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5.4

Section 5
Fuel System and Governor

High Altitude Operation

When operating the engine at altitudes of 1500 m
(5000 ft.) and above, the fuel mixture tends to get
over-rich. This can cause conditions such as black,
sooty exhaust smoke, misfiring, loss of speed and
power, poor fuel economy, and poor or slow governor
response.

To compensate for the effects of high altitude, special
high altitude jet kits are available. The kits include
new main jets, slow jets (where applicable), necessary
gaskets, and O-Rings. Refer to the parts manual for
the correct kit number.

Fuel Shut-off Solenoid

Most carburetors are equipped with a fuel shut-off
solenoid. The solenoid is attached to the fuel bowl. See
Figure 5-4. The solenoid has a spring-loaded pin that
retracts when 12 volts is applied to the lead, allowing
fuel flow to the main jets. When current is removed
the pin extends blocking the fuel flow.

Figure 5-4. Fuel Shut-off Solenoid.

Below is a simple test, made with the engine off, that
can determine if the solenoid is functioning properly:

1. Shut off fuel and remove the solenoid from the

carburetor. When the solenoid is loosened and
removed, gas will leak out of the carburetor.

Troubleshooting – Carburetor Related Causes

Condition

Possible Cause/Probable Remedy

1. Low idle fuel mixture (some models)/speed improperly adjusted.

Adjust the low idle speed tab, then adjust the low idle fuel needle.

1. Engine starts hard, runs roughly,

or stalls at idle speed.

2. Engine runs rich (indicated by

black, sooty exhaust smoke,
misfiring, loss of speed and power,
governor hunting, or excessive
throttle opening).

2a. Clogged air cleaner. Clean or replace.

b. Choke partially closed during operation. Check the choke lever/

linkage to ensure choke is operating properly.

c. Low idle fuel mixture is improperly adjusted. Adjust low idle

fuel needle (some models).

d. Float level is set too high. Adjust float according to Float

Replacement Procedure.

e. Dirt under the fuel inlet needle. Remove needle; clean needle and

seat and blow with compressed air.

f. Bowl vent or air bleeds plugged. Remove low idle fuel adjusting

needle. Clean vent, ports, and air bleeds. Blow out all passages
with compressed air.

g. Leaky, cracked or damaged float. Submerge float to check for

leaks.

3. Engine runs lean (indicated by

misfiring, loss of speed and power,
governor hunting, or excessive
throttle opening).

3a. Low idle fuel mixture is improperly adjusted. Adjust low idle

fuel needle (some models).

b. Float level is set too low. Adjust float according to Float

Replacement Procedure.

c. Idle holes plugged; dirt in fuel delivery channels. Remove low

idle fuel adjusting needle. Clean main fuel jet and all passages;
blow out with compressed air.

4. Fuel leaks from carburetor.

4a. Float level set too high. See Remedy 2d.

b. Dirt under fuel inlet needle. See Remedy 2e.

c. Bowl vents plugged. Blow out with compressed air.

d. Carburetor bowl gasket leaks. Replace gasket.

Fuel Shut-Off

Solenoid

Содержание CH980

Страница 1: ...SERVICE MANUAL HORIZONTAL CRANKSHAFT COMMAND PRO CH940 CH980...

Страница 2: ...on 3 Troubleshooting Section 4 Air Cleaner and Air Intake System Section 5 Fuel System and Governor Section 6 Lubrication System Section 7 Electrical System and Components Section 8 Disassembly Sectio...

Страница 3: ...s should be followed at all times Failure to follow these precautions could result in injury to yourself and others Rotating Parts can cause severe injury Stay away while engine is in operation WARNIN...

Страница 4: ...d cable make sure all switches are OFF If ON a spark will occur at the ground cable terminal which could cause an explosion if hydrogen gas or gasoline vaporsarepresent Explosive Fuel can cause fires...

Страница 5: ...umbers appear on a decal or decals affixed to the engine shrouding See Figure 1 1 An explanation of these numbers is shown in Figure 1 2 Figure 1 1 Engine Identification Decal Location Figure 1 2 Expl...

Страница 6: ...nd the spark plug leads to prevent the possibility of sparks from the ignition system General Recommendations Purchase gasoline in small quantities that can be used within 30 days and store only in cl...

