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7.7

Section 7

Electrical System and Components

7

Troubleshooting DSAI Ignition Systems

The DSAI ignition system is designed to be trouble
free for the life of the engine. Other than periodically
checking/replacing the spark plugs, no maintenance,
timing, or module adjustments are necessary or
possible. Mechanical systems do occasionally
fail or break down however, so the following
troubleshooting information is provided to help you
get to the root of a problem.

Reported ignition problems are most o

ft

en due

to poor connections. Before beginning the test
procedure, check all external wiring. Be certain all
ignition-related wires are connected, including the
spark plug leads. Be certain all terminal connections

fi

t snugly. Make sure the ignition switch is in the

RUN

position.

Test Procedure for DSAI Ignition Systems

The following procedures are provided for
troubleshooting ignition problems on DSAI equipped
engines. They will allow you to isolate and pinpoint
the failed component(s).

Special Tools Required:

•  Hand Tachometer
  •  Ignition Tester* (Kohler Part No. 25 455 01-S)
  •  Automotive Timing Light
•  Multi-meter (Digital)

Specifi cations Required:

• Spark plug gap 0.76 mm (0.030 in.)

*NOTE: Ignition tester (Kohler Part No.

25 455 01-S), must be used to test ignition
on these engines. Use of any other tester can
result in inaccurate

fi

ndings. The ba

tt

ery on

the unit must be fully charged and properly
connected before making any of these tests
(a ba

tt

ery that is hooked up or charged

backward will crank the engine, but it won’t
have spark). Be certain the drive is in neutral
and all external loads are disconnected.

Figure 7-6. Digital Spark Advance Ignition (DSAI) System.

STARTER ASSEMBLY

STARTER

SOLENOID

TANG

STARTER

SOLENOID

STUD

BLUE

FUSE

RED

POS.

BATTERY

NEG.

SWITCH, KEY

STARTER

M-MAGNETO

R-RECTIFIER

BLUE WIRE

WHITE WIRES

CONNECTOR, 5-CIRCUIT

B-BATTERY

A-ACCESSORY

GROUND

YELLOW WIRES

BLACK WIRE

RED WIRE

CONNECTOR, 1-CIRCUIT

(ACCESSORY)

YELLOW

OIL SENTRY

LIGHT

RED

RED

CARB.

SOLENOID

RED

CARB.

BLACK

WHITE

RED

YELLOW (ACCESSORY) (+)

GREEN

(OIL SENTRY PULSE SIGNAL)

(NOT VALID WITH INDICATOR

LIGHT OR NO PRESSURE SWITCH)

WHITE

(ALTERNATIVE IGNITION

PULSE SIGNAL) (-)

VIOLET (B+ LEAD)

REGULATOR

RECTIFIER

REGULATOR

CONNECTOR

BLOCK

WHITE

(AC CHARGING

LEADS)

SPARK PLUG

#2 CYLINDER

(SPARK PLUG LEAD)

BLACK

(GROUD)

RED

(B+)

WHITE

(SHUT OFF)

MODULE LEAD

DESIGNATION

GROUND

MODULE

MTG SCREW

IGNITION

(MODULES)

FLYWHEEL

STATOR

ASS’Y

GROUND

CARB MOUNTING

STUD

SPARK PLUG

#1 CYLINDER

GREEN

(NOT VALID WITH INDICATOR

LIGHT OR NO PRESSURE SWITCH)

OIL PRESSURE SWITCH

(OPTIONAL)

LIGHT ASSEMBLY, INDICATOR

(OPTIONAL)

BLACK

RED WIRES

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Содержание Comand Pro CH1000

Страница 1: ...SERVICE MANUAL HORIZONTAL CRANKSHAFT CH940 CH1000...

Страница 2: ......

Страница 3: ...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 4: ......

Страница 5: ...hould 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 WARNING R...

Страница 6: ...and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from sparks or flames Do not fill the fuel tank while the engine is hot o...

Страница 7: ...decal or decals a xed 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 Explanation of Engine Id...

Страница 8: ...clean fresh unleaded gasoline with a pump sticker octane rating of 87 R M 2 or higher In countries using the Research Octane Number RON it should be 90 octane minimum Leaded gasoline is not recommende...

