Kohler KT715 Service Manual Download Page 67

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Disassembly/Inspection and Service

32 690 03 Rev. I

KohlerEngines.com

Clean all parts thoroughly as engine is disassembled.

Only clean parts can be accurately inspected

and gauged for wear or damage. There are many

commercially available cleaners that will quickly remove

grease, oil and grime from engine parts. When such a

cleaner is used, follow manufacturer’s instructions and

safety precautions carefully.
Make sure all traces of cleaner are removed before

engine is reassembled and placed into operation. Even

small amounts of these cleaners can quickly break down

lubricating properties of engine oil.

Disconnect Spark Plug Leads

NOTE: Pull on boot only, to prevent damage to spark

plug lead.

1. Disconnect leads from spark plugs.
2. Shut off fuel supply.

Drain Oil From Crankcase and Remove Oil Filter

1. Remove

oil

ll/dipstick and oil drain plug.

2. Allow ample time for oil to drain from crankcase and

oil

lter.

3. Remove and appropriately discard oil

lter.

Remove Muffl er

Remove exhaust system and attaching hardware from

engine.

Remove Fuel Pump (if equipped)

WARNING

Explosive Fuel can cause

res and severe

burns.
Do not

ll fuel tank while engine is hot or

running.

Gasoline is extremely

ammable and its vapors can

explode if ignited. Store gasoline only in approved

containers, in well ventilated, unoccupied buildings,

away from sparks or

ames. Spilled fuel could ignite

if it comes in contact with hot parts or sparks from

ignition. Never use gasoline as a cleaning agent.

1. Disconnect pulse (vacuum) hose and outlet fuel line

from fuel pump.

2. Remove mounting screws, unhook outlet hose from

blower housing clip, and remove fuel pump from

blower housing.

Remove Blower Housing and Outer Baffl es

1.  Remove air cleaner cover.
2.  Remove screws securing blower housing.
3.  Remove blower housing from engine.
4.  Remove M5 and M6 screws securing baf

es to

cylinders, heads and backing plate.

Remove Throttle Controls

Control Bracket Components

Choke Linkage

Throttle Linkage

Governor Lever

Governor Spring

Cross Shaft

Control Bracket

Dampener Spring

1. Remove screws securing throttle control bracket to

cylinder heads.

2. Disconnect choke linkage from choke actuator lever.

Unhook governor spring, and dampener spring from

governor lever. Note hole locations for reassembly.

Remove External Governor Controls

Loosen nut and remove governor lever from cross shaft.

Leave lever attached to throttle linkage.

Summary of Contents for KT715

Page 1: ...tion System 52 Electrical System 59 Starter System 63 Emission Compliant Systems 66 Disassembly Inspection and Service 79 Reassembly IMPORTANT Read all safety precautions and instructions carefully before operating equipment Refer to operating instruction of equipment that this engine powers Ensure engine is stopped and level before performing any maintenance or service KT610 KT620 KT715 KT745 ...

Page 2: ...xhaust fumes Engine exhaust gases contain poisonous carbon monoxide Carbon monoxide is odorless colorless and can cause death if inhaled WARNING Accidental Starts can cause severe injury or death Disconnect and ground spark plug lead s before servicing Before working on engine or equipment disable engine as follows 1 Disconnect spark plug lead s 2 Disconnect negative battery cable from battery WAR...

Page 3: ...quipped with precleaner Air Cleaner Intake Every 75 Hours Replace high performance air cleaner element if equipped with precleaner Air Cleaner Intake Replace PRO performance air cleaner element if not equipped with precleaner Air Cleaner Intake Every 100 Hours Replace PRO performance air cleaner element if equipped with precleaner Air Cleaner Intake Change oil and filter Lubrication System Remove ...

Page 4: ... agent NOTE E15 E20 and E85 are NOT approved and should NOT be used effects of old stale or contaminated fuel are not warrantable Fuel must meet these requirements Clean fresh unleaded gasoline Octane rating of 87 R M 2 or higher Research Octane Number RON 90 octane minimum Gasoline up to 10 ethyl alcohol 90 unleaded is acceptable Methyl Tertiary Butyl Ether MTBE and unleaded gasoline blend max 15...

Page 5: ... Side F E G H I M A B D C J K L A 423 0 mm 16 65 in B 136 7 mm 5 38 in C 89 6 mm 3 53 in D 50 1 mm 1 97 in E Oil Fill and Dipstick Yellow F Fuel Line Connection Point G Mounting Hole A H 136 9 mm 5 39 in I 141 5 mm 5 57 in J 89 7 mm 3 53 in K 307 9 mm 12 12 in L 7 2 mm 0 28 Center of Gravity M 45 5 mm 1 79 in Center of Gravity ...

Page 6: ...al B 329 1 mm 12 96 in Top of Low Profile Air Cleaner C 159 4 mm 6 28 in Center of Gravity D Engine Mounting Surface E 80 3 mm 3 16 in Oil Filter F Mounting Hole A G 51 2 mm 2 02 in Oil Filter H 134 0 mm 5 28 in Spark Plug Center Line I 340 9 mm 13 42 in J 380 7 mm 14 99 in K Optional Fixed Guard L 392 1 mm 15 44 in High Performance Air Cleaner Removal M 354 2 mm 13 94 in Top of High Performance A...

