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Reassembly

KohlerEngines.com

32 690 01 Rev. D

Install Flywheel and Fan

CAUTION

Damaging Crankshaft and Flywheel can

cause personal injury.

Using improper procedures can lead to broken

fragments. Broken fragments could be thrown from

engine. Always observe and use precautions and

procedures when installing flywheel.

NOTE: Before installing flywheel, make sure crankshaft

taper and flywheel hub are clean, dry, and

completely free of lubricants. Presence of

lubricants can cause flywheel to be overstressed

and damaged when screw is torqued to

specifications.

NOTE: Make sure flywheel key is installed properly in

keyway. Flywheel can become cracked or

damaged if key is not installed properly.

1. Install woodruff key into keyway of crankshaft. Make

sure key is properly seated and parallel with shaft

taper.

2. Install flywheel onto crankshaft being careful not to

shift woodruff key.

3. Install fan onto flywheel, so locating pins fit into

corresponding recesses.

4. Install fan mounting plate onto fan, aligning 4

cutouts, followed by heavy 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.).

Install Ignition Modules

1. Rotate flywheel to position magnet away from

ignition module bosses.

2. DSAI or DSAM ignition system ignition modules are

installed in similar ways with tabs out.

Fixed ignition system ignition modules are installed

with spark plug lead from module always away from

cylinder. On cylinder 1, single kill tab should be up/

towards you. On cylinder 2, single kill tab should be

down/away from you.

3. Install each ignition module to crankcase bosses

with screws. Slide modules up as far away from

flywheel as possible and snug screws to hold them

in position.

4. Rotate flywheel to position magnet directly under 1

ignition module.

Install Breather Reed and Outer Cover
Breather Cover Sealant

Sealant Bead

NOTE: RTV sealant should be allowed to cure a

minimum of 1 hour before engine is started.

1. Install breather reed, followed by retainer over

passage hole and mounting hole in crankcase. Hold

in position and secure with mounting stud. Torque

stud to 6.2 N·m (55 in. lb.) into a new, cored hole, or

4.0 N·m (35 in. lb.) into a used hole.

2. Invert breather housing (cover) and apply a 1.5 mm

(1/16 in.) bead of RTV sealant to perimeter flange of

outer housing (cover) as shown. Use Loctite

5900

or 5910.

3. Immediately install housing over mounting stud and

onto crankcase. Do not allow RTV sealant to come

in contact with breather reed, or reed sealing

surface.

4. Secure with a new sealing washer 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.

5. Attach breather hose to housing if disconnected

earlier. Make sure cover is between formed lips of

breather hose. Position hose so opposite end is

away from crankshaft.

Install Stator and Backing Plate

1. Apply pipe sealant with Teflon

(Loctite

PST

592

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 6.2 N·m (55 in. lb.).
4. Route stator leads in crankcase recess, then install

backing plate. Secure with screws. Torque screws in

a crisscross pattern to 7.3 N·m (65 in. lb.).

Содержание Courage

Страница 1: ...1 Electrical System 43 Starter System 49 Emission Compliant Systems 52 Disassembly Inspection and Service 64 Reassembly 1 32 690 01 Rev D KohlerEngines com IMPORTANT Read all safety precautions and in...

Страница 2: ...haust 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 Disco...

Страница 3: ...eaner element if not equipped with precleaner Air Cleaner Intake Every 100 Hours Replace air cleaner element if equipped with precleaner Air Cleaner Intake Change oil and filter Lubrication System Rem...

Страница 4: ...proved 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...

Страница 5: ...5 Specifications 32 690 01 Rev D KohlerEngines com Dimensions in millimeters Inch equivalents shown in Engine Dimensions...

Страница 6: ...6 Specifications KohlerEngines com 32 690 01 Rev D Dimensions in millimeters Inch equivalents shown in Engine Dimensions...

Страница 7: ...Cover Stud Outer Cover Hex Nut 10 7 N m 95 in lb into new hole 7 3 N m 65 in lb into used hole 6 2 N m 55 in lb into new hole 4 0 N m 35 in lb into used hole 1 3 N m 11 5 in lb Oil Drain Plug 13 6 N m...

Страница 8: ...g 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...

Страница 9: ...arance 0 025 0 063 mm 0 0010 0 0025 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 19 962 19 975 mm 0 7859 0 7864 in 19 959...

Страница 10: ...0 0010 in Connecting Rod Journal O D New O D Max Wear Limit Max Taper Max Out of Round 35 955 35 973 mm 1 4156 1 4163 in 35 94 mm 1 415 in 0 018 mm 0 0007 in 0 025 mm 0 0010 in T I R PTO End Crank in...

Страница 11: ...re Max 0 25 0 56 mm 0 0100 0 0224 in 0 94 mm 0 037 in Thrust Face O D 7 New Max Wear Limit 82 947 mm 3 2656 in 82 802 mm 3 2599 in Piston Thrust Face to Cylinder Bore7 Running Clearance New 0 06 0 100...

