CV940-CV1000

Service Manual

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.

2 Safety
3 Maintenance
5 Specifications
13 Tools and Aids
16 Troubleshooting
20 Air Cleaner/Intake
21 Fuel System
27 Governor System
28 Lubrication System
30 Electrical System
38 Starter System
42 Disassembly/Inspection and Service
57 Reassembly

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Safety
SAFETY PRECAUTIONS
WARNING: A hazard that could result in death, serious injury, or substantial property damage.
CAUTION: A hazard that could result in minor personal injury or property damage.
NOTE: is used to notify people of important installation, operation, or maintenance information.

WARNING WARNING CAUTION

Explosive Fuel can cause Accidental Starts can Electrical Shock can
fires and severe burns. cause severe injury or cause injury.
Do not fill fuel tank while death. Do not touch wires while
engine is hot or running. Disconnect and ground engine is running.
Gasoline is extremely flammable spark plug lead(s) before
and its vapors can explode if servicing. CAUTION
ignited. Store gasoline only in
approved containers, in well Before working on engine or Damaging Crankshaft
ventilated, unoccupied buildings, equipment, disable engine as and Flywheel can cause
away from sparks or flames. follows: 1) Disconnect spark plug personal injury.
Spilled fuel could ignite if it comes lead(s). 2) Disconnect negative (–)
in contact with hot parts or sparks battery cable from battery.
from ignition. Never use gasoline
as a cleaning agent. WARNING Using improper procedures can
Hot Parts can cause lead to broken fragments. Broken
WARNING severe burns. fragments could be thrown from
engine. Always observe and use
Rotating Parts can cause Do not touch engine precautions and procedures when
severe injury. while operating or just installing flywheel.
Stay away while engine after stopping.
is in operation. Never operate engine with heat CAUTION
Keep hands, feet, hair, and shields or guards removed.
clothing away from all moving Failure to utilize or
parts to prevent injury. Never reassemble debris
WARNING screen as designed could
operate engine with covers,
shrouds, or guards removed. Cleaning Solvents can result in debris screen
cause severe injury or failure and serious
death. personal injury.
WARNING
Use only in well
Carbon Monoxide can ventilated areas away
cause severe nausea, from ignition sources.
fainting or death.
Carburetor cleaners and solvents
Avoid inhaling exhaust are extremely flammable. Follow
fumes. Never run engine cleaner manufacturer’s warnings
indoors or in enclosed and instructions on its proper and
spaces. safe use. Never use gasoline as a
Engine exhaust gases contain cleaning agent.
poisonous carbon monoxide.
Carbon monoxide is odorless,
colorless, and can cause death if
inhaled.

2 KohlerEngines.com 62 690 02 Rev. N

 Maintenance
MAINTENANCE INSTRUCTIONS

WARNING
Accidental Starts can cause severe injury or Before working on engine or equipment, disable engine as
death. follows: 1) Disconnect spark plug lead(s). 2) Disconnect
negative (–) battery cable from battery.
Disconnect and ground spark plug lead(s)
before servicing.
Normal maintenance, replacement or repair of emission control devices and systems may be performed by any repair
establishment or individual; however, warranty repairs must be performed by a Kohler authorized dealer.
MAINTENANCE SCHEDULE
Weekly
● Check filter minder. Air Cleaner/Intake

Every 25 Hours or Annually¹

● Service/replace low-profile precleaner. Air Cleaner/Intake

Every 100 Hours or Annually¹

● Change oil. Oil filter is recommended. Lubrication System

Every 150 Hours¹

● Replace low-profile air cleaner element. Air Cleaner/Intake
● Remove cooling shrouds and clean cooling areas. Air Cleaner/Intake

Every 150 Hours

● Check heavy-duty air cleaner element. Air Cleaner/Intake
● Replace fuel filter.
● Check oil cooler fins, clean as necessary. Lubrication System

Every 200 Hours

● Change oil filter. Lubrication System

Every 300 Hours

● Replace heavy-duty air cleaner element. Air Cleaner/Intake

Every 300 Hours3

● Change oil and filter (KOHLER PRO 10W-50 oil and KOHLER PRO filter only). Lubrication System

Every 500 Hours or Annually1

● Replace spark plugs and set gap. Electrical System

Every 500 Hours²

● Have crankshaft splines lubricated.

Every 600 Hours

● Replace heavy-duty inner air cleaner element. Air Cleaner/Intake
1
Perform these procedures more frequently under severe, dusty, dirty conditions.
2
Have a Kohler authorized dealer perform this service.
3
Option only if using KOHLER® PRO oil and PRO filter.

REPAIRS/SERVICE PARTS
Kohler genuine service parts can be purchased from Kohler authorized dealers. To find a local Kohler authorized
dealer visit KohlerEngines.com or call 1-800-544-2444 (U.S. and Canada).

62 690 02 Rev. N KohlerEngines.com 3

Maintenance
OIL RECOMMENDATIONS STORAGE
All-season KOHLER® PRO 10W-50 Synthetic Oil is the If engine will be out of service for 2 months or more
ideal oil for KOHLER engines. It is specifically formulated follow procedure below.
to extend the oil and oil filter change interval to 300
Hours when paired with a KOHLER PRO Extended Life 1. Add Kohler PRO Series fuel treatment or equivalent
Oil Filter. to fuel tank. Run engine 2-3 minutes to get stabilized
fuel into fuel system (failures due to untreated fuel
300-Hour oil and oil filter change intervals are exclusive are not warrantable).
to and only authorized on KOHLER engines that utilize 2. Change oil while engine is still warm from operation
both the KOHLER PRO 10W-50 Synthetic Oil and (NOT required if using KOHLER PRO 10W-50
KOHLER PRO Extended Life Oil Filter. Alternative full-synthetic oil). Remove spark plug(s) and pour
engine oils and oil filters may be used with KOHLER about 1 oz. of engine oil into cylinder(s). Replace
engines but require 100-Hour oil and 200-Hour oil filter spark plug(s) and crank engine slowly to distribute
change intervals for proper maintenance. Oil must be oil.
API (American Petroleum Institute) service class SJ or 3. Disconnect negative (-) battery cable.
higher. Select viscosity based on air temperature at time
of operation as shown below. 4. Store engine in a clean, dry place.

KOHLER PRO 10W-50

20W-50

10W-30

SAE 30
5W-30

°F -20 0 20 32 40 50 60 80 100
°C -30 -20 -10 0 10 20 30 40

FUEL RECOMMENDATIONS

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 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.

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% MTBE by volume) are
approved.
● Do not add oil to gasoline.
● Do not overfill fuel tank.
● Do not use gasoline older than 30 days.