Страница 9: ...ection 6 Section 4 Section 6 Every 200 Hours Check spark plug condition and gap Section 7 Seasonally or Every 300 Hours Change oil filter Replace heavy duty air cleaner element Section 6 Section 4 Yea...

Страница 10: ...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 11: ...327 60 41 2 378 119 80 4 717 ENGINE MOUNTING SURFACE MOUNTING HOLE A 418 22 16 465 LIFTING POINT 5 3 0 207 SPARK PLUG WIRE STEPPING MOTOR CONNECTOR 484 33 19 068 85 47 3 368 LIFTING POINT LIFTING POI...

Страница 12: ...5 in lb Used Tapped Hole casting 7 3 N m 65 in lb New Extruded Hole sheet metal 4 0 N m 35 in lb Used Extruded Hole sheet metal 2 0 N m 18 in lb Mounting Clip valley ba e 2 5 N m 22 in lb M6 Screw Tor...

Страница 13: ...rque Torque In Increments 11 3 N m 100 in lb Crankpin End I D 70 F New 44 030 44 037 mm 1 7334 1 7337 in Max Wear Limit 0 070 mm 0 0028 in Connecting Rod to Crankpin Running Clearance New 0 030 0 055...

Страница 14: ...1 771 in O D Max Wear Limit 44 90 mm 1 767 in Max Taper 0 022 mm 0 0009 in Max Out of Round 0 025 mm 0 0010 in Connecting Rod Journal O D New 43 982 44 000 mm 1 731 1 732 in O D Max Wear Limit 43 97 m...

Страница 15: ...160 mm 0 0027 0 0063 in Governor Gear Shaft O D New 5 990 6 000 mm 0 2358 0 2362 in Max Wear Limit 5 977 mm 0 2353 in Governor Lever Nut Torque 7 3 N m 65 in lb Ignition Spark Plug Type Champion or Eq...

Страница 16: ...ed Bore Max 0 94 mm 0 037 in Piston Thrust Face O D New 89 953 89 967 mm 3 5414 3 5420 in Max Wear Limit 89 925 mm 3 540 in Piston Thrust Face to Cylinder Bore Running Clearance New 0 033 0 72 mm 0 00...

Страница 17: ...d 7 048 mm 0 2775 in 0 25 mm O S 7 298 mm 0 2873 in Nominal Valve Face Angle 45 General Torque Values Metric Fastener Torque Recommendations for Standard Applications Tightening Torque N m in lb or 10...

Страница 18: ...6 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 1...

Страница 19: ...l K M Series To hold balance gears in timed position when assembling engine Kohler 25 455 06 S Formerly Y 357 Camshaft Endplay Plate For checking camshaft endplay SE Tools KLR 82405 Camshaft Seal Prot...

Страница 20: ...nents Available CS PRO Regulator Test Harness Special Regulator Test Harness with Diode Design Technology Inc DTI 031 DTI 033 Spark Advance Module SAM Tester To test the SAM ASAM and DSAM on engines w...

Страница 21: ...357 01 S Electric Starter Drive Lubricant Solenoid Shift Kohler 52 357 02 S RTV Silicone Sealant Loctite 5900 Heavy Body in 4 oz aerosol dispenser Only oxime based oil resistant RTV sealants such as...

Страница 22: ...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 Find...

Страница 23: ...ne 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 24: ...eners 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 tha...

Страница 25: ...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 fi...

Страница 26: ...tool and crankshaft PTO If the flywheel end is more accessible use a breaker bar and socket on the flywheel nut screw to hold it in position An assistant may be needed to hold the breaker bar during...

Страница 27: ...d remove the end caps Perform inspection of the paper element and inlet screen area Seasonally or every 300 hours of operation more often under extremely dusty or dirty conditions replace the paper el...

Страница 28: ...r element See Figure 4 5 Element Precleaner Cover Knobs Air Cleaner Cover Element Latch Figure 4 5 Low Profile Air Cleaner Service Precleaner If so equipped wash and reoil the precleaner every 25 hour...

Страница 29: ...ining knobs 9 When element replacement is necessary order genuine Kohler parts Air Cleaner Components Whenever the air cleaner cover is removed or the paper element or inner element are serviced check...