Page 7: ...nt F 4 X 5 16 18 UNC 2B in 16 5 mm 0 649 in Deep No Studs G 30 H 50 0 mm 1 97 in Exhaust Port 2 I 268 3 mm 10 56 in J 104 0 mm 4 10 in K 242 1 mm 9 53 in L 89 8 mm 3 54 in M 18 0 mm 0 71 in Oil Filter Removal N 116 8 mm 4 60 in O Mounting Hole A P Rotation Direction Q 248 1 mm 9 77 in Starter Stud R 4 X 9 005 mm 0 355 in 37 0 mm 1 46 in Deep on a Ø 254 0 mm 10 0 in B C S 93 1 mm 3 66 in Starter St...

Page 8: ...ile or High Performance Air Cleaner Starter Side A B C D E F G H A 55 8 mm 2 20 in Starter Stud B 13 0 mm 0 51 in C Mounting Hole A D 40 8 mm 1 61 in E Engine Mounting Surface F 72 0 mm 2 83 in Exhaust Port 2 G 92 0 mm 3 62 in Exhaust Port 1 H 154 0 mm 6 06 in Spark Plug Center Line ...

Page 9: ... I KohlerEngines com Engine Dimensions with Low Profile or High Performance Air Cleaner Valve Cover Side A B C D E F A 87 6 mm 3 45 in B Engine Mounting Surface C 152 9 mm 6 02 in D 4 4 mm 0 17 in E Mounting Hole A F 39 8 mm 1 57 in ...

Page 10: ... G H I K A B D C J L M A 424 7 mm 16 72 in B 136 7 mm 5 38 in C 89 6 mm 3 53 in D 50 1 mm 1 97 in E Oil Fill and Dipstick Yellow F Fuel Line Connection Point G 136 9 mm 5 39 in H Mounting Hole A I 141 5 mm 5 57 in J 89 7 mm 3 53 in K 9 7 mm 0 38 in Center of Gravity L 307 9 mm 12 12 in M 47 0 mm 1 85 in Center of Gravity ...

Page 11: ...r Removal B 398 7 mm 15 70 in Top of Air Cleaner C 265 2 mm 10 44 in Evap Connection Point D 166 5 mm 6 56 in Center of Gravity E Engine Mounting Surface F 80 3 mm 3 16 in Oil Filter G Mounting Hole A H 51 2 mm 2 02 in Oil Filter I 134 0 mm 5 28 in Spark Plug Center Line J 340 9 mm 13 42 in K 380 7 mm 14 99 in L Optional Fixed Guard M 272 0 mm 10 71 in Evap Connection Point ...

Page 12: ... 5 mm 0 649 in Deep No Studs E 30 F 50 0 mm 1 97 in Exhaust Port 2 G 242 1 mm 9 53 in H 104 0 mm 4 10 in I 89 8 mm 3 54 in J 18 0 mm 0 71 in Oil Filter Removal K 116 8 mm 4 60 in L Mounting Hole A M 248 1 mm 9 77 in Starter Stud N 89 8 mm 3 54 in O Rotation Direction P 4 X 9 005 mm 0 355 in 37 mm 1 46 in Deep on a Ø 254 mm 10 0 in B C Q 93 1 mm 3 66 in Starter Stud R 312 0 mm 12 28 in Throttle and...

Page 13: ... PRO Performance Air Cleaner Starter Side A B C D E F G H A 55 8 mm 2 20 in Starter Stud B 13 0 mm 0 51 in C Mounting Hole A D 40 8 mm 1 61 in E Engine Mounting Surface F 72 0 mm 2 83 in Exhaust Port 2 G 92 0 mm 3 62 in Exhaust Port 1 H 154 0 mm 6 06 in Spark Plug Center Line ...

Page 14: ...rEngines com 32 690 03 Rev I Engine Dimensions with PRO Performance Air Cleaner Valve Cover Side A B C D E F A 87 6 mm 3 45 in B Engine Mounting Surface C 152 9 mm 6 02 in D 4 4 mm 0 17 in E Mounting Hole A F 39 8 mm 1 57 in ...

Page 15: ... hole M6 Thread Forming Fasteners 10 7 N m 95 in lb into new hole 7 3 N m 65 in lb into used hole Blower Housing and Sheet Metal M3 HI LO Screw 2 3 N m 20 in lb M4 HI LO Screw 2 8 N m 25 in lb M5 Fasteners 6 2 N m 55 in lb into new hole 4 0 N m 35 in lb into used hole M6 Fasteners 10 7 N m 95 in lb into new hole 7 3 N m 65 in lb into used hole ENGINE IDENTIFICATION NUMBERS Kohler engine identifica...

Page 16: ... to 41 8 N m 370 in lb Rocker Arm Stud 11 3 N m 100 in lb Flywheel Retaining Screw 74 5 N m 55 ft lb Fuel Pump Screw 2 8 N m 25 in lb Governor Lever Nut 6 8 N m 60 in lb Ignition Spark Plug 27 N m 20 ft lb Module Fastener 4 0 6 2 N m 35 55 in lb Rectifier Regulator Fastener 4 0 N m 35 in lb Intake Manifold Mounting Fastener torque in 2 increments first to 7 4 N m 66 in lb finally to 9 9 N m 88 in ...