4 KohlerEngines.com 62 690 02 Rev. N

 Specifications
Engine Dimensions
Dimensions in millimeters.
Inch equivalents shown in [ ].

(Optional Guard)

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Specifications

ENGINE IDENTIFICATION NUMBERS

Kohler engine identification numbers (model, specification and serial) should be referenced for efficient repair,
ordering correct parts, and engine replacement.

Model . . . . . . . . . . . . . . . . . . . . . CV940
Command Engine
Vertical Shaft
Numerical Designation
Specification . . . . . . . . . . . . . . . CV940-0001
Serial . . . . . . . . . . . . . . . . . . . . . 5023500328
Year Manufactured Code Factory Code
Code Year
50 2020
51 2021
52 2022

GENERAL SPECIFICATIONS4,7 CV940 CV960 CV980 CV1000

Bore 90 mm (3.54 in.)
Stroke 78.5 mm (3.1 in.)
Displacement 999 cc (61 cu. in.)
Oil Capacity (refill) 1.9-2.6 L (2.0-2.7 U.S. qt.)
Maximum Angle of Operation (@ full oil level)5 25°

TORQUE SPECIFICATIONS4,6 CV940 CV960 CV980 CV1000

Blower Housing and Sheet Metal

M6 Screw
New, Untapped Hole (casting) 10.7 N·m (95 in. lb.)
Used, Tapped Hole (casting) 7.3 N·m (65 in. lb.)
New, Extruded Hole (sheet metal) 2.5 N·m (22 in. lb.)
Used, Extruded Hole (sheet metal) 2.0 N·m (18 in. lb.)
Mounting Clip (valley baffle) 2.5 N·m (22 in. lb.)

Carburetor, Intake Manifold, and Air Cleaner

Intake Manifold Mounting Fastener (torque in 2 increments) first to 16.9 N·m (150 in. lb.)
finally to 22.6 N·m (200 in. lb.)
Carburetor/Air Cleaner Mounting Nut 11.3 N·m (100 in. lb.)
Air Cleaner Mounting Screw (into intake manifold) 11.3 N·m (100 in. lb.)
Fuel Bowl Screw 2.5 ± 0.3 N·m (22 ± 2.3 in. lb.)

Connecting Rod
Cap Fastener (torque in increments) 11.6 N·m (103 in. lb.)

Control Bracket
Mounting Screw (into intake manifold from air cleaner) 10.2 N·m (90 in. lb.)

Crankcase
Breather Cover Fastener 12.4 N·m (110 in. lb.)
Oil Drain Plug 21.4 N·m (16 ft. lb.)
Dipstick Tube Screw 7.7 N·m (68 in. lb.)
4
Values are in Metric units. Values in parentheses are English equivalents.
5
Exceeding maximum angle of operation may cause engine damage from insufficient lubrication.
6
Lubricate threads with engine oil prior to assembly.
7
Any and all horsepower (hp) references by Kohler are Certified Power Ratings and per SAE J1940 & J1995 hp
standards. Details on Certified Power Ratings can be found at KohlerEngines.com.
6 KohlerEngines.com 62 690 02 Rev. N
 Specifications

TORQUE SPECIFICATIONS4,6 CV940 CV960 CV980 CV1000

Cylinder Head
Fastener (torque in 2 increments)
Head Bolt first to 23.7 N·m (210 in. lb.)
finally to 46.9 N·m (415 in. lb.)
Pipe Plug 3/4 in. 28.5 N·m (252 in. lb.)
Rocker Arm Stud (AVT) 11.3 N·m (100 in. lb.)
Setscrew, AVT pivot locking 7.7 N·m (69 in. lb.)
Rocker Arm Screw (Non-AVT)
15.5 N·m (137 in. lb.)

11.9 N·m (105 in. lb.)

Debris Screen
Hex Stud 21.5 N·m (190 in. lb.)
Mounting Screw - Hex Flange Screw 20.3 N·m (180 in. lb.)
Mounting Screw - Button Head Cap Screw 9.9 N·m (88 in. lb.)

Fan/Flywheel
Fan Fastener 10.4 N·m (92 in. lb.)
Flywheel Retaining Screw 69.8 N·m (51 ft. lb.)

Fuel Pump
Screw 7.9 N·m (70 in. lb.)

Governor
Lever Nut 7.1 N·m (63 in. lb.)
Yoke Mounting Screw 2.2 N·m (20 in. lb.)

Ignition
Spark Plug 27 N·m (20 ft. lb.)
Module Fastener 9.7 N·m (86 in. lb.) into new holes
4.1 N·m (37 in. lb.) into used holes
Rectifier-Regulator Fastener 2.5 N·m (22 in. lb.)

Lifter Feed Chamber Cover

Screw 7.7 N·m (68 in. lb.)

Muffler
Retaining Nut 24.4 N·m (216 in. lb.)
Screw, intermittent bracket (into weld nut) 13.6 N·m (120 in. lb.)
M6 Screw 9.9 N·m (88 in. lb.)
M8 Screw 24.4 N·m (216 in. lb.)

Oil Cooler
Mounting Screw 2.3 N·m (21 in. lb.)

Oil Filter Adapter/Housing

Mounting Screw 23.7 N·m (210 in. lb.)
Oil Filter Nipple 17.8 N·m (158 in. lb.)

Oil Pan
Fastener 25.6 N·m (227 in. lb.)
4
Values are in Metric units. Values in parentheses are English equivalents.
6
Lubricate threads with engine oil prior to assembly.
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Specifications

TORQUE SPECIFICATIONS4,6 CV940 CV960 CV980 CV1000

Oil Pickup Screen

Mounting Screw 11.3 N·m (100 in. lb.) into a new hole
7.7 N·m (68 in. lb.) into a used hole

Oil Pump
Mounting Screw 9.9 N·m (88 in. lb.)

Oil SentryTM
Pressure Switch 10.7 N·m (95 in. lb.)

Solenoid (starter)
Mounting Hardware 4.0-6.0 N·m (35-53 in. lb.)
Nut, Positive (+) Brush Lead 8.0-11.0 N·m (71-97 in. lb.)

Starter Assembly
Thru Bolt 5.6-9.0 N·m (49-79 in. lb.)
Mounting Screw 16.0 N·m (142 in. lb.)
Brush Holder Mounting Screw 2.5-3.3 N·m (22-29 in. lb.)

Stator
Mounting Screw 9.3 N·m (82 in. lb.)

Throttle/Choke Control Bracket

Fastener 10.2 N·m (90 in. lb.)

