods of service The file should not be allowed to become g r e a s y and ...

Page 39: ... This requires two inspections and adjustments The a r m a t u r e a i r gap and the voltage setting Disconnect battery before making these adjustments 1 Armature Air Gap To check a i r gap push the a r m a t u r e down until contact points a r e still just touching then m e a s u r e a i r gap This should be 075 Adjust by loosening con tact mounting screws and raising o r lowering the contact bra...

Page 40: ... the brushes a r e serviced 500 hours If dirty clean with No 00 Sandpaper Make s u r e dust i s removed after cleaning If suriace i s grooved rough o r out of round remove a r m a t u r e and place in lathe s o that commutator can be turned down Remove only enough material to make commutator smooth and round After resurfacing undercut the mica insulation 1 32 deep Finish with No 00 Sandpaper after...

Page 41: ...close to s t a r t the a r m a t u r e turning With Bendix drive the drive pinion moves laterally on a splined sleeve into engagement a s the a r m a t u r e s t a r t s to rotate When the pinion butts against a stop located at end of the a r m a t u r e shaft K662 Bendix s t a r t e r s it locks in positive engagement with the shaft to crank the engine On K482 Bendix type s t a r t e r s a spring...

Page 42: ... high the a r m a t u r e s h o u l d b e m o v e d f o r reconditioning FIGURE 7 7 K662 STARTING MOTORS EXPLODED VIEW Trouble Analysis If s t a r t e r fails to energize f i r s t check wiring starting switch o r solenoid and con F t i o n of battery Clean o r replace badly corroded o r dirty contacts replace wires if frayed o r cracked Bypass s t a r t switch o r solenoid with jumper wire if s t...

Page 43: ...r is supported by brackets a t front and r e a r The brackets when properly installed and tightened provide alignment of the drive pinion to ring gear Make s u r e these a r e secure at all t i m e s to prevent gear damage Drive pinion to ring gear backlash must be from 015 to 030H on K482 and 015 to 035 on K662 models To m e a s u r e this move drive pinion into engagement then check clearance be...

Page 44: ...SPARK PLUGS OFF IGNITION SWITCH 4 OR 6 GA WIRE p7 a GENERATOR 64 OR 66 GA WIRE O I L PRESSURE DISCHARGE INDICATING LAMP FIGURE 7 9 WIRING DIAGRAMS K662 ELECTRICAL SYSTEMS ...

Page 45: ...avoid damaging charging system components 15 A M P SYSTEM I KEEP FINS CLEAN RECTIFIER REGULATOR MOUNTED ON ENGINE OR EQUIPMENT POWERED BY ENGINE 1 30 A M P SYSTEM FIGURE 7 10 RECTIFIER REGULATOR IDENTIFIES CHARGING SYSTEM PRECAUTIONS 15 A M P SYSTEM 1 Battery polarity must be c o r r e c t Negative ground s y s t e m s a r e used with Kohler Engines 2 Prevent alternator leads AC f r o m touching o...

Page 46: ...black leads about gohms should be n o t e d B With engine stopped connect leads o f flash l i g h t type continuity t e s t e r between BAT NEG and one o f the A C terminals then reverse these leads lamp should t u r n ONone way and OFF the other Repeat procedure on the other A C terminal I f lamp i n d i c a t i o n i s the same both ways diode i s f a u l t y A Remove red lead from REG terminal ...

Page 47: ...REGULATOR A Key Start y CONDENSER 1 I FIGURE 7 12 TYPICAL 30 AMP ALTERNATOR SYSTEM WIRING DIAGRAM FIGURE 7 13 K662 30 AMP BATTERY CHARGING WGNETO IGNITION SYSTEM 7 11 ...

Page 48: ...l t e r n a t o r system OK b a t t e r y was f u l l y charged A 2 Check f o r defective s t a t o r or r e c t i f i e r u l a t o T T L I 8 1 I f less than 28 v o l t s 8 2 I f more than 28 v o l t s CONDITION BATTERY CONTINUOU LY CHARGES AT HIGH RATE TEST C Check B t o ground w i t h DC Voltmeter C l I f over 14 7 v o l t s Turn lights on i f 60 watts or more or simulate Zood by pZacing a 2 5 ...