Страница 7: ...ansported To empty the system run the engine until the tank and the system are empty 4 Remove the spark plugs and add one tablespoon of engine oil into each spark plug hole Install the spark plugs but...

Страница 8: ...1 6 Section 1 Safety and General Information Figure 1 4 Typical CH PRO Series Engine Dimensions with Heavy Duty Air Cleaner Dimensions in millimeters Inch equivalents shown in...

Страница 9: ...metal 4 0 N m 35 in lb Used Extruded Hole sheet metal 2 0 N m 17 7 in lb Mounting Clip valley baffle 2 5 N m 22 1 in lb M6 Screw Torque New Untapped Hole casting 10 7 N m 95 in lb Used Tapped Hole cas...

Страница 10: ...070 mm 0 0028 in Connecting Rod to Crankpin Side Clearance 0 30 0 59 mm 0 0118 0 0232 in Connecting Rod to Piston Pin Running Clearance 0 015 0 028 mm 0 0006 0 0011 in Piston Pin End I D 70 F New 19 0...

Страница 11: ...imit 43 97 mm 1 731 in Max Taper 0 018 mm 0 0007 in Max Out of Round 0 025 mm 0 0010 in Width 53 00 53 09 mm 2 0866 2 0901 in Crankshaft T I R PTO End Crank in Engine 0 279 mm 0 0110 in Entire Crank i...

Страница 12: ...on or Equivalent XC10YC Spark Plug Gap 0 76 mm 0 030 in Spark Plug Torque 24 4 29 8 N m 18 22 ft lb Ignition Module Air Gap 0 28 0 33 mm 0 011 0 013 in Ignition Module Fastener Torque 6 2 N m 55 in lb...

Страница 13: ...elco Remy Starter 2 5 3 3 N m 22 29 in lb Solenoid Starter Mounting Hardware Torque Delco Remy Starter 4 0 6 0 N m 35 53 in lb Nut Positive Brush Lead Torque Delco Remy Starter 8 0 11 0 N m 71 97 in l...

Страница 14: ...ers Into Aluminum Size M4 1 2 11 1 7 15 2 9 26 4 1 36 5 0 44 2 0 18 M5 2 5 22 3 2 28 5 8 51 8 1 72 9 7 86 4 0 35 M6 4 3 38 5 7 50 9 9 88 14 0 124 16 5 146 6 8 60 M8 10 5 93 13 6 120 24 4 216 33 9 300...

Страница 15: ...16 20 61 0 45 101 7 75 142 4 105 1 2 13 67 8 50 108 5 80 155 9 115 1 2 20 94 9 70 142 4 105 223 7 165 9 16 12 101 7 75 169 5 125 237 3 175 9 16 18 135 6 100 223 7 165 311 9 230 5 8 11 149 2 110 244 1...

Страница 16: ...f a h s m a C n o i t a l l a t s n i t f a h s m a c g n i r u d l a e s t c e t o r p o T 7 1 4 2 8 R L K s l o o T E S r e t s e T n w o d k a e L r e d n i l y C n r o w e r a s e v l a v r o s g...

Страница 17: ...c e p S c n I y g o l o n h c e T n g i s e D 1 3 0 I T D 3 3 0 I T D r e t s e T M A S e l u d o M e c n a v d A k r a p S K R A P S T R A M S h t i w s e n i g n e n o M A S D d n a M A S A M A S e...

Страница 18: ...e l E t f i h S d i o n e l o S S 2 0 7 5 3 2 5 r e l h o K t n a l a e S e n o c i l i S V T R e t i t c o L r e s n e p s i d l o s o r e a z o 4 n i y d o B y v a e H 0 0 9 5 e s u r o f d e v o r...

Страница 19: ...or removing with a puller Figure 2 1 Flywheel Holding Tool Rocker Arm Crankshaft Tool A spanner wrench to lift the rocker arms or turn the crankshaft may be made out of an old junk connecting rod 1 F...

Страница 20: ...ine 4 Loose or faulty wires or connections 5 Faulty or misadjusted choke or throttle controls 6 Faulty spark plugs 7 Low compression 8 Weak spark 9 Fuel pump malfunction causing lack of fuel 10 Engine...

Страница 21: ...asteners Check the air cleaner cover and base for damage or indications of improper fit and seal Check the air cleaner element Look for holes tears cracked or damaged sealing surfaces or other damage...