Page 17: ...ft End Play 0 06 0 40 mm 0 0024 0 0157 in Running Clearance 0 040 0 077 mm 0 0016 0 0030 in Bore I D New Max Wear Limit 20 000 20 025 mm 0 7874 0 7884 in 20 038 mm 0 7889 in Bearing Surface O D New Max Wear Limit 19 948 19 960 mm 0 7854 0 7858 in 19 945 mm 0 7852 in Connecting Rod Connecting Rod to Crankpin Running Clearance New Max Wear Limit 0 037 0 083 mm 0 0015 0 0033 in 0 098 mm 0 0039 in Con...

Page 18: ...m 0 0010 in Connecting Rod Journal O D New O D Max Wear Limit Max Taper Max Out of Round 35 950 35 974 mm 1 4154 1 4163 in 35 950 mm 1 4154 in 0 018 mm 0 0007 in 0 025 mm 0 0010 in T I R PTO End Crank in Engine Entire Crank in V Blocks 0 279 mm 0 0110 in 0 200 mm 0 0079 in Cylinder Bore Bore I D New Max Wear Limit Max Out of Round Max Taper 83 006 83 031 mm 3 2679 3 2689 in 83 069 mm 3 2704 in 0 1...

Page 19: ...Top Compression Ring End Gap New Bore Used Bore Max Middle Compression Ring End Gap New Bore Used Bore Max 0 189 0 277 mm 0 0074 0 0109 in 0 531 mm 0 0209 in 1 519 1 797 mm 0 0598 0 0708 in 2 051 mm 0 0808 in Thrust Face O D 7 New Max Wear Limit 82 978 mm 3 2668 in 82 833 mm 3 2611 in Piston Thrust Face to Cylinder Bore7 Running Clearance New 0 019 0 062 mm 0 0007 0 0024 in Valves and Valve Tappet...

Page 20: ... English Fastener Torque Recommendations for Standard Applications Bolts Screws Nuts and Fasteners Assembled Into Cast Iron or Steel Grade 2 or 5 Fasteners Into Aluminum Size Grade 2 Grade 5 Grade 8 Tightening Torque N m in lb 20 8 32 2 3 20 2 8 25 2 3 20 10 24 3 6 32 4 5 40 3 6 32 10 32 3 6 32 4 5 40 1 4 20 7 9 70 13 0 115 18 7 165 7 9 70 1 4 28 9 6 85 15 8 140 22 6 200 5 16 18 17 0 150 28 3 250 ...

Page 21: ...ology Inc DTI 731 03 Dealer Tool Kit Domestic Complete kit of Kohler required tools Components of 25 761 39 S Ignition System Tester Cylinder Leakdown Tester Oil Pressure Test Kit Rectifier Regulator Tester 120 V AC 60Hz Kohler 25 761 39 S Kohler 25 455 01 S Kohler 25 761 05 S Kohler 25 761 06 S Kohler 25 761 20 S Dealer Tool Kit International Complete kit of Kohler required tools Components of 25...

Page 22: ...and brushes Individual component available Starter Brush Holding Tool Solenoid Shift SE Tools KLR 82411 SE Tools KLR 82416 Triad OHC Timing Tool Set For holding cam gears and crankshaft in timed position while installing timing belt Kohler 28 761 01 S Valve Guide Reamer K and M Series For properly sizing valve guides after installation Design Technology Inc DTI K828 Valve Guide Reamer O S Command ...

Page 23: ...ring gear teeth Bosses will lock tool and flywheel in position for loosening tightening or removing with a puller A spanner wrench to lift rocker arms or turn crankshaft may be made out of an old junk connecting rod 1 Find a used connecting rod from a 10 HP or larger engine Remove and discard rod cap 2 Remove studs of a Posi Lock rod or grind off aligning steps of a Command rod so joint surface is...

Page 24: ...e to check simple causes which at first may seem too obvious to be considered For example a starting problem could be caused by an empty fuel tank Some general common causes of engine troubles are listed below and vary by engine specification Use these to locate causing factors Engine Will Not Crank Battery is discharged Faulty electric starter or solenoid Faulty key switch or ignition switch Inte...

Page 25: ... indications of improper fit and seal Check air cleaner element Look for holes tears cracked or damaged sealing surfaces or other damage that could allow unfiltered air into engine A dirty or clogged element could indicate insufficient or improper maintenance Check carburetor throat for dirt Dirt in throat is further indication that air cleaner was not functioning properly Check if oil level is wi...

Page 26: ...is closed 2 Start engine and run no load high speed 3 Open clamp and note water level in tube Level in engine side should be a minimum of 10 2 cm 4 in above level in open side If level in engine side is less than specified low no vacuum or level in engine side is lower than level in open side pressure check for conditions in table below 4 Close pinch clamp before stopping engine To test crankcase ...