Page 49: ...with a sharp piece of wood wood o r similar material is suggested to avoid scratching aluminum surfaces of head Always use new cylinder head gaskets make s u r e head bolts a r e tightened in the proper sequence and to the torque value stated in the Specification Section Before reinstalling the serviced heads check and adjust valve tappet clearance p e r the following instructions VALVE TAPPET CLE...

Page 50: ...properly The tabs on the reed stop must be adjusted s o that they a r e 020 above the flat surface of the reed when the engine i s not running The reed allows a i r to exit from the crankcase but blocks return of a i r The filter element should be serviced occasionally s o that crankcase ventila tion is not blocked A closed system i s a l s o employed on the K662 The components of this system a r ...

Page 51: ... a l s o cause this Disassemble breather thorouehlv clean then recheck crankcase Dressure a f t e r serviced breather i s reinstalled B Worn jamaged Oil Seals Oil leakage is usually evident around worn o r damaged oil seals Replace oil seals and recheck vacuum C Blowby Leaky Valves Can be the cause of positive crankcase p r e s s u r e s These condi tions c a n h e confirmed by taking compression ...

Page 52: ...ders A difference in pressure reading between cylinders in excess of 15 or readings below 90 PSI can indicate the following POSSIBLE CAUSE A Cylinder head gasket blown B Cylinder head warped or loose C Piston rings worn blowby occurring D Valves leaking E Excessive combustion deposits REMEDY A Remove head check for flatness replace gasket reinstall head recheck compression Locate cause of initial ...

Page 53: ... but can in severe c a s e s cause scuffing and scoring of the cylinder walls A s raw fuel s e e p s down the cylinder walls it washes the necessary lubricating oils off the piston and cylinder walls s o that the piston rings make metal to metal contact with the walls Scoring of the cylinder walls c a n a l s o be caused by localized hot spots resulting f r o m blocked cooling fins o r from inadeq...

Page 54: ...ng If this has not already been done f o r cleaning external surfaces of engine 4 Instrument Panel Disconnect line to oil p r e s s u r e gauge affix numbers for ease in recon n e c t i n g l a t e i a n d disconnect all electrical leads then remove instrument panel from gear housing Other electrical components such a s ignition coil condenser rectifier regulator can a l s o be removed a t this ti...

Page 55: ... assembly i s pinned to the s t a r t e r shaft drive pin out remove nut a t end of s t a r t e r shaft then slip Bendix Assembly off shaft B After loosening setscrew o r removing roll pin block and prevent flywheel from turn ing i n s e r t board between cooling fins an flywheel then remove retaining nut C Use puller to remove flywheel f r o m shaft Do not bump to remove a s this may weaken o r b...

Page 56: ...s Also tag tappets s o that they can be reinstalled if reusable in s a m e cylinder during reassembly Oil Pan Tilt engine on its side to gain a c c e s s to t h r u bolts securing pan to crankcase Remove t h r u bolts then being careful not to damage oil s c r e e n remove oil pan Tappets can now be removed working thru inside of crankcase Oil Pump After pan i s removed disconnect oil s c r e e n ...

Page 57: ...s e e if wear i s within limits Do not remove parts unless replacement i s necessary If crankshaft h a s to be reground undersize hearings K482 K532 and t r a n s f e r sleeves K662 will have to b e used regardless of condition of old parts Running clearance of t r a n s f e r sleeves on K662 i s 000 0025 C Bushings Camshaft Check bushings f o r signs of scuffing scoring and excessive wear See Cle...

Page 58: ...not necessary t o separate the crankshaft f r o m the closure plate if the bearing turns easily and noiselessly on the shaft Replacement of the bearing is not usually necessary T o recondition o r replace bearing remove inner retaining ring then p r e s s crankshaft out of closure plate The bearing will r e m a i n on the shaft and can b e p r e s s e d off a f t e r two remaining snap rings a r e...

