Kohler KT17 Service Manual Download Page 36 | Manualshive

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Summary of Contents for KT17

Page 1: ......

Page 2: ...TING Section 3 AIR INTAKE SYSTEM Section 4 FUEL SYSTEM AND GOVERNOR Section 5 LUBRICATION SYSTEM Section 6 ELECTRICAL SYSTEMS COMPONENTS Section 7 DISASSEMBLY Section 8 ASSEMBLY SUBJECT INDEX 1 I I 3...

Page 3: ...It is recommended the technician study the procedures and illustrations in this manual and use them as references when per forming repairs KT engines use one of two types of Pressurized Lubrication Sy...

Page 4: ...icance of each of these numbers is shown below Serial Number Specification And Model Number Figure 1 1 Engine Identification Decals Engine Model Code 24 KT17 32 KT21 49 KT19 Year of Manufacture 90 94...

Page 5: ...e overemphasized Insufficient or dirty oil causes premature engine wear and failure Oil Type Use high quality detergent oil of API American Pe troleum Institute service class SF or SG Select the visco...

Page 6: ...pressure may build up in tank causing flooding or dangerous spraying of gasoline when cap is re moved A vacuum may also be created which could disrupt fuel flow to the carburetor during en gine operat...

Page 7: ...te engine with blower housing or cooling shrouds removed They direct air flow past cooling fins and removal results in improper air circulation overheating and engine damage External surfaces see Figu...

Page 8: ...051 580 mm 002 023 051 580 mm 002 023 051 580 mm Crankshaft End Play Sleeve Bearing 002 014 051 355 mm 002 014 051 355 mm 002 014 051 355 mm Crankshaft Running Clearance Sleeve Bearing 0013 0033 034...

Page 9: ...82 34 895 mm 1 3733 34 882 34 895 mm 1 4993 38 082 38 095 mm 1 3738 1 3738 1 4998 Series II 1 3733 34 882 34 895 mm 1 4993 38 082 38 095 mm 1 3738 1 4998 Crankshaft Crankpin Max Out of Round 0005 013...

Page 10: ...epair procedures will be made easier by using proper tools Use only the correct size tool to fit each size of fastener Some procedures detailed in this manual recom mend use oftools which can be made...

Page 11: ...en Columns t 3 v 2 1 c 0 u 1 2 M 3 4 Drill a 112 hole in the center of a rubber stopper the size to be a snug fit in the engine oil fill hole Insert long end oftube thru stopper hole Figure 1 5 U Tube...

Page 12: ...system Engine Will Not Idle Idle speed too slow Idle mixture needle not properly adjusted Dirt or water in fuel system Restricted fuel tank filler cap Defective spark plugs Wrong valve clearance Low e...

Page 13: ...D Check the air cleaner element Look for holes tears cracked or damaged sealing surfaces or other damage that could allow dirt to enter engine Also note if the element is plugged or restricted which...

Page 14: ...evel in the open side Ifthere is no vacuum or a positive pressure check for the following conditions NOTE Clamp must be closed before stopping engine a Crankcase breather clogged or inoper ative Disas...

Page 15: ...eal and element 2 Remove the breather hose and air intake tube from air cleaner base 3 Remove the screws securing base to intake elbow Lift base from intake elbow Assembly 1 Install air cleaner base a...

Page 16: ...om air cleaner base 3 Remove the screw securing air cleaner base to intake manifold Lift base from intake elbow Assembly 1 Install air cleaner base and new base gasket on elbow and secure to intake ma...

Page 17: ...recleaner Element Base Screw Base cQ Gasket Intake Elbow ft i lij KJl Figure 3 5 Round Air Cleaner Assembly 17 SECTION 3 AIR INTAKE SYSTEM Anti Icing System Figure 3 6 DTal d Win Nut Aor Cleaner __ Co...

Page 18: ...over Or Heater Plate Correct entering engine make sure air cleaner cover is sealed around entire perimeter of base 7 Install wing nut and finger tighten 1 2 to 1 full turn after nut contacts cover Do...