Page 27: ...ft Install a 3 8 in breaker bar into hole slot of holding tool so it is perpendicular to both holding tool and crankshaft PTO If flywheel end is more accessible use a breaker bar and socket on flywheel nut screw to hold it in position An assistant may be needed to hold breaker bar during testing If engine is mounted in a piece of equipment it may be possible to hold it by clamping or wedging a dri...

Page 28: ...w engine oil squeeze out excess oil 4 Reinstall precleaner over paper element Paper Element 1 Remove element from base service precleaner Discard element 2 Install precleaner over new paper element and install on base Position air cleaner cover with levers outward over air cleaner turn levers inward to lock or Reinstall cover place latches onto cover pull down bails to secure cover AIR CLEANER The...

Page 29: ...ise or remove blower housing for access to air cleaner base 3 Remove air cleaner components from base 4 Remove nuts securing air cleaner base onto mounting studs 5 Disconnect ground lead and fuel shut off solenoid lead if equipped 6 If equipped with eChoke disconnect connecter from stepper motor 7 Remove Smart Choke or eChoke bracket assembly if equipped 8 Disconnect choke linkage from carburetor ...

Page 30: ...ff valve if equipped and observe flow Performance Minimum fuel delivery rate must be 7 5 l hr 2 gal hr with a pressure at 0 3 psi and a fuel lift of 24 in A 1 3 l hr 0 34 gal hr fuel rate must be maintained at 5 Hz Fuel Pump Replacement NOTE Make sure orientation of new pump is consistent with removed pump Internal damage may occur if installed incorrectly To replace pulse pump follow these steps ...

Page 31: ...ke Lever Engines in this series are equipped with either a Keihin or Walbro fixed main jet carburetor Most carburetors utilize a fuel shut off solenoid and feature a self relieving choke Troubleshooting Checklist When engine starts hard runs rough or stalls at low idle speed check these areas before adjusting or disassembling carburetor 1 Make sure fuel tank is filled with clean fresh gasoline 2 M...

Page 32: ...th a shop towel or blow with compressed air to remove any remaining fuel Take solenoid to a location with good ventilation and no fuel vapors present You will also need a 12 volt power source that can be switched on and off 3 Be sure power source is switched OFF Connect positive power source lead to red lead of solenoid Connect negative power source lead to solenoid body 4 Turn power source ON and...

Page 33: ...wear or damage Inspect float for cracks holes and missing or damaged float tabs Check float hinge and shaft for wear or damage Inspect fuel inlet needle and seat for wear or damage Inspect spring loaded choke plate to make sure it moves freely on shaft Float Setting Keihin Only A A 12 mm 0 472 in NOTE Inlet needle center pin is spring loaded Make sure float assembly rests against fuel inlet needle...

Page 34: ...ll new float and new inlet needle down into seat and carburetor body Insert new pivot pin through float hinge and secure with new retaining screw 27 Hold carburetor body so float assembly hangs vertically and rests lightly against fuel inlet needle Inlet needle should be fully seated but center pin of needle on retainer clip end should not be depressed Check float height adjustment 28 Correct floa...

Page 35: ... air vane deflector assembly that operates by air from cooling fan opens choke partially when engine is running When engine is cold a spring on air vane deflector assembly in conjunction with a bimetallic spring holds choke closed for starting A bimetallic spring reacts to heat generated by electrical resistance as engine is running and opens choke plate position When engine is warm bimetallic spr...

Page 36: ...e plate should be fully closed when engine is cold 3 There should be light spring tension holding choke closed 4 There should not be any binding when choke shaft assembly is rotated which could cause choke to remain partially open 5 Remove blower housing 6 Check choke linkage and air vane deflector assembly for binding or debris build up Gently actuate linkage and observe that choke plate has full...

Page 37: ... is potentially faulty Remove switch and install a pressure test gauge and start engine Consult troubleshooting section of this manual for oil pressure testing instructions If adequate pressure is found replace pressure switch and confirm operation voltage readings 13 If linkage is free and choke plate fails to open fully after 2 minutes check spring tension of bimetallic assembly If necessary rep...

Page 38: ...ted at idle with thermostat wire disconnected to test system function 4 If engine runs correctly no further adjustment is needed 5 If engine speed does not increase to idle speed on start up thermostat position must be adjusted by rotating housing clockwise in 1 mm increments and retested Position should not exceed high adjustment range shown D 6 Plug in thermostat wire Adjustable Thermostat B D E...

Page 39: ... assembly with thermostat in proper position Do not plug thermostat wire at this time 3 Engine must be started at idle with thermostat wire disconnected to test system function 4 If engine runs correctly no further adjustment is needed 5 If engine speed does not increase to idle speed on start up ensure spring tab E is engaged in lever slot F and thermostat is in proper position for ignition syste...

Page 40: ...top before attempting to restart engine If starter is engaged while flywheel is rotating starter pinion and flywheel ring gear may clash resulting in damage to starter 1 Smart Choke system will automatically control choke plate position for starting 2 Make sure equipment is in neutral 3 Activate starter switch Release switch as soon as engine starts If starter does not turn engine over shut starte...