Valve Cover
Aluminum Valve Cover Fastener
Into New Head Torque screw to 26 N·m (230 in. lb.) to ensure
seal seats in valve cover groove. Back off
screw to zero and then torque screw again
to 18.1 N·m (160 in. lb.).
Into Used Head Torque screw to 16.4 N·m (145 in. lb.) to
ensure seal seats in valve cover groove.
Back off screw to zero and then torque
screw again to 16.4 N·m (145 in. lb.).
Plastic Valve Cover Fastener 13.6 N·m (120 in. lb.)

CLEARANCE SPECIFICATIONS4 CV940 CV960 CV980 CV1000

Camshaft
End Play 0.3/1.3 mm (0.011/0.051 in.)
Running Clearance 0.025/0.063 mm (0.0010/0.0025 in.)
Bore I.D.
New 20.000/20.025 mm (0.7874/0.7884 in.)
Max. Wear Limit 20.038 mm (0.7889 in.)
Bearing Surface O.D.
New 19.962/19.975 mm (0.7859/0.7864 in.)
Max. Wear Limit 19.959 mm (0.7858 in.)
Cam Lobe Profile (minimum dimension, measured from base circle
to top of lobe)
Exhaust 35 mm (1.3779 in.)
Intake 34.1 mm 35 mm (1.3779 in.)
(1.3425 in.)
4
Values are in Metric units. Values in parentheses are English equivalents.
6
Lubricate threads with engine oil prior to assembly.
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 Specifications

CLEARANCE SPECIFICATIONS4 CV940 CV960 CV980 CV1000

Connecting Rod
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 mm (0.0012/0.0022 in.)
Max. Wear Limit 0.070 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 19.015/19.023 mm (0.7486/0.7489 in.)
Max. Wear Limit 19.036 mm (0.7494 in.)

Crankcase
Governor Cross Shaft Bore I.D.
New 8.025/8.050 mm (0.3159/0.3169 in.)
Max. Wear Limit 8.088 mm (0.3184 in.)

Crankshaft
End Play (free) 0.30/1.50 mm (0.011/0.059 in.)
Bore (in crankcase)
New, Without Main Bearing 50.00/50.025 mm (1.9685/1.969 in.)
With Main Bearing Installed 45.040/45.145 mm (1.7732/1.7773 in.)
Max. Wear Limit 45.158 mm (1.7778 in.)
Crankshaft to Sleeve Bearing (crankcase) Running Clearance
New 0.040/0.167 mm (0.0015/0.0065 in.)
Bore (in oil pan)
New, Without Bearing 50.025/50.00 mm (1.9694/1.9685 in.)
Crankshaft to Sleeve Bearing (in oil pan) Running Clearance
New 0.040/0.167 mm (0.0015/0.0065 in.)
Oil Pan End Main Bearing Journal
O.D. - New 44.978/45.00 mm (1.770/1.771 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 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.)
T.I.R.
PTO End, Crank in Engine 0.279 mm (0.0110 in.)
Entire Crank, in V-Blocks 0.10 mm (0.0039 in.)
Flywheel End Main Bearing Journal
O.D. - New 44.978/45.00 mm (1.770/1.771 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.)

Crankshaft Bearing (flywheel/PTO)

New (installed) 45.040/45.145 mm (1.773.1.777 in.)
Max. Wear Limit 45.158 mm

4
Values are in Metric units. Values in parentheses are English equivalents.
62 690 02 Rev. N KohlerEngines.com 9
Specifications

CLEARANCE SPECIFICATIONS4 CV940 CV960 CV980 CV1000

Cylinder Bore
I.D.
New 90.000/90.025 mm (3.543/3.544 in.)
Max. Wear Limit 90.075 mm (3.546 in.)
Max. Taper 0.013 mm (0.00051 in.)
Max. Out-of-Round 0.013 mm (0.00051 in.)

Cylinder Head
Max. Out-of-Flatness 0.076 mm (0.003 in.)

Governor
Governor Cross Shaft-to-Crankcase Running Clearance 0.025/0.087 mm (0.0009/0.0034 in.)
Cross Shaft O.D. 7.963/8.000 mm (0.3135/.3149 in.)
New 7.936 mm (0.3124 in.)
Max. Wear Limit
Governor Gear Shaft-to-Governor Gear Running Clearance 0.070/0.160 mm (0.0027/0.0063 in.)
Gear Shaft O.D.
New 5.990/6.000 mm (0.2358/0.2362 in.)
Max. Wear Limit 5.977 mm (0.2353 in.)

Ignition
Spark Plug Gap 0.76 mm (0.030 in.)
Module Air Gap 0.28/0.33 mm (0.011/0.013 in.)

Piston, Piston Rings, and Piston Pin

Piston Style A
Piston-to-Piston Pin Running Clearance 0.006/0.018 mm (0.0002/0.0007 in.)
Pin Bore I.D.
New 19.006/17.013 mm (0.7482/0.7485 in.)
Max. Wear Limit 19.025 mm (0.7490 in.)
Pin O.D.
New 18.995/19.000 mm (0.7478/0.7480 in.)
Max. Wear Limit 18.994 mm (0.7478 in.)
Top Compression Ring-to-Groove Side Clearance 0.04/0.08 mm (0.0015/0.0031 in.)
Middle Compression Ring-to-Groove Side Clearance 0.04/0.08 mm (0.0015/0.0031 in.)
Oil Control Ring-to-Groove Side Clearance 0.03/0.19 mm (0.0011/0.0074 in.)
Top and Middle Compression Ring End Gap
New Bore 0.30/0.55 mm (0.011/0.021 in.)
Used Bore (max.) 0.94 mm (0.037 in.)
Thrust Face O.D.8
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 Bore8 Running Clearance
New 0.033/0.071 mm (0.0013/0.0028 in.)

4
Values are in Metric units. Values in parentheses are English equivalents.
8
Measure 11 mm (0.4331 in.) above bottom of piston skirt at right angles to piston pin.
10 KohlerEngines.com 62 690 02 Rev. N
 Specifications

CLEARANCE SPECIFICATIONS4 CV940 CV960 CV980 CV1000

Piston, Piston Rings, and Piston Pin (continued)

Piston Style B
Piston-to-Piston Pin Running Clearance 0.006/0.017 mm (0.0002/0.0007 in.)
Pin Bore I.D.
New 20.006/20.012 mm (0.7876/0.7879 in.)
Max. Wear Limit 20.025 mm (0.7884 in.)
Pin O.D.
New 19.995/20.000 mm (0.7872/0.7874 in.)
Max. Wear Limit 19.994 mm (0.7872 in.)
Top Compression Ring-to-Groove Side Clearance 0.030/0.070 mm (0.001/0.0026 in.)
Middle Compression Ring-to-Groove Side Clearance 0.030/0.070 mm (0.001/0.0026 in.)
Oil Control Ring-to-Groove Side Clearance 0.060/0.190 mm (0.0022/0.0073 in.)
Top Compression Ring End Gap
New Bore 0.125/0.304 mm (0.0049/0.0120 in.)
Used Bore (max.) 0.515 mm (0.0203 in.)
Middle Compression Ring End Gap
New Bore 0.900/1.179 mm (0.0345/0.0464 in.)
Used Bore (max.) 1.432 mm (0.0564 in.)
Thrust Face O.D.8
New 89.972 mm (3.5422 in.)
Max. Wear Limit 89.827 mm (3.5365 in.)
Piston Thrust Face-to-Cylinder Bore8 Running Clearance
New 0.021/0.060 mm (0.0008/0.00236 in.)