Страница 12: ...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 Ti...

Страница 13: ...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...

Страница 14: ...nt 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 be...

Страница 15: ...ing 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...

Страница 16: ...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 lis...

Страница 17: ...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 e...

Страница 18: ...s 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 i...

Страница 19: ...t 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...

Страница 20: ...base then remove base and gasket 6 Reverse procedure to reassemble components Torque nuts to 6 2 7 3 N m 55 65 in lb Torque blower housing screws to 4 0 N m 35 in lb and front HI LO screws to 2 8 N m...

Страница 21: ...uel line from inlet fitting of fuel pump b Hold line below bottom of tank Open shut off valve if equipped and observe flow Performance Minimum fuel delivery rate must be 7 5 L hr 2 gal hr with a press...

Страница 22: ...s Keihin One Barrel Carburetor Components J I H E F G D B C A A Idle Speed Screw B Idle Fuel Adjusting Screw C Carburetor Body D Idle Jet E Plug F Main Jet G Float H Shut off Solenoid Assembly I Fuel...

Страница 23: ...dle clean needle and seat and blow with compressed air 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 L...

Страница 24: ...ression holes As throttle plate opens further vacuum signal becomes great enough at venturi so main circuit begins to work Main high speed At high speeds loads engine operates on main circuit As a met...

Страница 25: ...aterial before disassembling carburetor Remove bowl retaining screws or solenoid assembly on most single cylinder engines and carefully separate fuel bowl from carburetor Do not damage fuel bowl O rin...

Страница 26: ...and choke control will have either a left side pull or a right side pull Governor Throttle Control Connections M C E I H I H A F J K B B E D C F A E G C A Left Side Pull B Cable Clamp C Speed Control...

Страница 27: ...ilure to follow these guidelines can burn out starter motor NOTE If engine develops sufficient speed to disengage starter but does not keep running a false start engine rotation must be allowed to com...

Страница 28: ...ernal throttle linkage When engine is at rest and throttle is in fast position tension of governor spring holds throttle plate open When engine is operating governor gear assembly is rotating Force ap...

Страница 29: ...urface Reinstall drain plug Torque to 13 6 N 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...

Страница 30: ...o 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 PS...

Страница 31: ...e feeler gauge Adjust gap to 0 76 mm 0 03 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 a...

Страница 32: ...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 min...

Страница 33: ...Ignition Timing 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 Driv...

Страница 34: ...engine 2 spark plugs Wiring Diagram Digital Spark Advance Ignition DSAI System R N O U A B C E D F F I H G G B B J J L K M N J W X Y Z Q P B T V V U P B J N N S AB AD AF AE AC AA A Oil SentryTM Optio...

Страница 35: ...e DSAM Ignition System W B R Z A B C E D F F H K G G J Q O N P Q S U T B X T B Q Y Y K L M I V AI AH AF AG AE AM AL AK AA AA AB AJ AC AD A Oil Sentry Optional B Green C Violet Charging D Rectifier Reg...

Страница 36: ...kill lead connection for affected module DSAI and DSAM only Test for Spark NOTE If 2 testers are available testing can be performed simultaneously for both cylinders However if only 1 tester is avail...

Страница 37: ...s in checking for timing advance Condition Possible Cause Conclusion All tests are OK but module has no spark or fails to advance Ignition Module Replace affected module Any test is BAD Ignition Modul...

Страница 38: ...ween magnet and all three legs of module Ignition module air gap is critical to proper system performance Do not attempt to set it with a business card or folded microfiche card Use feeler gauge speci...

Страница 39: ...black voltmeter lead directly to negative post of battery and test voltage again in both key positions If correct voltage is still not indicated check harness connector terminal for a good connection...

Страница 40: ...layed starting with a 6 and progressing down to 1 followed by a P pass or F fail indicating condition of part 4 If you get a negative sign instead of numerical sequence and or an F at end of test cycl...

Страница 41: ...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 connection...

Страница 42: ...gulator 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...

Страница 43: ...dition Possible Cause Conclusion Starter does not energize Battery Check specific gravity of battery If low recharge or replace battery as necessary Wiring Clean corroded connections and tighten loose...

Страница 44: ...cted position assemble inner halves of removal tool around armature shaft with retaining ring in inner groove Slide collar over inner halves to hold them in position 5 Thread center screw into removal...

Страница 45: ...stall drive end cap over drive shaft and align with cutout starter frame 3 Installing new brushes carefully remove tape holding thrust washer cup in place against brushes Do not allow thrust washer cu...

Страница 46: ...r fatigue or damage Measure length of each brush Minimum length for each brush is 7 6 mm 0 300 in Replace brushes if they are worn undersize or condition is questionable Armature Components and Detail...