Page 41: ...ylinder 2 which provides a signal for stepper motor by way of a control harness that is routed through cylinder 2 baffle An interconnection harness between two modules may exist model dependent eChoke Components Includes ignition due to integrated system Master slave ignition modules with interface cables Stepper motor Stepper motor bracket linkage and associated fasteners Wire harness for power a...

Page 42: ...es indicate a temperature read failure or RPM failure see blink code info then master controller ignition is at fault and needs to be replaced 9 If all standard checks are correct proceed to Blink Codes Blink Codes NOTE Use of any other type of lamp other than LED could damage components eChoke system is equipped with an MIL connector that will allow connection of an LED lamp to show normal eChoke...

Page 43: ...arting engine speed IF engine does not start go to Failure Mode description 1B or 3B based on MIL lamp code 3A Choke Adjusting Engine started release Key to RUN position ON OFF ON OFF ON DELAY eChoke moving to open position 4A Normal Choke operation completed ON eChoke stays in open position 5A Engine Shutdown Turn Key from RUN to OFF ON DELAY Once engine has come to a stop choke will fully close ...

Page 44: ...lug ignition carburetor fuel solenoid 2B Temperature Read Failure ON OFF ON OFF ON OFF ON OFF ON DELAY Faulty temperature sensor System will keep choke closed at Key ON and ramp to open within 10 seconds of engine starting if this is root failure Replace Master controller ignition 3B RPM Read Failure ON OFF ON OFF ON OFF ON DELAY System defaults to this failure after 30 seconds of being in Key ON ...

Page 45: ...r governor hunting or excessive throttle opening Choke partially closed during operation a Incorrect set up of stepper motor link bracket to carburetor b Broken or missing link Stepper motor bracket link assembly must allow for full travel make sure link is located properly and connected c Loss of constant power or switched power d Loss of system ground e Fusible link is open f Stepper motor not f...

Page 46: ...r cleaner from air cleaner base 6 Confirm connection of stepper motor assembly to carburetor 7 With key switch set to OFF choke plate should nearly fully closed stepper motor for eChoke should be near full extension expanded bellows 8 With engine ambient temperature above 40 F 4 C turn key switch from OFF to RUN There should be a noticeable movement of choke plate 9 If no movement a Shut off key s...

Page 47: ...E D C F A E G C A Left Side Pull B Cable Clamp C Speed Control Lever D Speed Setting Lever E Choke Lever F Right Side Pull G Contact Point H Choke Control Cable I Throttle Control Cable J Dual Control High Speed Lever Stop Screw Do Not Remove K High Speed Adjusting Screw L Choke Linkage M High Speed Control Lever ...

Page 48: ...mmediately Do not make further attempts to start engine until condition is corrected Do not jump start using another battery See your Kohler authorized dealer for trouble analysis 4 For Operation After engine starts move throttle choke control from fast choke ON position and set desired engine operating speed between slow and fast position UNITIZED THROTTLE AND CHOKE CONTROL Some engines are equip...

Page 49: ... is operating governor gear assembly is rotating Force applied by regulating pin against cross shaft tends to close throttle plate Governor spring tension and force applied by regulating pin balance each other during operation to maintain engine speed When load is applied and engine speed and governor gear speed decreases governor spring tension moves governor arm to open throttle plate wider This...

Page 50: ... m 10 ft lb 3 Place new filter in shallow pan with open end up Fill with new oil until oil reaches bottom of threads Allow 2 minutes for oil to be absorbed by filter material 4 Apply a thin film of clean oil to rubber gasket on new filter 5 Refer to instructions on oil filter for proper installation 6 Fill crankcase with new oil Level should be at top of indicator on dipstick 7 Reinstall oil fill ...

Page 51: ...to stop engine On vehicular applications lawn tractors mowers etc pressure switch can only be used to activate a low oil warning light or signal Installation 1 Apply pipe sealant with Teflon Loctite PST 592 Thread Sealant or equivalent to threads of switch 2 Install switch into tapped hole in oil filter adapter 3 Torque switch to 4 5 N m 40 in lb Testing Compressed air a pressure regulator pressur...

Page 52: ...re feeler gauge Adjust gap to 0 76 mm 0 030 in 2 Install plug into cylinder head 3 Torque plug to 27 N m 20 ft lb Inspection Inspect each spark plug as it is removed from cylinder head Deposits on tip are an indication of general condition of piston rings valves and carburetor Normal and fouled plugs are shown in following photos Normal Plug taken from an engine operating under normal conditions w...

Page 53: ...ry capacity shrinks Refer to equipment s operating instructions for specific battery requirements Battery Size Recommendations Temperature Battery Required Above 32 F 0 C 200 cca minimum 0 F to 32 F 18 C to 0 C 250 cca minimum 5 F to 0 F 21 C to 18 C 300 cca minimum 10 F 23 C or below 400 cca minimum If battery charge is insufficient to turn over engine recharge battery Battery Maintenance Regular...

Page 54: ... switch or key switch which grounds modules to stop engine 2 spark plugs Wiring Diagram Electronic Ignition System Diagram H Q L G AD D D S T H M K F D J I G E C B A U V W X Y Z S R P Q Q N O AA AB AE AF AF AC AB AC AG A Starter Solenoid Tang B Solenoid Shift Starter Assembly C Inertia Driver Starter Assembly D Green E Violet Charging F Oil SentryTM Optional G Spark Plug s H White AC Charging Lead...