Valves and Valve Lifters

Hydraulic Valve Lifter to Crankcase Running Clearance 0.012/0.050 mm (0.0004/0.0019 in.)
Intake Valve Stem-to-Valve Guide Running Clearance 0.038/0.076 mm (0.0015/0.0030 in.)
Exhaust Valve Stem-to-Valve Guide Running Clearance 0.050/0.088 mm (0.0020/0.0035 in.)
Intake Valve Guide I.D.
New 7.038/7.058 mm (0.2771/0.2779 in.)
Max. Wear Limit 7.135 mm (0.2809 in.)
Exhaust Valve Guide I.D.
New 7.038/7.058 mm (0.2771/0.2779 in.)
Max. Wear Limit 7.159 mm (0.2819 in.)
Guide Reamer Size
Standard 7.048 mm (0.2775 in.)
0.25 mm O.S. 7.298 mm (0.2873 in.)
Nominal Valve Face Angle 45°

4
Values are in Metric units. Values in parentheses are English equivalents.
8
Measure 11 mm (0.4331 in.) above bottom of piston skirt at right angles to piston pin.
62 690 02 Rev. N KohlerEngines.com 11
Specifications
GENERAL TORQUE VALUES

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) 39.6 (350) 17.0 (150)
5/16-24 18.7 (165) 30.5 (270) — —
3/8-16 29.4 (260) — — —
3/8-24 33.9 (300) — — —

Tightening Torque: N·m (ft. lb.) ± 20%

5/16-24 — — 40.7 (30) —
3/8-16 — 47.5 (35) 67.8 (50) —
3/8-24 — 54.2 (40) 81.4 (60) —
7/16-14 47.5 (35) 74.6 (55) 108.5 (80) —
7/16-20 61.0 (45) 101.7 (75) 142.5 (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) —
5/8-11 149.5 (110) 244.1 (180) 352.6 (260) —
5/8-18 189.8 (140) 311.9 (230) 447.5 (330) —
3/4-10 199.3 (147) 332.2 (245) 474.6 (350) —
3/4-16 271.2 (200) 440.7 (325) 637.3 (470) —

Metric Fastener Torque Recommendations for Standard Applications

Property Class Noncritical
Fasteners
Size 4.8 5.8 8.8 10.9 12.9
Into Aluminum
Tightening Torque: N·m (in. lb.) ± 10%
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) 40.7 (360) 17.0 (150)

Tightening Torque: N·m (ft. lb.) ± 10%

M10 21.7 (16) 27.1 (20) 47.5 (35) 66.4 (49) 81.4 (60) 33.9 (25)
M12 36.6 (27) 47.5 (35) 82.7 (61) 116.6 (86) 139.7 (103) 61.0 (45)
M14 58.3 (43) 76.4 (56) 131.5 (97) 184.4 (136) 219.7 (162) 94.9 (70)

Torque Conversions
N·m = in. lb. x 0.113 in. lb. = N·m x 8.85
N·m = ft. lb. x 1.356 ft. lb. = N·m x 0.737

12 KohlerEngines.com 62 690 02 Rev. N

 Tools and Aids

Certain quality tools are designed to help you perform specific disassembly, repair, and reassembly procedures. By
using these tools, you can properly service engines easier, faster, and safer! In addition, you’ll increase your service
capabilities and customer satisfaction by decreasing engine downtime.
Here is a list of tools and their source.
NOTE: Not all tools listed are required to service this engine.
SEPARATE TOOL SUPPLIERS
Kohler Tools SE Tools Design Technology Inc.
Contact your local Kohler source of 415 Howard St. 768 Burr Oak Drive
supply. Lapeer, MI 48446 Westmont, IL 60559
Phone 810-664-2981 Phone 630-920-1300
Toll Free 800-664-2981 Fax 630-920-0011
Fax 810-664-8181

TOOLS
Description Source/Part No.
Alcohol Content Tester Kohler 25 455 11-S
For testing alcohol content (%) in reformulated/oxygenated fuels.
Camshaft Endplay Plate SE Tools KLR-82405
For checking camshaft endplay.
Camshaft Seal Protector (Aegis) SE Tools KLR-82417
For protecting seal during camshaft installation.
Dual Gauge Cylinder Leakdown Tester Kohler 25 761 46-S
For checking combustion retention and if cylinder, piston, rings, or valves are worn.
Individual component available: Design Technology Inc.
Adapter 12 mm x 14 mm (Required for leakdown test on XT-6 engines) DTI-731-03
Dealer Tool Kit Kohler 25 761 39-S
Complete kit of Kohler required tools.
Components of 25 761 39-S
Ignition System Tester Kohler 25 455 01-S
Dual Gauge Cylinder Leakdown Test Tool Kohler 25 761 46-S
Oil Pressure Test Kit Kohler 25 761 06-S
Digital Vacuum/Pressure Tester Kohler 25 455 22-S
Digital Vacuum/Pressure Tester Kohler 25 455 22-S
For checking crankcase vacuum.
Individual component available: Design Technology Inc.
Rubber Adapter Plug DTI-721-10
EFI Service Kit Kohler 24 761 01-S
For troubleshooting and setting up an EFI engine.
Components of 24 761 01-S Design Technology Inc.
Fuel Pressure Tester DTI-019
Noid Light DTI-021
90° Adapter DTI-023
Code Plug, Red Wire DTI-027
Code Plug, Blue Wire DTI-029
Code Plug, Yellow Wire DTI-028
Can Bus Reset Tool, Green Wire DTI-030
Shrader Valve Adapter Hose DTI-037
Wire Probe Set (2 pieces regular wire with clip; 1 piece fused wire) DTI-031
Hose Removal Tool, Dual Size/End (also sold as individual Kohler tool) DTI-033
K-Line Adapter Jumper Lead Wiring Harness Kohler 25 176 23-S
KOHLER® Diagnostic System (KDS) Gen 2 Kohler 25 761 50-S
For Laptop or Desktop PC.
Components of 25 761 50-S
Engine Communication Module Kohler 25 761 47-S
7 Pin to DB9 Cable Kohler 25 761 48-S
USB Module to PC Cable Kohler 25 761 49-S
7 Pin to 4 Pin Adapter Kohler 25 761 53-S
Mobile KDS (Wireless) Module Kohler 25 761 45-S
For mobile Android or iOS EFI diagnostics.
Individual component available:
Wireless Diagnostic System Interface Cable Kohler 25 761 44-S