Page 19: ...up Turn main fuel adjusting screw clockwise from the preliminary setting until speed de creases and note position ofthe screw Now turn the screw counterclockwise the engine speed may first increase th...

Page 20: ...d fuel and make sure no sources ofheat flame or sparks are near as these can cause gasoline fumes to explode 1 Shut off fuel source 2 Disconnect breather hose from carburetor in take elbow or from air...

Page 21: ...ers with a 010 feeler gauge If feeler cannot be inserted or if there is interference between the float and towers file the towers to achieve proper clearance See Figure 4 6 010 Feeler Gauge Both Sides...

Page 22: ...s engine speed With the governor properly adjusted this action takes place so rapidly a reduction in speed is hardly noticed As speed reaches the governed setting the tension of the governor spring an...

Page 23: ...lamp securing choke control assembly to intake manifold Disconnectchokelinkage from choke lever on carburetor Assembly 1 Install throttle stop plate to intake manifold Secure with a 10 24x3 8 hex wash...

Page 24: ...lowing through the bi metal spring will heat to a point that the choke will open fully Automatic Choke Adjustment The choke unit Figure 4 10 is set at the factory for average conditions To readjust fo...

Page 25: ...on 1 Disconnect the high tension leads from spark plugs so the engine will not start 2 Remove the air cleaner cover element and base 3 Push the start switch on the controller to the start position and...

Page 26: ...multimeter Solenoid resistance is approxi mately 20 ohms 26 Shutdown Control Test Refer to Figure 4 11 lor identification of parts 1 Remove shutdown control solenoid and plung er from carburetor body...

Page 27: ...connecting rod journals is provided by oil sprayed from two small holes drilled in the camshaft See Figure 5 1 Figure 5 1 Pressurized Spray Lubrication System 27 ssrtUlC FULL PRESSURE LUBRICATION SYST...

Page 28: ...relief valve ball and spring can be serviced without splitting the crankcase To service these parts the closure plate must be removed To service the rest of the pump components the crankcase must be s...

Page 29: ...k plug lead and spark plug Crank engine rapidly If a sharp spark jumps the tester gap the trouble apparently is notin the ignition coil condenser or breaker points A weak spark indicates ignition trou...

Page 30: ...l be eroded 010 or more than the correct setting Replace worn plugs as they will require excessive voltage to fire properly Always replace plugs in pairs 30 Carbon Soft sooty black deposits indicate i...

Page 31: ...s and draw it between the points To prevent lint or fibers from remaining on the points open the breaker points to withdraw the paper SECTION 6 ELECTRICAL SYSTEMS AND COMPONENTS 31 CONDENSER If the co...

Page 32: ...ly The positive terminal must be connected to the positive side of the battery through the ignition switch The break er points and condenser are connected to the negative terminal Ignition Coil Check...

Page 33: ...fthe carbon core Slide boot onto the lead wire approximately 2 inches Insert high tension lead into coil tower and turn in a clockwise direc tion while applying an inward pressure Continue turning and...

Page 34: ...n ofnormal rotation clockwise when viewed from flywheel 34 end Watch continuity tester or ohmmeter if light on tester goes out or infinity ohms is measured on ohmmeter points are just begin ning to br...

Page 35: ...AND COMPONENTS 35 Valve Overlap Method If the cam to crankshaft timing is correct the intake and exhaust valve will be level with each other equal valve lift at top dead center on valve overlap If th...

Page 36: ...ternator I I _ r T _ __ Shutdown L __ 1 Solenoid Coli Spark Plug Condenser L lC T Spark Plug H Points t Figure 6 8 3 Amp System Wiring Diagram APPLICATION DIAGRAM Key Switch Fuse Off Run Start Optiona...

Page 37: ...ohms the sta nections Check resistance on the sta tor winding is open or the lead wire is tor side of diode to ground reading broken should be 1 ohm 1 Disconnect lighting lead from wir If 15 volts or...