Page 55: ...ectifier Regulator Connector J Rectifier Regulator K Flywheel Stator Assembly L Ignition Module s M Intake Manifold Screw N Ground O Carburetor P White Ignition Kill Q Red R Solenoid Lead S Orange T Connector U Blue V Starter Solenoid Stud W Relay Stud X Relay Cranking Customer Supplied Y Battery Negative Z Battery AA Battery Positive AB Violet shown or Orange AC White AD Orange shown or Red AE Bl...

Page 56: ...a known good ground location Engine should kill completely If not or only one cylinder is affected test ignition modules Test for Spark NOTE If 2 testers are available testing can be performed simultaneously for both cylinders However if only 1 tester is available 2 individual tests must be performed Side not being tested must have spark plug lead connected or grounded Do not crank engine or perfo...

Page 57: ...e end of tandem adapter lead 2 Connect tester ground lead with spring clamp to body of rectifier regulator 3 Connect red lead and 1 black lead to terminals on open end of tandem adapter lead connections are not location specific 4 Connect remaining black lead from tester to 1 outer AC terminal on rectifier regulator 5 Plug tester into proper AC outlet power for tester being used Turn on power swit...

Page 58: ...regulator steps 2 and 3 2 Remove connector from rectifier regulator With engine running at 3600 RPM measure AC voltage across stator leads using an AC voltmeter Condition Conclusion Voltage is 28 volts or more Stator is OK Rectifier regulator is faulty replace Voltage is less than 28 volts Stator is faulty replace Test stator further using an ohmmeter steps 3 and 4 3 With engine stopped measure re...

Page 59: ...with frayed or broken insulation Starter Switch or Solenoid By pass switch or solenoid with a jumper wire If starter cranks normally replace faulty components Remove and perform individual solenoid test procedure Starter energizes but turns slowly Battery Check specific gravity of battery If low recharge or replace battery as necessary Brushes Check for excessively dirty or worn brushes and commut...

Page 60: ...oid to starter 3 Unhook plunger pin from drive lever Remove gasket from recess in housing 4 Remove thru larger bolts 5 Remove commutator end plate assembly containing brush holder brushes springs and locking caps Remove thrust washer from inside commutator end 6 Remove frame from armature and drive end cap 7 Remove drive lever pivot bushing and backing plate if equipped from end cap 8 Take out dri...

Page 61: ...own onto armature shaft with counter bore recess up b Install a new retainer in larger rear groove of armature shaft Squeeze with a pliers to compress it in groove c Slide stop collar up and lock it into place so recess surrounds retainer in groove If necessary rotate pinion outward on armature splines against retainer to help seat collar around retainer 3 Install offset thrust stop washer so smal...

Page 62: ...ct all leads from solenoid including positive brush lead attached to lower stud terminal Remove mounting hardware and separate solenoid from starter for testing To test solenoid pull in coil plunger Actuation 1 Use a 12 volt power supply and 2 test leads 2 Connect 1 lead to flat spade S start terminal on solenoid Momentarily connect other lead to lower large post terminal When connection is made s...

Page 63: ...r supplied canisters breather filter can be removed and cleaned with hot soapy water dried and reinstalled Do not oil breather screen This is done periodically or if system operation is suspect Carbon canister is sealed and requires no maintenance In some applications or installations OEM will have installed a different canister or fuel vapor recovery system See OEM equipment documentation for ser...

Page 64: ... through an inlet screen of secondary air valve Air is then drawn into exhaust manifold and muffler where it mixes with any unburned hydrocarbons which then burn in heat of muffler A hose is connected between a carburetor port and a diaphragm chamber in secondary air valve Carburetor vacuum moves diaphragm to close valve when air induction is not required primary idle Maintenance Air inlet screen ...

Page 65: ...nlet screen from secondary air valve assembly by grasping inlet screen at base and gently pulling away from valve assembly 2 Use a soft brush to remove debris from screen 3 Run water through inlet screen in reverse direction 4 To reinstall push inlet screen onto barb of secondary air valve assembly An audible click will be heard when inlet screen is properly reinstalled ...

Page 66: ...ound spark plug lead s before servicing External Engine Components J T E L G S R E E F H H I V U K B A C D M O N P Q W R S B S B A Fixed Guard B Air Cleaner Cover C Debris Screen D Blower Housing E Hose Clamp F Fuel Pump G Hose Clip H Fuel Line I Fuel Filter J Oil Filter K Outer Baffle L Electric Starter M Inner Baffle N Ignition Module O Intake Manifold P Carburetor Q Gasket R Air Cleaner Base S ...

Page 67: ... burns Do not fill fuel tank while engine is hot or running Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Spilled fuel could ignite if it comes in contact with hot parts or sparks from ignition Never use gasoline as a cleaning agent 1 Disconnect pulse vacuum hose an...