62 690 02 Rev. N KohlerEngines.com 13

Tools and Aids

TOOLS
Description Source/Part No.
Flywheel Puller SE Tools KLR-82408
For properly removing flywheel from engine.
Flywheel Anchor Bolts, Washers, Nuts Tool Kohler 25 086 753-S
Used with Flywheel Puller for properly removing flywheel from 5400 Series engine.
Hose Removal Tool, Dual Size/End (also available in EFI Service Kit) Kohler 25 455 20-S
Used to properly remove fuel hose from engine components.
Ignition System Tester Kohler 25 455 01-S
For testing output on all systems, including CD.
Inductive Tachometer (Digital) Design Technology Inc.
For checking operating speed (RPM) of an engine. DTI-110
Oil Pressure Test Kit Kohler 25 761 06-S
For testing/verifying oil pressure on pressure lubricated engines.
Rectifier-Regulator Tester (120 volt current) Kohler 25 761 20-S
Rectifier-Regulator Tester (240 volt current) Kohler 25 761 41-S
For testing rectifier-regulators.
Components of 25 761 20-S and 25 761 41-S Design Technology Inc.
CS-PRO Regulator Test Harness DTI-031R
Special Regulator Test Harness with Diode DTI-033R
Spark Advance Module (SAM) Tester Kohler 25 761 40-S
For testing SAM (ASAM and DSAM) on engines with SMART-SPARK™.
Starter Servicing Kit (All Starters) SE Tools KLR-82411
For removing and reinstalling drive retaining rings and brushes.
Individual component available:
Starter Brush Holding Tool (Solenoid Shift) SE Tools KLR-82416
Stepper Motor Controller Tool Kohler 25 455 21-S
For testing operation of stepper motor/Digital Linear Actuator (DLA).
Jumper Lead Tool Kohler 25 518 43-S
For use with Stepper Motor Controller Tool to test rotary stepper motor.
Triad/OHC Timing Tool Set Kohler 28 761 01-S
For holding cam gears and crankshaft in timed position while installing timing belt.
Valve Guide Reamer (K and M Series) Design Technology Inc.
For properly sizing valve guides after installation. DTI-K828
Valve Guide Reamer O.S. (Command Series) Kohler 25 455 12-S
For reaming worn valve guides to accept replacement oversize valves. Can be used
in low-speed drill press or with handle below for hand reaming.
Reamer Handle Design Technology Inc.
For hand reaming using Kohler 25 455 12-S reamer. DTI-K830

AIDS
Description Source/Part No.
Camshaft Lubricant (Valspar ZZ613) Kohler 25 357 14-S
Dielectric Grease Loctite® 51360
Kohler Electric Starter Drive Lubricant (Inertia Drive) Kohler 52 357 01-S
P80 Emulsion Lubricant Kohler 25 357 80-S
RTV Silicone Sealant
Loctite® 5900® Heavy Body in 4 oz. aerosol dispenser. Kohler 25 597 07-S
Only oxime-based, oil resistant RTV sealants, such as those listed, are approved Loctite® 5910®
for use. Permatex® the Right Stuff® 1 Minute Gasket™ or Loctite® Nos. 5900® or Loctite® Ultra Black 598™
5910® are recommended for best sealing characteristics. Loctite® Ultra Blue 587™
Loctite® Ultra Copper 5920™
Permatex® the Right Stuff® 1
Minute Gasket™
Spline Drive Lubricant Kohler 25 357 12-S

14 KohlerEngines.com 62 690 02 Rev. N

 Tools and Aids

FLYWHEEL HOLDING TOOL ROCKER ARM/CRANKSHAFT TOOL

A flywheel holding tool can be made out of an old junk A spanner wrench to lift rocker arms or turn crankshaft
flywheel ring gear and used in place of a strap wrench. may be made out of an old junk connecting rod.
1. Using an abrasive cut-off wheel, cut out a six tooth 1. Find a used connecting rod from a 10 HP or larger
segment of ring gear as shown. engine. Remove and discard rod cap.
2. Grind off any burrs or sharp edges. 2. Remove studs of a Posi-Lock rod or grind off
3. Invert segment and place it between ignition bosses aligning steps of a Command rod, so joint surface is
on crankcase so tool teeth engage flywheel ring flat.
gear teeth. Bosses will lock tool and flywheel in 3. Find a 1 in. long capscrew with correct thread size to
position for loosening, tightening, or removing with a match threads in connecting rod.
puller. 4. Use a flat washer with correct I.D. to slip on
capscrew and approximately 1 in. O.D. Assemble
capscrew and washer to joint surface of rod.