Страница 22: ...test the crankcase vacuum with the Vacuum Pressure Gauge Kit see Section 2 1 Remove the dipstick or oil fill plug cap 2 Install the adapter into the oil fill dipstick tube opening 3 Push the barbed f...

Страница 23: ...ut there is some wear present Customer should start planning for overhaul or replacement Gauge reading in high red zone Rings and or cylinder have considerable wear Engine should be reconditioned or r...

Страница 24: ...eaner Service Weekly and every 150 hours Check filter minder if equipped unhook the two retaining clips on each end and remove the end caps Perform inspection of the paper element and inlet screen are...

Страница 25: ...serviced check the following Air Cleaner Housing Make sure the housing is not damaged or broken and properly secured Air Cleaner Inlet Make sure the air cleaner inlet is secured tightly to the carbure...

Страница 26: ...ys and store only in clean approved containers Do not use gasoline left over from the previous season unless treated with a fuel stabilizer see Storage in Section 1 to minimize gum deposits and ensure...

Страница 27: ...flow 3 If fuel does flow from the line check for faulty fuel pump Test 4 If fuel does not flow from the line check the fuel tank cap vent fuel pickup screen in line filter shut off valve and fuel lin...

Страница 28: ...Figure 5 2 Optional Electric Fuel Pump Fuel Pump Replacement Replacing the Mechanical Fuel Pump The mechanical fuel pump is an integral part of the valve cover assembly and not serviced separately Se...

Страница 29: ...djust the low idle fuel needle 1 Engine starts hard runs roughly or stalls at idle speed 2 Engine runs rich indicated by black sooty exhaust smoke misfiring loss of speed and power governor hunting or...

Страница 30: ...h compressed air to remove any remaining fuel Take the 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...

Страница 31: ...procedure on the other low idle adjustment needle 4 Recheck adjust the Low Idle Speed RPM to the specified setting Figure 5 6 Optimum Low Idle Fuel Settings Governed Idle System A governed idle contr...

Страница 32: ...Speed RPM Air Cleaner Removed For Clarity 5 Move the throttle lever to the wide open full throttle position and hold in this position Check the RPM using a tachometer Turn the high speed screw to obta...

Страница 33: ...O Rings Transfer any remaining fuel into an approved container Save all parts Fuel can also be drained prior to bowl removal by loosening removal of the bowl drain screw See Figure 5 12 Figure 5 13 R...

Страница 34: ...the rubber gasket if still attached 9 When the proper float height is obtained carefully reinstall the fuel bowl onto the carburetor using new O Rings Secure with the four original screws Torque the...

Страница 35: ...jacent to the main jets Save the parts for cleaning and reuse See Figure 5 20 Main Nozzles Main Jets Slow Idle Fuel Jets O Ring Figure 5 20 Main Jets and Nozzles Removed 4 Remove the screw securing th...

Страница 36: ...ormed See Figure 5 23 Figure 5 24 Installing Idle Speed Adjusting Screw and Spring 12 Attach the inlet needle to the plastic tang of the float with the wire clip The formed 90 lip should point up with...

Страница 37: ...e engine Discard the old mounting gaskets for the air cleaner and carburetor 2 Clean the areas around the choke shaft and the self relieving choke mechanism thoroughly 3 Remove and discard the plastic...

Страница 38: ...hoke Shaft Figure 5 30 Assembling Choke Lever 8 Turn the old bushing upside down and use it as a driver to carefully press or tap the new bushing into the carburetor body until it bottoms Check that t...

Страница 39: ...w gaskets when servicing or reinstalling carburetors Repair kits are available which include new gaskets and other components Service repair kits available for Keihin BK two barrel carburetors and aff...

Страница 40: ...Clip 21 Float Valve Inlet Needle 22 Main Nozzle Right Side 1 Carburetor Body Subassembly 2 Idle Speed Screw 3 Idle Speed Spring 4 Screw 5 Ground Lead 6 Retaining Washer 7 Slow Jet RH Side 8 Slow Jet...

Страница 41: ...PM speed is obtained Figure 5 36 Governor Linkage Air Cleaner Removed for Clarity When the engine is at rest and the throttle is in the fast position the tension of the governor spring holds the throt...

Страница 42: ...her Select the viscosity based on the air temperature at the time of operation as shown in the following table NOTE Using other than service class SG SH SJ or higher oil or extending oil change interv...