Страница 30: ...4 4 Section 4 Air Cleaner and Air Intake System...

Страница 31: ...chamber Fuel Recommendations General Recommendations Purchase gasoline in small quantities that can be used within 30 days and store only in clean approved containers Do not use gasoline left over fr...

Страница 32: ...es not flow from the line check the fuel tank cap vent fuel pickup screen in line filter shut o valve and fuel line Correct any observed problem and reconnect the line 4 Check the operation of the fue...

Страница 33: ...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 See...

Страница 34: ...medy 1 Engine starts hard runs roughly or stalls at idle speed 1 Low idle fuel mixture some models speed improperly adjusted Adjust the low idle speed tab then adjust the low idle fuel needle 2 Engine...

Страница 35: ...stable The idle fuel adjusting needles are also set at the factory and normally do not need adjustment NOTE Engines operating at altitudes above approximately 1219 m 4000 ft may require a special high...

Страница 36: ...t counterclockwise from the preliminary setting until the engine speed decreases rich Note the position of the needle Now turn the adjusting needle in clockwise The engine speed may increase then it w...

Страница 37: ...pically 300 RPM approximate higher than the low idle speed See Figure 5 10 Figure 5 9 Throttle Lever in Idle Position Figure 5 10 Setting Governed Idle Speed RPM Air Cleaner Removed For Clarity 5 Move...

Страница 38: ...e a float kit to replace the float pin float valve clip and screw 1 Perform the removal procedures for the appropriate air cleaner and the carburetor outlined in Section 8 Disassembly 2 Clean the exte...

Страница 39: ...r body Install the new pivot pin through the float hinge and secure with the new retaining screw See Figure 5 15 Retaining Screw Pivot Pin Figure 5 15 Installing Float Assembly 7 Hold the carburetor b...

Страница 40: ...ving Float and Inlet Needle 3 Use an appropriate size flat screwdriver and carefully remove the two main jets from the carburetor Note and mark the jets by location for proper installation The main je...

Страница 41: ...age Inspect the fuel inlet seat for wear or damage Check the spring loaded choke plate to make sure it moves freely on the shaft 7 Clean the carburetor fuel bowl as required 8 Install the two main noz...

Страница 42: ...er and carburetor 2 Clean the areas around the choke shaft and the self relieving choke mechanism thoroughly 12 Attach the inlet needle to the plastic tang of the float with the wire clip The formed 9...

Страница 43: ...the protruding boss on the carburetor housing is between the two stops formed in the choke lever See Figure 5 30 Boss Stops Figure 5 30 Assembling Choke Lever 8 Turn the old bushing upside down and u...

Страница 44: ...t then tighten the screws securely Do not overtighten See Figure 5 34 Figure 5 34 Installing Choke Plate 12 Check for proper operation and free movement of the parts Install the new cap Always use new...

Страница 45: ...de 8 Slow Jet LH Side 9 O ring Slow Jet 2 10 Fuel Bowl 11 O ring Fuel Bowl Upper 12 O ring Fuel Bowl Lower 13 Drain Screw 14 Bowl Screw 4 15 Fuel Solenoid 16 Sealing Washer 17 Float 18 Pin 19 Screw 20...

Страница 46: ...by the regulating pin will again o set each other to hold a steady engine speed Adjustments NOTE Do not tamper with the governor setting Overspeed is hazardous and could cause personal injury General...

Страница 47: ...irty oil causes premature engine wear and failure Oil Type Use high quality detergent oil of API American Petroleum Institute service class SG SH SJ or higher Select the viscosity based on the air tem...

Страница 48: ...ure 6 4 Oil Drain Plug Starter Side The top portion of the symbol shows service class such as API SERVICE CLASS SJ The symbol may show additional categories such as SH SG CC or CD The center portion s...

Страница 49: ...he new filter Partial prefilling of the oil filter is recommended 6 Install the new oil filter to the filter adapter or oil cooler Refer to instructions on the oil filter for proper installation Oil D...

Страница 50: ...ean the underside After cleaning reinstall the oil cooler to the backing shroud with the two mounting screws Figure 6 10 Cleaning Top of Oil Cooler Oil Cooler Figure 6 11 Cleaning Underside of Oil Coo...