62 690 02 Rev. N KohlerEngines.com 15

Troubleshooting

TROUBLESHOOTING GUIDE
When troubles occur, be sure 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 Cranks But Will Not Start Engine Will Not Crank
● Battery connected backwards. ● Battery is discharged.
● Blown fuse. ● Faulty electric starter or solenoid.
● Carburetor solenoid malfunction. ● Faulty key switch or ignition switch.
● Choke not closing. ● Interlock switch is engaged or faulty.
● Clogged fuel line or fuel filter. ● Loose wires or connections that intermittently ground
● Diode in wiring harness failed in open circuit mode. ignition kill circuit.
● DSAI or DSAM malfunction. ● Pawls not engaging in drive cup.
● Empty fuel tank. ● Seized internal engine components.
● Faulty electronic control unit.
● Faulty ignition coil(s). Engine Runs But Misses
● Faulty spark plug(s). ● Carburetor adjusted incorrectly.
● Fuel pump malfunction-vacuum hose clogged or ● Engine overheated.
leaking. ● Faulty spark plug(s).
● Fuel shut-off valve closed. ● Ignition module(s) faulty or improperly gapped.
● Ignition module(s) faulty or improperly gapped. ● Incorrect crankshaft position sensor air gap.
● Insufficient voltage to electronic control unit. ● Interlock switch is engaged or faulty.
● Interlock switch is engaged or faulty. ● Loose wires or connections that intermittently ground
● Key switch or kill switch in OFF position. ignition kill circuit.
● Low oil level. ● Quality of fuel (dirt, water, stale, mixture).
● Quality of fuel (dirt, water, stale, mixture). ● Spark plug lead(s) disconnected.
● SMART-SPARKTM malfunction. ● Spark plug lead boot loose on plug.
● Spark plug lead(s) disconnected. ● Spark plug lead loose.
Engine Starts But Does Not Keep Running Engine Will Not Idle
● Faulty carburetor. ● Engine overheated.
● Faulty cylinder head gasket. ● Faulty spark plug(s).
● Faulty or misadjusted choke or throttle controls. ● Idle fuel adjusting needle(s) improperly set.
● Fuel pump malfunction-vacuum hose clogged or ● Idle speed adjusting screw improperly set.
leaking. ● Inadequate fuel supply.
● Intake system leak. ● Low compression.
● Loose wires or connections that intermittently ground ● Quality of fuel (dirt, water, stale, mixture).
ignition kill circuit. ● Restricted fuel tank cap vent.
● Quality of fuel (dirt, water, stale, mixture).
● Restricted fuel tank cap vent. Engine Overheats
● Cooling fan broken.
Engine Starts Hard ● Excessive engine load.
● Clogged fuel line or fuel filter. ● Fan belt failed/off.
● Engine overheated. ● Faulty carburetor.
● Faulty ACR mechanism. ● High crankcase oil level.
● Faulty or misadjusted choke or throttle controls. ● Lean fuel mixture.
● Faulty spark plug(s). ● Low cooling system fluid level.
● Flywheel key sheared. ● Low crankcase oil level.
● Fuel pump malfunction-vacuum hose clogged or ● Radiator, and/or cooling system components clogged,
leaking. restricted, or leaking.
● Interlock switch is engaged or faulty. ● Water pump belt failed/broken.
● Loose wires or connections that intermittently ground ● Water pump malfunction.
ignition kill circuit.
● Low compression. Engine Knocks
● Quality of fuel (dirt, water, stale, mixture). ● Excessive engine load.
● Weak spark. ● Hydraulic lifter malfunction.
● Incorrect oil viscosity/type.
● Internal wear or damage.
● Low crankcase oil level.
● Quality of fuel (dirt, water, stale, mixture).

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 Troubleshooting

Engine Loses Power EXTERNAL ENGINE INSPECTION

● Dirty air cleaner element. NOTE: It is good practice to drain oil at a location away
● Engine overheated. from workbench. Be sure to allow ample time for
● Excessive engine load. complete drainage.
● Restricted exhaust. Before cleaning or disassembling engine, make a
● Faulty spark plug(s). thorough inspection of its external appearance and
● High crankcase oil level. condition. This inspection can give clues to what
● Incorrect governor setting. might be found inside engines (and cause) when it is
● Low battery. disassembled.
● Low compression. ● Check for buildup of dirt and debris on crankcase,
● Low crankcase oil level. cooling fins, grass screen, and other external surfaces.
● Quality of fuel (dirt, water, stale, mixture). Dirt or debris on these areas can cause overheating.
Engine Uses Excessive Amount of Oil ● Check for obvious fuel and oil leaks, and damaged
components. Excessive oil leakage can indicate a
● Loose or improperly torqued fasteners. clogged or inoperative breather, worn or damaged
● Blown head gasket/overheated. seals or gaskets, or loose fasteners.
● Breather reed broken. ● Check air cleaner cover and base for damage or
● Clogged, broken, or inoperative crankcase breather. indications of improper fit and seal.
● Crankcase overfilled. ● Check air cleaner element. Look for holes, tears,
● Incorrect oil viscosity/type. cracked or damaged sealing surfaces, or other
● Worn cylinder bore. damage that could allow unfiltered air into engine. A
● Worn or broken piston rings. dirty or clogged element could indicate insufficient or
● Worn valve stems/valve guides. improper maintenance.
Oil Leaks from Oil Seals, Gaskets ● Check carburetor throat for dirt. Dirt in throat is further
indication that air cleaner was not functioning properly.
● Breather reed broken. ● Check if oil level is within operating range on dipstick.
● Clogged, broken, or inoperative crankcase breather. If it is above, sniff for gasoline odor.
● Loose or improperly torqued fasteners. ● Check condition of oil. Drain oil into a container; it
● Piston blow by, or leaky valves. should flow freely. Check for metal chips and other
● Restricted exhaust. foreign particles.

Sludge is a natural by-product of combustion; a small

accumulation is normal. Excessive sludge formation
could indicate over rich fuel settings, weak ignition,
overextended oil change interval or wrong weight or
type of oil was used.

CLEANING ENGINE
WARNING
Cleaning Solvents can cause severe injury or
death.
Use only in well ventilated areas away from
ignition sources.
Carburetor cleaners and solvents are extremely
flammable. Follow cleaner manufacturer’s warnings
and instructions on its proper and safe use. Never use
gasoline as a cleaning agent.

After inspecting external condition of engine, clean

engine thoroughly before disassembly. Clean individual
components 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.

62 690 02 Rev. N KohlerEngines.com 17

Troubleshooting

CRANKCASE VACUUM TEST

WARNING WARNING
Carbon Monoxide can cause severe nausea,
fainting or death. Rotating Parts can cause severe injury.
Avoid inhaling exhaust fumes. Never run Stay away while engine is in operation.
engine indoors or in enclosed spaces.
Engine exhaust gases contain poisonous carbon Keep hands, feet, hair, and clothing away from all
monoxide. Carbon monoxide is odorless, colorless, moving parts to prevent injury. Never operate engine
and can cause death if inhaled. with covers, shrouds, or guards removed.

A partial vacuum should be present in crankcase when engine is operating. Pressure in crankcase (normally caused
by a clogged or improperly assembled breather) can cause oil to be forced out at oil seals, gaskets, or other available
spots.
Crankcase vacuum is best measured with either a water manometer or a vacuum gauge. Complete instructions are
provided in kits.
To test crankcase vacuum with manometer: To test crankcase vacuum with vacuum/pressure gauge:
1. Insert rubber stopper into oil fill hole. Be sure pinch 1. Remove dipstick or oil fill plug/cap.
clamp is installed on hose and use tapered adapters 2. Install adapter into oil fill/dipstick tube opening,
to connect hose between stopper and one upside down over end of a small diameter dipstick
manometer tube. Leave other tube open to tube, or directly into engine if a tube is not used.
atmosphere. Check that water level in manometer is Insert barbed gauge fitting into hole in stopper.
at 0 line. Make sure pinch clamp is closed.
3. Run engine and observe gauge reading.
2. Start engine and run no-load high speed.
Analog tester–needle movement to left of 0 is a
3. Open clamp and note water level in tube. vacuum, and movement to right indicates a pressure.
Level in engine side should be a minimum of Digital tester–depress test button on top of tester.
10.2 cm (4 in.) above level in open side.
Crankcase vacuum should be a minimum of 10.2 cm
If level in engine side is less than specified (low/no (4 in.) of water. If reading is below specification, or if
vacuum), or level in engine side is lower than level in pressure is present, check table below for possible
open side (pressure), check for conditions in table causes and conclusions.
below.
4. Close pinch clamp before stopping engine.