Страница 43: ...or every 150 hours of operation more frequently under severe conditions Refill with service class SG SH SJ or higher oil as specified in the Viscosity Grades table on page 6 1 Change the oil while th...

Страница 44: ...hin film of clean oil to the rubber gasket on the new filter Partial prefilling of the oil filter is recommended 6 Install the replacement oil filter to the filter adapter or oil cooler Turn the oil f...

Страница 45: ...ition module to stop the engine On vehicular applications lawn tractors mowers etc the pressure switch can only be used to activate a low oil warning light or signal NOTE Make sure the oil level is ch...

Страница 46: ...a pressure regulator pressure gauge and a continuity tester are required to test the switch 1 Connect the continuity tester across the blade terminal and the metal case of the switch With 0 psi press...

Страница 47: ...ry Replace spark plugs every 600 hours To service the plugs perform the following steps 1 Before removing each spark plug clean the area around the base of the plug to keep dirt and debris out of the...

Страница 48: ...engine operating under normal conditions will have light tan or gray colored deposits If the center electrode is not worn a plug in this condition could be set to the proper gap and reused Carbon Foul...

Страница 49: ...conditions A smaller capacity battery is often sufficient if an application is started only in warmer temperatures Refer to the following table for minimum capacities based on anticipated ambient tem...

Страница 50: ...in an arc at the plug electrodes This spark ignites the fuel air mixture in the combustion chamber Troubleshooting CD Ignition Systems The CD ignition systems are designed to be trouble free for the...

Страница 51: ...testing is completed NOTE If the engine starts or runs during any of the testing you may need to ground the kill lead to shut it down Because you have interrupted the kill circuit it may not stop usi...

Страница 52: ...ed Battery Charging System with Fixed Timing Four Pin Connector 15 20 25 Amp Regulated Charging System Figure 7 5 25 Amp Stator and 20 25 AmpRectifier Regulator Figure 7 6 15 Amp Stator and Rectifier...

Страница 53: ...7 7 Section 7 Electrical System and Components 7 Figure 7 8 Wiring Diagram15 20 25 Amp Regulated Battery Charging System with Fixed Timing Five Pin Connector Key Switch and Fuse...

Страница 54: ...ndem adapter lead connections are not location specific 4 Connect the remaining black lead from the tester to one of the outer AC terminals on the rectifier regulator See Figure 7 11 Figure 7 9 Rectif...

Страница 55: ...onnected to 15 Amp Rectifier Regulator 3 Plug the tester into the proper AC outlet power for tester being used Turn on the power switch See Figure 7 12 The POWER light should be illuminated and one of...

Страница 56: ...tem is OK and battery was fully charged If voltage is less than 13 8 or charge rate does not increase when load is applied test stator Tests 2 and 3 2 Remove connector from rectifier regulator With en...

Страница 57: ...tarting Motors The engines in this series use solenoid shift starters A Delco Remy solenoid shift starter is typically used Starting Motor Precautions NOTE Do not crank the engine continuously for mor...

Страница 58: ...ections 2 Replace wires in poor condition and with frayed or broken insulation 1 By pass the switch or solenoid with a jumper wire If starter cranks normally replace the faulty components Remove and p...

Страница 59: ...ger 4 Remove the two thru larger bolts See Figure 7 20 Figure 7 20 Removing Thru Bolts 5 Remove the commutator end plate assembly containing the brush holder brushes springs and locking caps Remove th...

Страница 60: ...10 Push the stop collar down to expose the retaining ring See Figure 7 25 Figure 7 25 Retaining Ring Detail Figure 7 26 Removing Retaining Ring 12 Remove the drive pinion assembly from the armature 13...

Страница 61: ...to the Rx1 scale Touch the probes between two different segments of the commutator and check for continuity See Figure 7 30 Test all the segments Continuity must exist between all or the armature is...

Страница 62: ...r retainer assembly a Install the stop collar down onto the armature shaft with the counter bore recess up b Install a new retainer in the larger rear groove of the armature shaft Squeeze with a plier...

Страница 63: ...et Install the drain tube in the rear cutout if it was removed previously See Figure 7 37 Figure 7 37 Installing Frame and Drain Tube Figure 7 34 Installing Thrust Washer 4 Apply a small amount of oil...