Page 38: ...load measure voltage from charge Check condition of battery B at terminal on rectifier regulator to ground with a DC voltmeter If more than 14 7 volts the rectifier regulator is faulty Turn lights if...

Page 39: ...Figure 6 10 Components of Permanent Magnet Starter Starter Motor Service CAUTION In the event of a false start that is ifthe engine develops sufficient speed to disengage the starter but fails to Fol...

Page 40: ...s and tighten DRIVE ASSEMBLY If drive pinion is badly worn has chipped or broken teeth it must be replaced Replacement drive kits are available from your Kohler parts supplier It is not necessary to d...

Page 41: ...leads from spark plugs Disconnect other wiring harnesses as necessary 3 Remove the governor arm from governor clamp then disconnect the governor linkage 4 Disconnect the fuel line from carburetor 5 D...

Page 42: ...int or chalk mark the crankcase halves and cylinder heads 1 side and 2 side see Figure 7 3 CAUTION Do not use a metal stamp to mark crankcase as damage to crankcase may result 42 Figure 7 3 Marking Th...

Page 43: ...aluminum alloy head A cylinder head in this condition must be replaced Ifthe cylinder heads appear in good condition use a block ofwood to scrape away carbon deposits Be careful not to nick or scratc...

Page 44: ...ep in mind the tempera tures caused by honing may cause inaccurate measurements Make sure the barrel is cool when measuring 3 When bore is within 0025 of desired size remove coarse stones and replace...

Page 45: ...s Bad Condition The valve depicted here should be replaced Note the warped head margin damaged and too narrow These conditions could be attributed to excessive hours or a combination of poor operating...

Page 46: ...replaced if worn sufficiently to allow valve stem guide clearance to exceed limits stated in Section 1 Specifications Wear Toler ances Torques and Special Tools To remove press guide down into valve c...

Page 47: ...eals Valve Springs There are two different valve springs used on these models a short spring free length 1 542 and a longer spring free length 1 6876 The short spring is used with valve rotators while...

Page 48: ...hole is quickly burned right thru the piston dome by preignition Preignition is caused by a hot spot in the combustion chamber from sources such as glowing carbon deposits blocked fins improperly sea...

Page 49: ...llation to piston 4 Rings must be installed correctly Ring in stallation instructions are usually included with new ring sets Follow instructions carefully Use ring expander to install rings and check...

Page 50: ...crankcase nuts and screws 6 Put tape or governor spring around the tappet stems on the 2 side of the case to prevent the tappets from falling into the case when the halves are split 7 Lay crankcase do...

Page 51: ...tions and Tolerances are exceeded by more than 002 it will be necessary to either replace the crankshaft or regrind the crankpin to 010 undersize If reground a 010 undersize connecting rod big end mus...

Page 52: ...e roll pin in the oil pump gear hub through the hub and into the crankcase as in Figure 7 20 Dis card the roll pin Now remove the pump shaft gear and spacer Oil Pump Inspection And Service Check oil p...

Page 53: ...3 Slide one plain washer 266 I D 375 O D 030W onto governor cross shaft then insert shaft through hole in crankcase Slide another plain washer same as above over end of shaft Secure shaft with retain...

Page 54: ...Rod Machined edge of bolt hole must face up toward camshaft KT21 Forged Rod Machined edge of bolt hole must face up toward camshaft On earlier model KT17 Position rods on crankshaft so that when cran...

Page 55: ...ONENTS 1 Slide thrust washer onto P T O end of shaft chamfer toward crankshaft Lubricate bear ing journals on crankshaft and assemble bear ings sleeve or ball on either end see Figure 8 6 NOTE Engines...

Page 56: ...ly Of Roller Thrust Bearing 2 Position crankshaft over side 1 of crankcase P T O toward oil pump side then lower crank shaft into case Position locating tabs on sleeve 56 bearings to notches in the cr...

Page 57: ...ernor Spring to Hold Tappets 2 Side 2 Assemble camshaft into 1 side of case making sure timing marks on cam gear align with timing marks on crankshaft see Figure 8 11 Figure 8 11 Match Timing Marks On...