Condition Conclusion
Crankcase breather clogged or inoperative. NOTE: If breather is integral part of valve cover and
cannot be serviced separately, replace valve
cover and recheck pressure.
Disassemble breather, clean parts thoroughly, check
sealing surfaces for flatness, reassemble, and recheck
pressure.
Seals and/or gaskets leaking. Loose or improperly torque Replace all worn or damaged seals and gaskets. Make
fasteners. sure all fasteners are tightened securely. Use appropriate
torque valves and sequences when necessary.
Piston blow by or leaky valves (confirm by inspecting Recondition piston, rings, cylinder bore, valves and
components). valves guides.
Restricted exhaust. Check exhaust screen/spark arrestor (if equipped). Clean
or replace as needed. Repair or replace any other
damaged/restricted muffler or exhaust system parts.

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 Troubleshooting

COMPRESSION TEST
For Command Twins:
A compression test is best performed on a warm engine. Clean any dirt or debris away from base of spark plug(s)
before removing them. Be sure choke is off, and throttle is wide open during test. Compression should be at least 160
psi and should not vary more than 15% between cylinders.
All other models:
These engines are equipped with an automatic compression release (ACR) mechanism. It is difficult to obtain an
accurate compression reading because of ACR mechanism. As an alternative, use cylinder leakdown test described
below.
CYLINDER LEAKDOWN TEST
A cylinder leakdown test can be a valuable alternative to a compression test. By pressurizing combustion chamber
from an external air source you can determine if valves or rings are leaking, and how badly.
Cylinder leakdown tester is a relatively simple, inexpensive leakdown tester for small engines. This tester includes a
quick-connect for attaching adapter hose and a holding tool.
1. Run engine for 3-5 minutes to warm it up.
2. Remove spark plug(s) and air filter from engine.
3. Rotate crankshaft until piston (of cylinder being tested) is at top dead center (TDC) of compression stroke. Hold
engine in this position while testing. Holding tool supplied with tester can be used if PTO end of crankshaft is
accessible. Lock holding tool onto crankshaft. 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 driven component. Just be certain that engine cannot rotate off of
TDC in either direction.
4. Install adapter into spark plug hole, but do not attach it to tester at this time.
5. Turn regulator knob completely counterclockwise.
6. Connect an air source of at least 50 psi to tester.
7. Turn regulator knob clockwise (increase direction) until gauge needle is in yellow set area at low end of scale.
8. Connect tester quick-connect to adapter hose. While firmly holding engine at TDC, gradually open tester valve.
Note gauge reading and listen for escaping air at combustion air intake, exhaust outlet, and crankcase breather.
Condition Conclusion
Air escaping from crankcase breather. Ring or cylinder worn.
Air escaping from exhaust system. Defective exhaust valve/improper seating.
Air escaping from intake. Defective intake valve/improper seating.
Gauge reading in low (green) zone. Piston rings and cylinder in good condition.
Gauge reading in moderate (yellow) zone. Engine is still usable, but 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 replaced.

62 690 02 Rev. N KohlerEngines.com 19

Air Cleaner/Intake

AIR CLEANER 1. Unhook retaining clips and remove end cap(s).

These systems are CARB/EPA certified and components 2. Check and clean inlet screen (if equipped).
should not be altered or modified in any way. 3. Pull air cleaner element out of housing and replace.
Air Cleaner Components Check condition of inner element; replace when
dirty.
G 4. Check all parts for wear, cracks, or damage, and that
ejector area is clean.
D 5. Install new element(s).
C
B 6. Reinstall end cap(s) with dust ejector valve/screen
F down; secure with retaining clips.
BREATHER TUBE
A H Ensure both ends of breather tube are properly
E connected.
AIR COOLING
A Air Cleaner Housing B End Cap
WARNING
C Element D Inner Element
E Ejector Area F Inlet Screen Hot Parts can cause severe burns.
G Retaining Clip H Filter Minder Do not touch engine while operating or just
after stopping.
NOTE: Operating engine with loose or damaged air
cleaner components could cause premature Never operate engine with heat shields or guards
wear and failure. Replace all bent or damaged removed.
components. Proper cooling is essential. To prevent over heating,
NOTE: Paper element cannot be blown out with clean screens, cooling fins, and other external surfaces
compressed air. of engine. Avoid spraying water at wiring harness or any
electrical components. Refer to Maintenance Schedule.

20 KohlerEngines.com 62 690 02 Rev. N

 Fuel System

Typical carbureted fuel system and related components FUEL PUMP

include: Some engines use a pulse style fuel pump or optional
● Fuel tank and valve. remote-mounted electric fuel pump assembly. Pumping
● Fuel lines. action of pulse style pumps is created by oscillation of
● In-line fuel filter. positive and negative pressures within crankcase. This
● Fuel pump. pressure is transmitted to pulse pump through rubber
● Carburetor. hose connected between pump and crankcase. Pumping
action causes diaphragm on inside of pump to pull fuel
Fuel from tank is moved through in-line filter and fuel in on its downward stroke and to push it into carburetor
lines by fuel pump. Fuel then enters carburetor float bowl on its upward stroke. Two check valves prevent fuel from
and is drawn into carburetor body and mixed with air. going backward through pump.
This fuel-air mixture is then burned in engine combustion
chamber. Fuel Pump Replacement
FUEL RECOMMENDATIONS NOTE: Make sure orientation of new pump is consistent
Refer to Maintenance. with removed pump. Internal damage may occur
if installed incorrectly.
FUEL LINE
To replace pulse pump follow these steps. Note
Low permeation fuel line must be installed on carbureted orientation of pump before removing.
Kohler Co. engines to maintain EPA and CARB
regulatory compliance. 1. Disconnect fuel lines from inlet, outlet, and pulse
fittings on fuel pump.
2. Remove screws and take off pump.
3. Connect pulse line to new fuel pump and make sure
opposite end is properly connected to oil filter
housing fitting.
4. Attach new fuel pump using screws. Torque screws
to 7.9 N·m (70 in. lb.).
5. Reconnect fuel lines to inlet and outlet fittings and
secure with clamps.

FUEL SYSTEM TESTS

When engine starts hard or turns over but will not start, fuel system might be causing problems. Test fuel system by
performing following test.
1. Check for fuel in combustion chamber. 3. Check operation of fuel pump.
a. Disconnect and ground spark plug leads. a. Remove fuel line from inlet fitting of carburetor.
b. Close choke on carburetor. b. Crank engine several times and observe flow.
c. Crank engine several times.
d. Remove spark plug and check for fuel at tip.
2. Check for fuel flow from tank to fuel pump.
a. Remove fuel line from inlet fitting of fuel pump.
b. Hold line below bottom of tank. Open shut-off
valve (if equipped) and observe flow.