Page 68: ...Note that if no other connections are disturbed stepper motor will be repositioned at next key ON and master module will go back to normal choke operation mode NOTE Do not remove or loosen thermostat screws Position is set at factory 1 Remove carburetor air cleaner base mounting nuts and disconnect breather hose 2 Remove air cleaner element and precleaner if equipped from air cleaner base for serv...

Page 69: ...ake manifold and O rings Leave wiring harness attached to manifold Cylinder Head Components A B C I E F G H D K L M N J P O A Gasket B Valve C Cylinder Head D Valve Spring Cap E Valve Stem Seal F Valve Spring G Valve Spring Keeper H Stud I Spark Plug J Guide Plate K Push Rod L Rocker Arm M Rocker Arm Pivots N Adjusters O Washer P Valve Cover 4 Remove screws securing rectifier regulator to backing ...

Page 70: ...ere If gauge goes in anywhere cover needs to be replaced Remove Cylinder Heads NOTE Exhaust side is located on output shaft side of engine while intake side is located on fan side of engine Cylinder head number is embossed on outside of each cylinder head 1 Loosen inner setscrews T25 Torx and back off adjusters 2 Mark location of push rods as either intake or exhaust and cylinder 1 or 2 Push rods ...

Page 71: ...l consumption may be symptoms of faulty valves Although these symptoms could also be attributed to worn rings remove and check valves first After removal clean valve heads faces and stems with a power wire brush Then carefully inspect each valve for defects such as warped head excessive corrosion or worn stem end Replace valves found to be in bad condition Valve Guides If a valve guide is worn bey...

Page 72: ...ve face angle as specified and proper valve seat angle 44 5 half of full 89 angle will achieve desired 0 5 1 0 full cut interference angle where maximum pressure occurs on outside diameters of valve face and seat Lapping Valves NOTE Exhaust valves that are black in color cannot be ground and do not require lapping Reground or new valves must be lapped in to provide fit Use a hand valve grinder wit...

Page 73: ...g gear with large gear puller 5 Remove flywheel key from crankshaft Flywheel Inspection Inspect flywheel for cracks and flywheel keyway for damage Replace flywheel if it is cracked Replace flywheel crankshaft and key if flywheel key is sheared or keyway is damaged Inspect ring gear for cracks or damage Kohler does not provide ring gears as a serviceable part Replace flywheel if ring gear is damage...

Page 74: ... shaft press or lightly tap replacement shaft into oil pan to depth shown Reassembly 1 Install locking tab thrust washer on governor gear shaft with tab down 2 Position regulating pin within governor gear flyweights assembly and slide both onto governor shaft until assembly locks into place Oil Pump Assembly Oil pump is mounted inside oil pan If service is required continue with Disassembly Inspec...

Page 75: ...cross shaft seal is damaged and or leaks replace it using following procedure Remove oil seal from crankcase and replace it with a new one Install new seal to depth shown Connecting Rods Piston Breather Components G I F A B D B E H C A Piston Ring Set B Piston Pin Retainer C Piston D Piston Pin E Connecting Rod F Connecting Rod End Cap G Breather Filter H Breather Cover I Oil Seal Remove Breather ...

Page 76: ...s within wear limits and free of score or scuff marks old piston may be reused 3 Remove old rings and clean up grooves Never reuse old rings 4 Before installing new rings on piston place top 2 rings each in turn in its running area in cylinder bore and check end gap Top compression ring end gap clearance is 0 189 0 277 mm 0 0074 0 0109 in for a new bore or 0 531 mm 0 0209 in for a used bore Middle...

Page 77: ...re marks can be cleaned with crocus cloth soaked in oil If wear limits are exceeded as stated in Specifications it will be necessary to replace crankshaft Remove Flywheel and PTO End Oil Seals Remove oil seals from crankcase and oil pan Crankcase Inspection and Service Check all gasket surfaces to make sure they are free of gasket fragments Gasket surfaces must also be free of deep scratches or ni...

Page 78: ...ter a rebuild Final cleaning operation should always be a thorough scrubbing with a brush and hot soapy water Use a strong detergent capable of breaking down machining oil while maintaining a good level of suds If suds break down during cleaning discard dirty water and start again with more hot water and detergent Following scrubbing rinse cylinder with very hot clear water dry it completely and a...

Page 79: ...e of any nicks or burrs 2 Apply a light coat of engine oil to outside diameter of oil seal 3 Install oil seal into crankcase using a seal driver Make sure oil seal is installed straight and true in bore and tool bottoms against crankcase Install Breather Filter and Breather Cover Fastener Torque Sequence and Sealant 4 2 1 5 3 A A Sealant Bead NOTE Always use fresh sealant Using outdated sealant ca...

Page 80: ...r onto governor cross shaft and install cross shaft from inside of crankcase 3 Round Cross Shaft End Install nylon washer onto governor cross shaft then start push on retaining ring Hold cross shaft up in position place a 0 50 mm 0 020 in feeler gauge on top of nylon washer and push retaining ring down shaft to secure Remove feeler gauge which will have established proper end play 7 mm Hex Cross S...