Страница 47: ...cing brushes brush holder assembly a Hold starter assembly vertically on end housing and carefully position assembled brush holder assembly with supplied protective tube against end of commutator arma...

Страница 48: ...1 Use an ohmmeter set to audible or Rx2K scale and connect 2 ohmmeter leads to 2 large post terminals 2 Perform solenoid pull in coil plunger actuation test and check for continuity Ohmmeter should in...

Страница 49: ...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...

Страница 50: ...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...

Страница 51: ...let 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 scre...

Страница 52: ...plug lead s before servicing External Engine Components J X E P G W V E E F H K I L M N L O B A C D R Q S T U A Fixed Guard B Air Cleaner Access Door C Debris Screen D Blower Housing E Hose Clamp F F...

Страница 53: ...rdware from engine Remove Fuel Pump if equipped WARNING Explosive Fuel can cause fires and severe burns Do not fill fuel tank while engine is hot or running Gasoline is extremely flammable and its vap...

Страница 54: ...tach bushings to linkage following separation to avoid losing them Remove Electric Starter Motor 1 Disconnect leads from starter 2 Remove screws and starter 3 Pull out oil fill tube with lifting strap...

Страница 55: ...G L M N O K P Q A Gasket B Valve C Cylinder Head D Spring Cap E Valve Stem Seal F Valve Spring G Valve Spring Retainer H Valve Spring Keeper I Stud J Spark Plug K Guide Plate L Push Rod M Rocker Arm...

Страница 56: ...Guide I D 7 038 7 058 mm 0 2771 0 2779 in 7 038 7 058 mm 0 2771 0 2779 in E Valve Head Diameter 33 37 33 63 mm 1 3138 1 3240 in 29 37 29 63 mm 1 1563 1 1665 in F Valve Face Angle 45 45 G Valve Margin...

Страница 57: ...can be reconditioned if not too badly pitted or distorted If cracked or badly warped cylinder head should be replaced Recondition valve seat inserts following instructions provided with valve seat cu...

Страница 58: ...lywheel 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 p...

Страница 59: ...ting 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 continu...

Страница 60: ...s B A A 2 0 mm 0 0787 in B Governor Cross Shaft Seal 1 Remove retainer and washer from governor cross shaft 2 Remove cross shaft with small inner washer through inside of crankcase 3 Remove governor s...

Страница 61: ...high lacquer and varnish collect on pistons causing rings to 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 ab...

Страница 62: ...ns it will be necessary to replace crankshaft Remove Inner Breather Assembly Breather system is designed to control amount of oil in head area and still maintain necessary vacuum in crankcase When pis...

Страница 63: ...der walls following boring and or honing is very critical to a successful overhaul Machining grit left in cylinder bore can destroy an engine in less than 1 hour of operation after a rebuild Final cle...

Страница 64: ...ean and free 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...

Страница 65: ...de 1 Stagger piston rings in grooves until end gaps are 120 apart Oil ring rails should also be staggered 2 Lubricate cylinder bore piston and piston rings with engine oil Compress rings using a pisto...

Страница 66: ...5 mm 0 02725 0 02875 in Blue 0 74295 0 78105 mm 0 02925 0 03075 in Red 0 79375 0 83185 mm 0 03125 0 03275 in Yellow 0 84455 0 88265 mm 0 03325 0 03475 in Green 0 89535 0 99345 mm 0 03525 0 03675 in Gr...

Страница 67: ...st be installed within 5 minutes of sealant being applied for proper sealing to occur 4 Make sure end of governor cross shaft is lying against bottom of cylinder inside crankcase 5 Install oil pan to...

Страница 68: ...der 2 single kill tab should be down away from you 3 Install each ignition module to crankcase bosses with screws Slide modules up as far away from flywheel as possible and snug screws to hold them in...

Страница 69: ...P O Ring Q Valve Cover R Torque Sequence 5 Insert a 0 30 mm 0 012 in flat feeler gauge between magnet and ignition module Loosen screws enough to allow magnet to pull module against feeler gauge 6 Tor...

Страница 70: ...mble Cylinder Heads Prior to installation lubricate all components with engine oil paying particular attention to lip of valve stem seal valve stems and valve guides Install following items in order l...

Страница 71: ...ers Stamped Steel Valve Cover RTV Sealant A A RTV Sealant Stamped Steel Valve Cover Torque Sequence 1 5 3 2 4 NOTE Always use fresh sealant Using outdated sealant can result in leakage Refer to Tools...

Страница 72: ...ess Door 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 Nipple L O Ring M Oil Feed Tube Oil Pump Outlet N Oil Feed Tube Filter to Pan O...

Страница 73: ...rews as listed following step 2 2 Attach inner baffles including any lifting straps to cylinder head flanges and to 2 crankcase mounting bosses Lift strap should be outside outer baffle Secure with M5...

Страница 74: ...l 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...

Страница 75: ...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...

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