Страница 51: ...to the switch the tester should indicate continuity switch closed 2 Gradually increase the pressure to the switch As the pressure increases through the range of 7 11 psi the tester should indicate a c...

Страница 52: ...6 6 Section 6 Lubrication System...

Страница 53: ...new plug as necessary 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 an...

Страница 54: ...d and the gap will be greater than the specified gap Replace a worn spark plug immediately Wet Fouled A wet plug is caused by excess fuel or oil in the combustion chamber Excess fuel could be caused b...

Страница 55: ...ventilated areas Keep sources of ignition away from the battery at all times Keep batteries out of the reach of children Remove all jewelry when servicing batteries Before disconnecting the negative g...

Страница 56: ...agnet assembly which is permanently a xed to the flywheel Two electronic capacitive discharge ignition modules Figure 7 4 which mount on the engine crankcase A kill switch or key switch which grounds...

Страница 57: ...cted Always provide a path for the spark to discharge to ground Reported ignition problems are most often due to poor connections Before beginning the test procedure check all external wiring Be certa...

Страница 58: ...n of DSAI Ignition Systems DSAI Ignition System Explanation A digital spark advance ignition system DSAI is used on some models The DSAI ignition system is an advanced 12 volt version of the fixed tim...

Страница 59: ...on tester Kohler Part No 25 455 01 S must be used to test ignition on these engines Use of any other tester can result in inaccurate findings The battery on the unit must be fully charged and properly...

Страница 60: ...a good engine ground NOTE If two testers are available testing can be performed simultaneously for both cylinders However if only one tester is available two individual tests must be performed The sid...

Страница 61: ...k that a proper ground is established between the ground black lead of the DSAI module closest to spark plug lead and a known good ground location on the engine 4 Turn the key switch to the ON positio...

Страница 62: ...7 9 25 Amp Stator and 20 25 Amp Rectifier Regulator NOTE 20 amp charging systems use a 15 amp stator with a 25 amp rectifier regulator Figure 7 10 15 Amp Stator and Rectifier Regulator Figure 7 11 Wir...

Страница 63: ...7 11 Section 7 Electrical System and Components 7 Figure 7 12 Wire Diagram 15 20 25 Amp Regulated Battery Charging System with Fixed Timing Five Pin Connector Key Switch and Fuse...

Страница 64: ...7 12 Section 7 Electrical System and Components Figure 7 13 Wire Diagram 15 20 25 Amp Regulated Battery Charging System with DSAI Ignition Five Pin Connector and Key Switch...

Страница 65: ...13 Section 7 Electrical System and Components 7 Figure 7 14 Wire Diagram 15 20 25 Amp Regulated Battery Charging System with DSAI Ignition and Four Pin Connector LP NG Kohler Power Systems Applicatio...

Страница 66: ...ction 7 Electrical System and Components Figure 7 15 Wire Diagram 15 20 25 Amp Regulated Battery Charging System with DSAI Ignition and Five Pin Connector Gasoline LP NG Non Kohler Power Systems Appli...

Страница 67: ...Disconnect all electrical connections attached to the rectifier regulator Testing may be performed with the rectifier regulator mounted or loose The figures show the part removed from the engine for c...

Страница 68: ...n Make certain the connection location is clean and the clamp is secure 15 Amp Rectifier Regulators 1 Connect the tester ground lead with spring clamp to the body of the rectifier regulator being test...

Страница 69: ...plied the charging system 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 recti...

Страница 70: ...inion and flywheel ring gear may clash resulting in damage to the starter NOTE If the starter does not crank the engine shut o the starter immediately Do not make further attempts to start the engine...

Страница 71: ...orroded connections and tighten loose connections 2 Replace wires in poor condition and with frayed or broken insulation Starter Switch or Solenoid 1 By pass the switch or solenoid with a jumper wire...

Страница 72: ...sembly containing the brush holder brushes springs and locking caps Remove the thrust washer from inside the commutator end See Figure 7 28 Figure 7 28 Removing Commutator End Plate Assembly 6 Remove...