Page 59: ...n g and b e t t e r con formity t o cylinder wall regardless of wear Cylinder bore must be deglazed before service r i n g s e t s a r e used Chrome p l a t e d rings when used should be i n s t a l l e d i n the top groove I I Install Bottom Prod Single I Prod 3 Piece Service 4 Piece I I Ring First I I BOTTOM I GROOVE j I I I I I I I I Prod Type Prod Type Prod Type Service 3 Piece I I I MIDDLE I ...

Page 60: ...g install in down position o r toward the piston skirt Refer to Figure 10 7 f o r typical ring types and installation in grooves Ring installation instructions a r e a l s o included with new ring s e t s either printed on the carton o r on a printed sheet included in container Follow instructions carefully Use ring expander to lnstall rings and check side clearance of e a c h ring after instal la...

Page 61: ... s completely removed Be careful not to damage block when removing old guide P r e s s new guides to depth stated in Clearance Section Ream to proper I D after installation Valves and Valve Seats Consult p a r t s manual f o r c o r r e c t valve numbers when replacing valves Some applications require special hard faced valves for both intake and exhaust valves Exhaust valves a r e always h a r d ...

Page 62: ...n in o r out until proper clearance i s attained See Engine General Service Section for valve clearance and adjust ment procedure CYLINDER HEADS Blocked cooling fins often cause localized hot spotsu which can result in blown cylinder head gaskets If gasket fails in a r e a surrounding one of the retaining capscrews high temperature combus tion gases can burn away portions of aluminum alloy head If...

Page 63: ...ate and gasket controls end play of camshaft which should be in the 003 t o 024 range on a l l models If end play i s b e a t e r than this plate is r o b a h l worn excessively i n camshaft con tact a r e a and must therefore be replaced Before installing grease plate around camshaft contact a r e a to prevent seizure during initial start up STEP 4 Crankshaft Closure Plate While some K482 K532 mo...

Page 64: ...play check Install r e a r oil s e a l after end play is corrected K662 End Play 0035 to 0055 1 Start with two white 007 gaskets then place steel shim 020 Place three white 007 gas kets on top of shim N S Do not use shim if gasket thickness on either side i s l e s s than 014 o r if gasket stack totals l e s s than 048 substitute 020 size paper gasket if shim cannot be used 2 Install closure plate...

Page 65: ...re pump body to block C C a m Gear Turn crank g e a r until tooth with punch m a r k i s in 12 o clock position a s shown in Figure 11 3 Install woodruff key on camshaft rotate camshaft so that the two timing m a r k s punched on adjacent teeth of c a m gear will straddle single m a r k on crank g e a r After m a r k s a r e aligned install c a m gear and s e c u r e with retaining nut tighten nut...

Page 66: ... position S T E P 7 Oil Screen and Oil P a n Base Connect oil s c r e e n o r s t r a i n e r to oil pump body Thread oil tube into body then assemble clip and s t r a i n e r to tube After installine s t r a i n e r position new oil pan gasket place dowel then s e c u r e oil pan to block with oil pan capscrews If pan baffle i s used position gasket on each side of baffle S T E P 8 Gear Cover K48...

Page 67: ...htening DO NOT allow t h e key t o be pushed inward on the keyway while i n s t a l l i n g the flywheez I f the key rides up on t h e rounded surface a t the end o f the keyway as shown i n Figure 8 16 it w i l l a c t as a wedge and crack the flywheel hub DO NOT reuse a flywheel i f it has been dropped or damaged i n any way DO NOT use a s t e e l bar o r any other object beween the flywheeZ f i...

Page 68: ...hers a r e used Tighten capscrew in the sequence and to the torque values a s stated in the Specification Section of this manual Install new s p a r k plugs and tighten to 324 in lbs 27 it l h s torque value S T E P 13 Intake Exhaust Manifolds Place heavy flat washer o r spacer on manifold where capscrews a r e used to s e c u r e manifold and side baffles P l a c e intake and exhaust manifolds an...

Page 69: ...lower Housing Baffles Shrouds A Install lower baffles support on K662 models Support baffle has been installed with gear cover on K482 and K532 rnodets B Install blower housing Note On K662 engines with wire m e s h screen install screen on flywheel before placing h z n g in position On engines with rotating a i r screen install blower housing then screen assembly Use spacers between flywheel and ...