Страница 64: ...er reassembly when not replacing the Brushes Brush Holder Assembly a Carefully unhook the retaining caps from over each of the brush assemblies Do not lose the springs See Figure 7 40 Figure 7 39 Inst...

Страница 65: ...hold the solenoid gasket in position then mount the solenoid Torque the screws to 4 0 6 0 N m 35 53 in lb 14 Connect the positive brush lead bracket to the solenoid and secure with the hex nut Torque...

Страница 66: ...l Plunger Actuation Test 2 Solenoid Pull In Coil Contact Continuity Test Use an ohmmeter set to the audible or Rx2K scale and connect the two ohmmeter leads to the two large post terminals Perform the...

Страница 67: ...mmeter leads to the two large post terminals Perform the preceding test 3 and check for continuity See Figure 7 49 The meter should indicate continuity If no continuity is indicated the solenoid shoul...

Страница 68: ...ply 3 Drain oil from crankcase and remove oil filter 4 Remove muffler 5 Remove cylinder shrouds and blower housing 6 Remove electric starter motor 7 Remove air cleaner assembly 8 Remove control bracke...

Страница 69: ...lugs Figure 8 4 Oil Drain Plug Location 3 Allow ample time for the oil to drain from the crankcase Remove Muffler 1 Remove the exhaust system and attaching hardware from the engine Remove Cylinder Shr...

Страница 70: ...r and the formed vent hose from the vent port on the carburetor 2 Remove the four hex flange nuts ground lead and choke return spring bracket from the mounting studs See Figure 8 8 Figure 8 9 Mounting...

Страница 71: ...retor and linkages with choke return components as an assembly See Figure 8 14 Removing Control Bracket Governor Springs and Lever 1 Unhook the governed idle and governor springs from the controls on...

Страница 72: ...om the closure plate See Figure 8 15 Figure 8 16 Removing Valley Baffles Figure 8 17 Removing Outer Cylinder Baffles 3 Remove the four hex flange screws securing the intake manifold to the cylinder he...

Страница 73: ...mounting screws Do not lose any washers if used See Figure 8 19 Figure 8 21 Removing Oil Filter Housing From Adapter Perform the following only if the oil filter housing assembly requires individual s...

Страница 74: ...24 Rubber Valve and Spring Removed from Cup 2 Remove the screw securing the oil filter adapter and individual O Rings to the crankcase then carefully separate the parts See Figure 8 25 Figure 8 26 Re...

Страница 75: ...g the rectifier regulator to the backing shroud assembly Note the location of the ground lead If the rectifier regulator is not being replaced it may remain mounted to the lower blower housing See Fig...

Страница 76: ...rom ignition Do not start the engine near spilled fuel Never use gasoline as a cleaning agent NOTE Based on the style of fuel pump used refer to the following when removing valve covers Mechanical Fue...

Страница 77: ...er head See Figure 8 43 Electric Fuel Pump 1 Removal will be determined based on mounted location and application Disconnect the lead connections fuel line connections and mounting hardware as require...

Страница 78: ...8 46 and 8 47 Valve spring keepers Valve spring retainers Valve springs Valve spring caps Intake and exhaust valves mark position Valve stem seals Figure 8 42 Removing Hydraulic Lifters Figure 8 43 M...

Страница 79: ...Carefully break the gasket seals and remove all parts Do not pry on the sealing surfaces as it could cause damage resulting in leaks Note the assembly and orientation of parts See Figures 8 48 and 8 4...

Страница 80: ...s on the closure plate Carefully tap to break the gasket seal Do not pry on the sealing surfaces as this could cause leaks Separate the closure plate from the crankcase See Figure 8 53 and 8 54 Remove...

Страница 81: ...necessary If the governor cross shaft yoke or gear condition does not require removal the governor gear may be left in place If removal is necessary perform as follows 1 Remove the locking tab thrust...

Страница 82: ...the crankcase See Figure 8 62 Remove Flywheel and PTO End Oil Seals 1 Remove the oil seals from the crankcase and closure plate using a seal puller See Figure 8 63 Figure 8 63 Removing Oil Seals Remo...

Страница 83: ...or additional information Measurement Guide TP 2159 B and Engine Inspection Data Record TP 2435 are also available use these to record inspection results Camshaft Inspection and Service Check the lobe...

Страница 84: ...versize of either 0 25 mm 0 010 in or 0 50 mm 0 020 in Resizing to one of these oversizes will allow usage of the available oversize piston and ring assemblies Initially resize using a boring bar then...