Страница 73: ...etail 11 Remove the retainer from the armature shaft Save the stop collar NOTE Do not reuse the old retainer Figure 7 33 Removing Retaining Ring 12 Remove the drive pinion assembly from the armature 1...

Страница 74: ...s Armature 1 Clean and inspect the commutator outer surface The mica insulation must be lower than the commutator bars undercut to ensure proper operation of the commutator See Figure 7 36 Mica Insula...

Страница 75: ...ed Starter Service Clean the drive lever and armature shaft Apply Kohler electric starter drive lubricant see Section 2 Versilube G322L or Mobil Temp SHC 32 to the lever and shaft Clean and check the...

Страница 76: ...ever into the housing NOTE Correctly installed the center pivot section of the drive lever will be flush or below the machined surface of the housing which receives the backup washer See Figure 7 42 F...

Страница 77: ...n the cutout of the frame See Figure 7 46 The protective tube may be saved and used for future servicing Figure 7 46 Installing Brush Holder Assembly with Supplied Tube Starter reassembly when not rep...

Страница 78: ...ush lead 12 Install the two thru bolts and the two brush holder mounting screws Torque the thru bolts to 5 6 9 0 N m 49 79 in lb Torque the brush holder mounting screws to 2 5 3 3 N m 22 29 in lb See...

Страница 79: ...onnection Only Figure 7 53 Testing Pull In Coil 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 lea...

Страница 80: ...meter leads to the two large post terminals Perform the preceding test 3 and check for continuity See Figure 7 56 The meter should indicate continuity If no continuity is indicated the solenoid should...

Страница 81: ...pply 3 Drain oil from crankcase and remove oil filter 4 Remove mu er 5 Remove cylinder shrouds and blower housing 6 Remove electric starter motor 7 Remove air cleaner assembly 8 Remove control bracket...

Страница 82: ...llow 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 Shrouds and Blower Housing 1 Remove the top mo...

Страница 83: ...g the air cleaner and main control bracket to the intake manifold bosses See Figure 8 9 NOTE The low profile air cleaner is removed the same way as the heavy duty air cleaner Mounting Screws Figure 8...

Страница 84: ...ining fuel 3 Remove the carburetor and linkages with choke return components as an assembly See Figure 8 14 Figure 8 14 Removing Carburetor 4 Remove the carburetor gasket 3 Carefully pry o the pal nut...

Страница 85: ...es to the cylinder heads and backing shroud assembly Figure 8 16 Removing Valley Baffles 2 Remove the four screws securing each of the outer cylinder ba es in place Two of the screws are accessed fro...

Страница 86: ...ousing and individual O rings to the adapter Carefully separate the parts See Figure 8 21 NOTE Further disassembly of the oil filter housing assembly is not required unless individual servicing must b...

Страница 87: ...Remove Ignition Modules 1 Rotate the flywheel so the magnet is away from the modules 2 Remove the mounting screws and disconnect the kill lead from the ignition modules Note the position of ignition...

Страница 88: ...ankcase and carefully separate the stator wires from the blower housing clips Mounting Screws Mounting Screws Figure 8 29 Removing Fan Remove Flywheel 1 Use a flywheel strap wrench or holding tool see...

Страница 89: ...uel Pump WARNING Explosive Fuel Gasoline is extremely flammable and its vapors can explode if ignited Store gasoline only in approved containers in well ventilated unoccupied buildings away from spark...

Страница 90: ...ead Note the locations of washers and spacer See Figure 8 40 Washers Spacer Figure 8 40 Removing Cylinder Head Fasteners 3 Mark the position of the push rods as either intake or exhaust and cylinder 1...

Страница 91: ...ark position Valve stem seals Figure 8 46 Valve Train Components Valve Stem Seals Valve Stem Seals Figure 8 47 Valve Stem Seals Figure 8 42 Removing Hydraulic Lifters Match Numbers Figure 8 43 Match N...

Страница 92: ...cause damage resulting in leaks Note the assembly and orientation of parts See Figures 8 48 and 8 49 Breather Breather Adapter Figure 8 48 Removing Breather Assembly Breather Adapter Breather Adapter...

Страница 93: ...ted to the inside of the closure plate If service is required refer to the service procedures under Oil Pump Assembly in Section 9 Remove Camshaft 1 Remove the camshaft and shim if used See Figure 8 5...