Page 70: ... replace a c o r n nut Refer to wiring diagrams s e e Section 6 and 7 for proper connections of electrical equipment Connect throttle choke a m m e t e r and oil p r e s s u r e gauges RUN IN INSTRUCTIONS Refer to appropriate Service Section for adjustment procedures f o r carburetor governor etc After initial adjustment fill engine to proper oil level m a r k with non detergent type oil and run i...

Page 71: ... h e engine t h e p r e s s u r e must h e reduced t o about 4 t o 6 ounces p e r square inch The fuel supplier should i n s u r e that gas p r e s s u r e i s sufficient to operate the p r i m a r y regulator If p r e s s u r e drops too low the regulator may not function a t all While propane tends to maintain s o m e vaporizing p r e s s u r e even a t t e m p e r a t u r e s down to 20 F butan...

Page 72: ...reater the valve opening and a corresponding increase in intake of gas Since the valve was opened only by a vacuum created by passage of a i r i t closes completely when the engine is stopped On engines with the gasoline carburetor a n adapter i s installed between the carburetor and a i r cleaner The adapter consists of a gas jet and venturi Accurate metering of the gas i s accomplished by load a...

Page 73: ...ng then proceed a s follows 1 Close gasoline shut off valve usually located on fuel filter Open gas valve in gas fuel line 2 Depress gas p r i m e r if s o equipped then s t a r t engine Use Step 3 if final adjustments a r e needed 3 Allow engine to warm up to normal operating temperatures Move throttle control to normal operating speed and place engine under load Loosen locknut then move load adj...

Page 74: ... device with no intermediate positions it i s either in full open o r full closed positions When the choke is opened and the throttle plate is advanced beyond the idle speed range gas enters the carburetor t h r u the gas nozzle in volume proportionate to the velocity of a i r through the venturi The velocity i s in turn controlled by position of the throttle plate The balance line com pensates fo...

Page 75: ...lacement gaskets seals e t c a r e included in the Kohler Repair Kit for this carburetor refer to the P a r t s Manual K662 for the c o r r e c t part number Recondition carburetor a s follows Wash p a r t s in solvent blow out all p a s s a g e s 1 Disconnect balance idle and fuel inlet lines a l s o throttle and choke linkage a t carburetor 2 Remove carburetor f r o m engine for bench disassembl...

Page 76: ...reviously described model KG1 c a r buretor Refer to operation section on that carburetor for explanation of operating principles Adjustments Refer to Figure 12 5 for initial settings on carburetor After initial adjustment i s made s t a r t engine and make final adjustments a s follows 1 After engine s t a r t s hold choke in closed position while making final starting mixture adjustment Move sta...

Page 77: ... At full throttle and full load operation the position of the throttle plate i s such that maximum fuel i s metered to the engine The maximum amount of fuel allowed i s determined by setting of the main fuel load adjustment Adjustment F o r preliminary adjustment of carburetor r e f e r to Figure 12 6 T u r n screws in lightly against seats before opening do not force closed Final adjustments a r ...

Page 78: ...r and spril Remove idle lever axle lever and rubber disc valve Remove the two housing screws thc remove idle diaphragm housing and gasket 5 Regulator Diaphragm Remove four cover screws then remove regulator diaphragm a s a u n t Separate components discard used diaphragms 6 Main Fuel Valve Remove fuel valve axle retainer axle and valve lever Loosen inlet orifice setscrew 8 32 Allen then remove ori...

Page 79: ...f t e r reinstalling on engine GAS REGULATORS Model F 1 F and KN secondary regulators a r e used While they differ in appearance they a r e single diaphragm type regulators which function to control the amount of fuel entering a n engine under varying speed and load conditions Vacuum created within the engine i s communicated to one side of the diaphragm while the other side is subject to atmosphe...

Page 80: ... l imbedded in rubber Before reassembling regulator make s u r e all parts a r e clean and f r e e of d i r t lint etc Reassembly After reinstalling orifice s e a t and idle adjustment insert diaphragm lever and spring then carefully secure with retaining screw tighten s c r e w only enough to hold lever in place overtightening will bind lever Position diaphragm and engage it to lever Position cov...