Page 81: ...en used If black coating torque in increments to 11 3 N m 100 in lb If gray metallic coating it is not necessary to lubricate this screw torque in increments to 13 6 N m 120 in lb Illustrated instructions are provided in service rod package 6 Repeat above procedure for other connecting rod and piston assembly Install Valve Tappets and Camshaft NOTE Exhaust valve tappets are located on output shaft...

Page 82: ...use fresh sealant Using outdated sealant can result in leakage 1 Be sure sealing surfaces have been cleaned and prepared as described at beginning of Reassembly 2 Check to make sure there are no nicks or burrs on sealing surfaces of oil pan or crankcase 3 Apply a 1 5 mm 1 16 in bead of black RTV sealant to sealing surface of oil pan See sealant pattern Oil pan must be installed within 5 minutes of...

Page 83: ...er and M5 nut Torque nut to 1 3 N m 12 in lb Check that a complete seal has occurred by RTV sealant being squeezed out around entire flange perimeter Install Stator and Backing Plate 1 Apply pipe sealant with Teflon Loctite PST 592TM or equivalent to stator mounting holes 2 Position stator aligning mounting holes so leads are at bottom toward crankcase 3 Install and torque screws to 8 8 N m 78 in ...

Page 84: ...flat washer and screw 5 Use a flywheel strap wrench or holding tool to hold flywheel Torque screw securing flywheel to crankshaft to 74 5 N m 55 ft lb Cylinder Head Components A B C I E F G H D K L M N J P O 1 4 2 3 2 2 4 3 1 1 Q A Gasket B Valve C Cylinder Head D Valve Spring Cap E Valve Stem Seal F Valve Spring G Valve Spring Keeper H Stud I Spark Plug J Guide Plate K Push Rod L Rocker Arm M Roc...

Page 85: ...s 0 25 mm 0 010 in Check Assembly Rotate crankshaft a minimum of 2 revolutions to check longblock assembly and overall proper operation Install Cylinder Heads NOTE Match numbers embossed on cylinder heads and crankcase NOTE When installing cylinder heads new screws should always be used New screws are supplied in gasket sets NOTE Push rods should always be installed in same position as before disa...

Page 86: ...inder head Refer to Tools and Aids for a listing of approved sealants 1 Prepare sealing surfaces of cylinder heads and valve covers Flatness of sealing surface must be checked prior to reinstallation See Disassembly 2 Apply a 1 5 mm 1 16 in bead of sealant to valve cover as shown 3 Position covers on cylinder heads If a pulse style fuel pump is used valve cover with pulse fitting hole must be inst...

Page 87: ... B Air Cleaner Cover C Debris Screen D Blower Housing E Hose Clamp F Fuel Pump G Hose Clip H Fuel Line I Fuel Filter J Oil Filter K Outer Baffle L Electric Starter M Inner Baffle N Ignition Module O Intake Manifold P Carburetor Q Gasket R Air Cleaner Base S Air Cleaner Element T Rectifier Regulator U Dipstick Tube V Oil Fill Dipstick W Breather Hose ...

Page 88: ...inal air gap 0 203 0 305 mm 0 008 0 012 in Install Intake Manifold Torque Sequence 1 2 3 4 1 On engines equipped with Smart Choke install air vane deflector into intake manifold Torque screw to 1 N m 9 in lb 2 Install intake manifold using new O rings with wiring harness attached onto cylinder heads Slide any wiring harness clips onto appropriate bolts before installing Using sequence shown torque...

Page 89: ...r Components E C G B F A A Air Cleaner Base B Breather Hose C Ground Lead D Solenoid Lead E Smart Choke Bracket Assembly F Thermostat G Carburetor Choke Unloader Linkage A B A Choke Unloader Linkage B Choke Lever Actuator Lever Engaged with Choke Shaft Pin A B A Actuator Lever B Choke Shaft Pin NOTE If thermostat was removed from assembly refer to procedure in Fuel System section to install 1 Inst...

Page 90: ...ll carburetor throttle linkage and governor lever as an assembly 3 If carburetor is equipped with a fuel solenoid connect red power lead Attach eyelet terminal of ground lead to inner top carburetor cover mounting screw 4 Install a new air cleaner base gasket and air cleaner base onto mounting studs Install eChoke bracket assembly Connect eChoke stepper motor harness and follow routine indicated i...

Page 91: ...choke actuator lever on main control bracket assembly 2 Install main control bracket to cylinder heads using screws Two lower screws should also secure inner baffles Torque screws to 10 7 N m 95 in lb into new holes or 7 3 N m 65 in lb into used holes 3 Connect governed idle spring to governor lever and main control bracket Connect governor spring from throttle control bracket to appropriate hole ...

Page 92: ...5 16 18 head capscrews based on head design to secure muffler Torque nuts to 24 4 N m 216 in lb or capscrews to 16 9 N m 150 in lb Install Oil Filter and Fill Crankcase with Oil NOTE Make sure oil drain plug is installed and torqued to specification to prevent oil leakage 1 Install oil drain plug Torque plug to 13 6 N m 10 ft lb 2 Place new filter in shallow pan with open end up Fill with new oil ...

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Page 94: ...94 KohlerEngines com 32 690 03 Rev I ...

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Kohler KT715, Service Manual

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