Страница 94: ...nkshaft Removal of Governor Gear Assembly The governor gear is held onto the shaft by small molded tabs in the gear When the gear is removed from the shaft these tabs are destroyed and the gear must b...

Страница 95: ...re 8 62 Baffle Some Baffle Some Models Only Models Only Gasket Gasket Cover Cover Screws Screws Figure 8 62 Removing Lifter Feed Chamber Cover Components Remove Flywheel and PTO End Oil Seals 1 Remove...

Страница 96: ...8 16 Section 8 Disassembly...

Страница 97: ...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 98: ...aces to make sure they are free of gasket fragments Gasket surfaces must also be free of deep scratches or nicks Inspect the main bearing if so equipped for wear or damage refer to Section 1 Specifica...

Страница 99: ...easurements should be taken at three locations in the cylinder at the top middle and bottom Two measurements should be taken perpendicular to each other at each of the three locations Clean Cylinder B...

Страница 100: ...r 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 check...

Страница 101: ...Valve Margin Min Valve Stem Diameter 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 Exhau...

Страница 102: ...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 excessi...

Страница 103: ...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 104: ...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 ach...

Страница 105: ...o stick which results in rapid wear A worn ring usually takes on a shiny or bright appearance Scratches on rings and pistons are caused by abrasive material such as carbon dirt or pieces of hard metal...

Страница 106: ...gs 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 Figur...

Страница 107: ...n to ensure that correct replacements are used Hydraulic Lifters Inspection Check the base surface of the hydraulic lifters for wear or damage If the lifters need to be replaced apply a liberal coatin...

Страница 108: ...d 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 Figure 9 15 Mounting...

Страница 109: ...Tube Clamp and Screw Mounting Screws Figure 9 17 Installed Oil Pump and Pickup Tube 7 Install the clamp for the pickup tube and finger tighten the screw Check the alignment of the parts and torque the...

Страница 110: ...Section 9 Inspection and Reconditioning 9 14...

Страница 111: ...Install lifter feed chamber gaskets and cover 3 Install flywheel end main bearing 4 Install governor shafts seal and governor gear 5 Install crankshaft 6 Install connecting rods with pistons and ring...

Страница 112: ...at of clean engine oil to the inner surface of the main bearing Figure 10 5 Installing Main Bearing 2 Apply a light coat of clean engine oil to the outside diameter of the oil seal 3 Install the oil s...

Страница 113: ...r gear yoke into the crankcase first and position so the flat is up See Figure 10 11 Governor Governor Cross Shaft Cross Shaft Figure 10 11 Installing Governor Cross Shaft Notch Main Bearing Figure 10...

Страница 114: ...yweight assembly in down onto the governor shaft until it locks into position Apply a small amount of grease to the locking tab thrust washer and install on top of the governor gear so the tang is fac...

Страница 115: ...ston 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 flywheel sid...

Страница 116: ...oved during servicing install a new bearing 1 Make sure the closure plate bore for the main bearing is clean dry and free of nicks or burrs 2 Install a new bearing with the notch in the 12 o clock pos...

Страница 117: ...tall a new O ring in the closure plate See Figure 10 27 O ring Figure 10 27 O ring Installed 2 Install a new closure plate gasket onto the crankcase 3 Make sure the oil pump is installed and the oil p...

Страница 118: ...ure Plate 6 Install the fourteen hex flange screws securing the closure plate to the crankcase Torque the fasteners in the sequence shown in Figure 10 31 to 24 4 N m 216 in lb Figure 10 30 Torquing Cl...

Страница 119: ...Pins Gasket Gasket Figure 10 34 Installing Oil Reservoir Gasket 3 Install the oil reservoir onto the crankcase and temporary alignment pins The flywheel side is indicated on the cover Install and fing...

Страница 120: ...properly aligned Figure 10 38 Breather Chamber and Gasket Figure 10 39 Breather Assembly Details Breather Hose Flange Nuts 4 Breather Gasket Screw Baffle Filter Adapter Gasket Studs 4 Filter Must Not...