Page 81: ...ulator h a s been completely disassembled o r if fuel i s not being shut off properly a f t e r engine stops Use following procedure to adjust With engine stopped slowly turn lock off s c r e w out counterclockwise direction until fuel s t a r t s to flow through the regulator then turn s c r e w in clockwise until the flow stops note position of s c r e w when flow stops then turn in one m o r e ...

Page 82: ...ut the need for priming Operation Fuel entering regulator p a s s e s through a s c r e e n then flows to the electric solenoid valve When actuated the valve disc is lifted off its s e a t which allows fuel to flow through the high p r e s s u r e valve which i s in turn controlled by a diaphragm to reduce p r e s s u r e to about 4 5 psi F r o m here fuel flows into the low p r e s s u r e chambe...

Page 83: ...he installation of gaskets and diaphragms When replacing the high p r e s s u r e valve assembly make certain that machined seat in casting i s perfectly clean and f r e e of nicks Wipe out any foreign matter which could affect DrODer seatine of valve bodv and O ring ADDIV a small amount of oil to O ring to u aid in the initial sealing Carefully note the dimension shown on insert Figure 12 13 This...

Page 84: ...per oil level m u s t be maintained to provide efficient lubrication The oil should be changed after each 100 hours of operation When refilling use 1 pint of oonl detergent oil of p r o p e r weight SAE viscosity f o r the prevailing temperatures s e e accompanying chart TEMPERATURE SAE VISCOSITY Above 50 F 0 to 50 F Below 0 F SAE 30 SAE 20 SAE 10 ...

Page 85: ...d through chain sprocket drive to a gear reduction unit which runs in oil Service the separate units a s follows at 50 hour intervals Clutch Open lubrication cover plate marked on side of clutch housing and lightly lubricate the clutc beaFing collar If clutch slippage o r overheating is noted readjust clutch a s follows Remove name plate release clutch then using large screwdriver turn collar cloc...

Page 86: ...d outlet screen a r e maintained in clean condition a t all times to pre vent overheating due to restricted a i r circulation Special cold weather equipment is a l s o available with Air Vac systems This system i s com prised of a thermostatically operated a i r shutter unit and often includes a carburetor de icer o r heat ing unit When the engine is cold the shutters a r e held in partially close...

Page 87: ... s directed to the unit Thermostatic shutter units a r e adjusted i n the factory however slight readjustment may have to be made to suit local weather conditions A turnbuckle i s provided in the linkage for adjustment of shutters To adjust loosen locknut then move turnbuckle to reposition angle of shutters Adjustment i s made on cold engine TOOL LISTING Common Tools Following i s a l i s t o f to...

Page 88: ...SPECIFICATIONS AND TOLERANCES ALL DIMENSIONS IN INCHES GENERAL CAMSHAFT CONNECTION CRANKSHAFT CYLINDER Maximum limits combination of I D and O D measurements 2Sleevebearing 1 7495 1 7500 ...

Page 89: ...D IGNITION Service Replacement Sires 4 003 010 020 030 Thrust Face O D 003 RH 10 025 018 020 Max Out of Flatness New Maximum Wear Limit Spark Plug Type Gap 3 2432 3 2413 Type Battery Magneto Gaseous Fuels 3125 3125 3125 34375 3 4941 3 4925 3 491 007 010 010 020 030 006 8752 8754 3 36W3 365 Thrust Face To Bore Clearance New 2 Nominal Point Gap 3 6240 3 6235 3 691 0005 002 010 020 030 006 8749 8751 ...

Page 90: ... Lubricate with engine oil Overtorque ZO loosen below torque value 8 retorque to final torque value 14 3 Gear Cover 3 install y o shoulder Capscrews Vf thread depth ln sacond and lhird holes a s indi cated Tlghtento 150in lbs then install other P X A W S and toque to 150in Ibs Oil Pump Drive Gear Backlash Feeler Gauge Method Check backlash d three points an the gear 120 apart lo petermine il backl...

Page 91: ...ENGINE DIVISION KOHLER CO KOHLER WISCONSIN53044 L i t h o i n U S A 5 8 2 U ...

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