Страница 85: ...troy an engine in less than one hour of operation after a rebuild The final cleaning operation should always be a thorough scrubbing with a brush and hot soapy water Use a strong detergent that is cap...

Страница 86: ...ar for cracks or damage Kohler does not provide the ring gear as a serviceable part Replace the flywheel if the ring gear is damaged Cylinder Head and Valves Inspection and Service After cleaning chec...

Страница 87: ...Dimension 89 30 8 5 mm 0 334 in 7 038 7 058 mm 0 2771 0 2779 in 38 625 38 685 mm 1 5206 1 5230 in 45 1 0 mm 0 0393 in 6 982 7 000 mm 0 2749 0 2756 in Intake Exhaust 89 30 8 5 mm 0 334 in 7 038 7 058...

Страница 88: ...1000 hours under controlled test conditions Bad Condition The valve depicted here should be replaced Note the warped head margin damaged and too narrow These conditions could be attributed to excessiv...

Страница 89: ...on their condition Stem Corrosion Moisture in fuel or from condensation are the most common causes of valve stem corrosion Condensation occurs from improper preservation during storage and when engine...

Страница 90: ...89 cutter as specified for the valve seat angle in Figure 9 6 Cutting the proper 45 valve face angle as specified in Figure 9 6 and the proper valve seat angle 44 5 half of the full 89 angle will achi...

Страница 91: ...aterial such as carbon dirt or pieces of hard metal Detonation damage occurs when a portion of the fuel charge ignites spontaneously from heat and pressure shortly after ignition This creates two flam...

Страница 92: ...ngs on the piston place the top two rings each in turn in its running area in the cylinder bore and check the end gap See Figure 9 9 Compare the ring gap to the specifications listed in Section 1 Figu...

Страница 93: ...damage If the lifters need to be replaced apply a liberal coating of Kohler lubricant see Section 2 to the base of each new lifter before it is installed Bleeding the Lifters To prevent a possible ben...

Страница 94: ...one piece style staked to the oil pump housing removal should not be attempted nor is internal servicing possible If a problem with the relief valve is encountered the oil pump should be replaced See...

Страница 95: ...all the clamp for the pickup tube and finger tighten the screw Check the alignment of the parts and torque the oil pump housing screws as specified using the sequence shown in Figure 9 18 Torque the h...

Страница 96: ...17 Install valve covers 18 Install spark plugs 19 Install oil filter adapter 20 Install intake manifold 21 Install oil filter housing assembly 22 Install backing shroud assembly 23 Install stator wir...

Страница 97: ...clock position using an arbor press and driver See Figure 10 5 Make sure the bearing is fully seated against the flange and the oil feed hole is open in the crankcase See Figure 10 6 3 Apply a light c...

Страница 98: ...to depth shown in Figure 10 10 Figure 10 7 Installing Governor Cross Shaft Seal Figure 10 8 Governor Shaft Seal Depth Figure 10 9 Installed Governor Gear Shaft Figure 10 10 Governor Gear Shaft Press...

Страница 99: ...he yoke Install the governor gear with the second regulating pin and the flyweight assembly in down onto the governor shaft until it locks into position Apply a small amount of grease to the locking t...

Страница 100: ...of the 1 piston using a piston ring compressor 3 Lubricate the crankshaft journals and connecting rod bearing surfaces with engine oil 4 Make sure the FLY stamping on the piston is facing toward the...

Страница 101: ...n 3 Slide the camshaft into the bearing surface of the crankcase positioning the timing mark of the camshaft gear at the 6 o clock position Make sure that the camshaft gear and crankshaft gear mesh wi...

Страница 102: ...stalled Main Bearing In Closure Plate Oil Seal 1 Check to make sure there are no nicks or burrs in the crankshaft seal bore of the closure plate 2 Lightly oil the outside diameter of the oil seal 3 In...

Страница 103: ...the oil pump and governor gears mesh See Figure 10 29 Figure 10 29 Installing Closure Plate 6 Install the fourteen hex flange screws securing the closure plate to the crankcase Torque the fasteners i...

Страница 104: ...tighten the screws Remove the two alignment pins and install the two remaining screws Torque the screws in the sequence shown in Figure 10 36 to 24 4 N m 216 in lb Figure 10 32 Installing Pickup Scree...