Страница 121: ...use a magnet See Figure 10 42 Figure 10 42 Installing Hydraulic Lifters NOTE Hydraulic lifters should always be installed in the same position as they were disassembled The exhaust lifters are located...

Страница 122: ...of the cylinder head or the crankcase 2 Check that the dowel pins are in place in the two lower locations and install a new cylinder head gasket printed side up See Figure 10 47 Figure 10 47 Installi...

Страница 123: ...fore disassembly 1 Note the mark or tag identifying the push rod as either intake or exhaust and cylinder 1 or 2 Dip the ends of the push rods in engine oil and install making sure that each push rod...

Страница 124: ...he crankshaft to check for free operation of the valve train Check the clearance between the valve spring coils at full lift Minimum allowable clearance is 0 25 mm 0 010 in Install Valve Covers 1 Make...

Страница 125: ...o the dowel pins of the oil filter adapter See Figure 10 59 O rings O rings O rings O rings Crankcase Adapter Figure 10 59 Installed O rings on Crankcase and Oil Filter Adapter 2 Install the oil filte...

Страница 126: ...locked 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 sm...

Страница 127: ...the adapter and secure with the M8 hex head screw Make sure the housing is flat on the crankcase and all O rings remain in position Torque the screw to 24 4 N m 216 in lb Oil Filter Housing Mounting S...

Страница 128: ...2 N m 55 in lb See Figure 10 73 4 Route the stator wires under the two molded clips in the backing shroud assembly See Figure 10 73 Mounting Screws Molded Clips Figure 10 73 Installing Stator 5 Check...

Страница 129: ...ankshaft taper and the flywheel hub are clean dry and completely free of any lubricants The presence of lubricants can cause the flywheel to be over stressed and damaged when the hex flange screw is t...

Страница 130: ...ble and snug the screws to hold them in that position Clamp Kill Lead Figure 10 81 Ignition Module Mounting Details 4 Rotate the flywheel to position the magnet directly under one ignition module 5 In...

Страница 131: ...Torque the M6 screws going into the cylinder head and crankcase to 10 7 N m 95 in lb for new holes or 7 3 N m 65 in lb for used holes See Figure 10 84 Cylinder Baffle Mounting Mounting Screws Screws...

Страница 132: ...ee Figure 10 87 3 Install the sti ener followed by the metal grass screen onto the four hex studs Secure with the four special washers and mounting screws using Loctite 243 Threadlocker on the threads...

Страница 133: ...Return Spring and Bracket Choke Choke Lever Lever Figure 10 91 Choke Return Spring and Bracket Details 3 Connect the throttle and choke linkages to the carburetor if they were previously disconnected...

Страница 134: ...4 Slide the air cleaner assembly onto the four carburetor mounting studs Align the two forward mounting holes in the base with the mounting holes bosses of the intake manifold and control bracket Atta...

Страница 135: ...ull control cable actuation See Figures 10 99 and 10 100 1 Connect the choke linkage to the appropriate hole in the choke lever and secure with the small clip Linkages Connected Here A A Throttle Cont...

Страница 136: ...t be toward the governor lever Make sure the springs do not contact the valley ba e See Figure 10 103 Governed Idle Governed Idle Spring Spring Governor Spring Governor Spring Figure 10 103 Governor S...

Страница 137: ...e the screws to 4 0 N m 35 in lb for initial installations or 2 0 N m 18 in lb for reinstallations See Figure 10 108 Mounting Locations Cylinder Shrouds Figure 10 108 Installing Cylinder Shrouds Insta...

Страница 138: ...E Make sure that both oil drain plugs are installed and torqued to the above specifications to prevent oil leakage Oil Drain Plug Location Starter Side Shown Figure 10 111 Reinstall Oil Drain Plugs 2...

Страница 139: ...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 Engine It is recommended that the engin...

Страница 140: ...10 30 Section 10 Reassembly...

Страница 141: ......

Страница 142: ...0 01 Rev A ISSUED 9 10 REVISED 3 11 FOR SALES AND SERVICE INFORMATION IN U S AND CANADA CALL 1 800 544 2444 KohlerEngines com ENGINE DIVISION KOHLER CO KOHLER WISCONSIN 53044 2011 by Kohler Co All rig...

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