Page 58: ...ite Permatex RECOMMENDED SEALANTS These commercially available sealants are recommended for use on crankcase assemblies of KT17 KT19 and KT21 engines PRODUCT VENDOR NO DESCRIPTION Silicone Rubber Seal...

Page 59: ...h engine oil or liquid soap Insert the plug into the camshaft bore in the 1 crankcase half When reinstalling a used plug make sure the marks scribed on the plug and crankcase during disassembly are al...

Page 60: ...in the sequence shown in Figure 8 17 Torque the remaining fasteners to 200 in lbs 23Nm or3 3 Kgm in the most expedient sequence 60 Engines with serial number 9755084 or earlier torque the crankcase b...

Page 61: ...using four 10 24 x 3 4 hex washer head screws See Figure 8 21 Figure 8 21 Installing Stator PISTONS CYLINDER BARRELS AND CLOSURE PLATE 1 Position barrel gaskets on crankcase barrel studs 2 Using a pis...

Page 62: ...g the recom mended tightening sequence shown in Figure 8 26 Figure 8 26 Closure Plate Screw Tightening Sequence Rear Oil Seal 8 Apply a 1116 diameter sealant bead around outside edge of closure plate...

Page 63: ...Tube Cover Gasket __ Cover Filter Seal _ ilreather Plate Gasket 1 SECTION 8 ASSEMBLY head Install the screws and 5 16 washers in heads Position new head gaskets on screws and assemble cylinder heads t...

Page 64: ...14 20 x 3 4 fillister head screws and lockwashers into fuel pump flange Position pump gasket on screws then secure pump to fuel pump mounting pad which is just to the right of the 2 cylinder barrel to...

Page 65: ...re 8 32 Torquing Flywheel Retaining Screw 65 SECTION 8 ASSEMBLY 5 Attach the air intake grass screen to the fly wheel with four 1 4 20 x 3 4 pan head screws and torque as follows Metal Air Intake Gras...

Page 66: ...screen on flywheel Screen must be centered on flywheel to prevent it from rubbing on deflector and damaging one or both of these parts 1 Fasten lower leg of deflector to blower housing Spacer Washer...

Page 67: ...two 10 internal teeth washers and 10 32 x 1 112 pan head screws in side of elbow Use a new gasket between elbow and carburetor NOTE Make certain none of the holes in the carburetor body are covered b...

Page 68: ...s adjusted step 6 6 With a pliers turn governor cross shaft clock wise as far as it will go Pull governor arm back away from carburetor as far as it will go then tighten governor clamp nut see Figure...

Page 69: ...ker point cover screws into the breaker mounting pad NOTE The breaker point cover screws must be installed at this time to prevent engine oil from squirting out ofthe crankcase while the ignition timi...

Page 70: ...Cover Assembly 8 Breather Hose and Fuel Line Assembly 8 Camshaft Bore Plug Machined Installation 8 Camshaft Bore Plug Machined Removal 7 Camshaft Bore Cup Plug Installation 8 Camshaft Crankshaft Insp...

Page 71: ...s 4 Governor Operation 4 Governor Arm and Linkage Assembly 8 Governor Gear and Cross Shaft Assembly 8 Governor Gear and Cross Shaft Removal 7 Governor Cross Shaft Assembly Generator Applications 8 Gov...

Page 72: ...Type 1 Pistons Removal 7 Pistons and Rings Inspection 7 Pistons and Rings Service 7 Pistons Cylinder Barrels and Closure Plate Assembly 8 Posi Lock Connecting Rods Installation 8 4 5 27 53 52 62 50 5...

Page 73: ...and Camshaft Assembly 8 57 Throttle Control Engine Mounted 4 23 Torque Settings 1 9 Troubleshooting 2 11 Valves Inspection and Service 7 44 Valves Removal 7 43 Valve Guides 7 46 Valve Seat Inserts 7 4...

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