Страница 105: ...during disassembly 2 Install the breather chamber gasket as shown See Figure 10 38 Assemble and install breather assembly components as illustrated in Figure 10 39 Make sure the filter does not exten...

Страница 106: ...gine The cylinder numbers are embossed on the top of the crankcase and each cylinder head See Figure 10 43 Figure 10 40 Breather Assembly Fastener Torque Sequence 4 Lightly oil the lower end of the br...

Страница 107: ...nder Heads Prior to installation lubricate all components with engine oil paying particular attention to the lip of the valve stem seal valve stems and valve guides Install the following items in the...

Страница 108: ...ener Torque Sequence Figure 10 51 Installing Pipe Plug in Cylinder Heads Install Push Rods and Rocker Arms NOTE Push rods should always be installed in the same position as before disassembly 1 Note t...

Страница 109: ...m 130 in lb See Figure 10 54 Figure 10 54 Torquing Rocker Arm Screws 5 If push rods were not already seated use a spanner wrench or rocker arm lifting tool see Section 2 to lift the rocker arms and po...

Страница 110: ...m 216 in lb See Figure 10 60 Figure 10 58 Installing Spark Plugs Install Oil Filter Adapter 1 Make sure all sealing surfaces are clean and the three dowel pins are in place on the crankcase adapter s...

Страница 111: ...flange to flange and tighten each of the studs until bottomed tight Install Oil Filter Housing Assembly Reassemble the oil filter housing if disassembled previously Reassembly 1 Install the small spr...

Страница 112: ...the oil filter adapter See Figure 10 69 Figure 10 69 O Rings Installed on Adapter for Oil Filter Housing Figure 10 70 Installing Oil Filter Housing 3 The oil filter may be installed now or upon compl...

Страница 113: ...the stator aligning the mounting holes so the leads are at the bottom and toward the rectifier regulator mount on the No 1 side 3 Install and torque the two hex flange screws to 6 2 N m 55 in lb See...

Страница 114: ...r stressed and damaged when the hex flange screw is torqued to specifications See Figures 10 77 and 10 78 Figure 10 78 Clean and Dry Flywheel Hub NOTE Make sure the flywheel key is installed properly...

Страница 115: ...th checking for clearance between the magnet and ignition modules Make sure the magnet does not strike the modules Check the gap with a feeler gauge and readjust if necessary Final Air Gap 0 280 0 330...

Страница 116: ...e or reassemble the grass screen as designed could result in grass screen failure and serious personal injury 1 Position the cooling fan onto the flywheel aligning the mounting locations Apply a small...

Страница 117: ...ecure with the mounting screws The lower section should fit under the outer baffle Torque the M6 screws going into the cylinder head to 10 7 N m 95 in lb for new holes or 7 3 N m 65 in lb for used hol...

Страница 118: ...rear supports with the top valley baffle cylinder head mounting screw locations and install the two screws but do not fully tighten See Figure 10 94 Figure 10 95 Installing Choke Link and Push On Nut...

Страница 119: ...ol Bracket Screws Figure 10 98 Torque Sequence for Air Cleaner Mounting Nuts 5 Connect the breather hose to the fitting on the outlet of the air cleaner and connect the fuel solenoid lead 6 Connect th...

Страница 120: ...vernor 4 Ensure that the correct color springs are used Connect the governor spring with long looped end to the inner hole on the governor lever and control bracket Connect the governed idle spring to...

Страница 121: ...See Figure 10 107 Figure 10 107 Installing Blower Housing 2 Secure the blower housing with the four shoulder screws Torque the screws to 4 0 N m 35 in lb for initial installations or 2 0 N m 17 7 in l...

Страница 122: ...ke sure that both oil drain plugs are installed and torqued to the above specifications to prevent oil leakage 3 Apply a thin film of clean engine oil to the rubber gasket on the oil filter and thread...

Страница 123: ...and General Information and in Section 6 Lubrication System 4 Adjust the carburetor idle fuel needles or idle speed adjusting screw as necessary Refer to Section 5 Fuel System and Governor Testing the...

Страница 124: ...LITHO IN U S A FORMNO TP 2580 ISSUED 5 07 REVISED ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 FOR SALESAND SERVICE INFORMATION IN U S AND CANADA CALL 1 800 544 2444 KohlerEngines com...

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