Condition Conclusion
Fuel at tip of spark plug. Fuel is reaching combustion chamber.
No fuel at tip of spark plug. Check fuel flow from fuel tank (step 2).
Fuel flows from fuel line. Check for faulty fuel pump (step 3).
If fuel pump is working, check for faulty carburetor. Refer
to Carburetor.
No fuel flow from fuel line. Check fuel tank cap vent, fuel pickup screen, in-line
filter, shut-off valve, and fuel line. Correct any observed
problem and reconnect line.
Fuel line condition. Check for a clogged fuel line. If fuel line is unobstructed,
check for overfilled crankcase and/or oil in pulse line. If
checks don't reveal cause of problem, replace pump.

62 690 02 Rev. N KohlerEngines.com 21

Fuel System

CARBURETOR

WARNING Gasoline is extremely flammable and its vapors can

explode if ignited. Store gasoline only in approved
Explosive Fuel can cause fires and severe containers, in well ventilated, unoccupied buildings, away
burns. from sparks or flames. Spilled fuel could ignite if it comes
Do not fill fuel tank while engine is hot or in contact with hot parts or sparks from ignition. Never use
running. gasoline as a cleaning agent.

Two-Barrel Carburetor Components

D
E
H
F AB
G Z
AA
B I AC
AF
C AD

AE
A

K
U L
J
T
Q
R
W N
V

M
P
X Y
S O

Carburetor Body B Idle Speed Idle Speed

A C D Screw E Ground Lead
Subassembly Screw Spring
Retaining Slow Jet- Slow Jet- O-Ring
F G H I J Fuel Bowl
Washer Right Side Left Side (Slow Jet)
O-Ring (Fuel O-Ring (Fuel
K L M Drain Screw N Bowl Screw O Fuel Solenoid
Bowl-Upper) Bowl-Lower)
P Sealing Washer Q Float R Pin S Screw T Float Clip
Float Valve/ Main Nozzle- Main Nozzle- Main Jet- Main Jet-
U V W X Y
Inlet Needle Right Side Left Side Right Side Left Side
Z Choke Dust Cap AA Choke Shaft AB Spring AC Bushing AD Choke Lever
Choke Plate
AE Choke Plate AF
Screw

22 KohlerEngines.com 62 690 02 Rev. N

 Fuel System

Engines in this series are equipped with a two-barrel, 3. Make sure fuel is reaching carburetor. This includes
side-draft carburetor with fixed main jets on a matching checking fuel shut-off valve, fuel tank filter screen,
intake manifold. Carburetor features a self-relieving in-line fuel filter, fuel lines and fuel pump for
choke, serviceable slow jets, main jets, bowl drain and a restrictions or faulty components as necessary.
fuel shutdown solenoid. 4. Make sure air cleaner base and carburetor are
securely fastened to engine using gaskets in good
Troubleshooting Checklist condition.
When engine starts hard, runs rough, or stalls at low 5. Make sure air cleaner element (including precleaner
idle speed, check these areas before adjusting or if equipped) is clean and all air cleaner components
disassembling carburetor. are fastened securely.
1. Make sure fuel tank is filled with clean, fresh 6. Make sure ignition system, governor system,
gasoline. exhaust system, and throttle and choke controls are
2. Make sure fuel tank cap vent is not blocked and is operating properly.
operating properly.

Troubleshooting-Carburetor Related Causes

Condition Possible Cause Conclusion
Engine starts hard, runs rough, or Low idle fuel mixture (some models)/ Adjust low idle speed tab, then adjust
stalls at idle speed. speed improperly adjusted. low idle fuel needle.
Engine runs rich (indicated by black, Clogged air cleaner. Clean or replace air cleaner.
sooty exhaust smoke, misfiring, loss Choke partially closed during Check choke lever/linkage to ensure
of speed and power, governor operation. choke is operating properly.
hunting, or excessive throttle
opening). Low idle fuel mixture is improperly Adjust low idle fuel needle (some
adjusted. models).
Float level is set too high. Adjust float according to Float
Replacement Procedure.
Dirt under fuel inlet needle. Remove needle; 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.
Leaky, cracked, or damaged float. Submerge float to check for leaks.
Engine runs lean (indicated by Low idle fuel mixture is improperly Adjust low idle fuel needle (some
misfiring, loss of speed and power, adjusted. models).
governor hunting, or excessive Float level is set too low. Adjust float according to Float
throttle opening). Replacement Procedure.
Idle holes plugged; dirt in fuel delivery Remove low idle fuel adjusting
channels. needle. Clean main fuel jet and all
passages; blow out with compressed
air.
Fuel leaks from carburetor. Float level set too high. Adjust float according to Float
Replacement Procedure.
Dirt under fuel inlet needle. Remove needle; clean needle and
seat and blow with compressed air.
Bowl vents plugged. Blow out with compressed air.

Carburetor bowl gasket leaks. Replace gasket.

62 690 02 Rev. N KohlerEngines.com 23

Fuel System

Fuel Shut-off Solenoid Carburetor Adjustments

Most carburetors are equipped with a fuel shut-off NOTE: Carburetor adjustments should be made only
solenoid. Solenoid is attached to fuel bowl. Solenoid has after engine has warmed up.
a spring-loaded pin that retracts when 12 volts is applied Carburetor is designed to deliver correct fuel-to-air
to lead, allowing fuel flow to main jets. When current is mixture to engine under all operating conditions. Main
removed pin extends blocking fuel flow. fuel jet is calibrated at factory and is not adjustable.
Below is a simple test, performed with engine off, that Idle fuel adjusting needles are also set at factory and
can determine if solenoid is functioning properly: normally do not need adjustment.
1. Shut off fuel and remove solenoid from carburetor. Low Idle Speed (RPM) Adjustment
When solenoid is loosened and removed, gas will NOTE: Actual low idle speed depends on application.
leak out of carburetor. Have a container ready to Refer to equipment manufacturer’s
catch fuel. recommendations. Low idle speed for basic
2. Wipe tip of solenoid with a shop towel or blow with engines is 1200 RPM. To ensure best results
compressed air to remove any remaining fuel. Take when setting low idle fuel needle, low idle speed
solenoid to a location with good ventilation and no should be 1200 RPM (± 75 RPM).
fuel vapors present. You will also need a 12 volt Place throttle control into idle or slow position. Turn low
power source that can be switched on and off. idle speed adjusting screw in or out to obtain a low idle
3. Be sure power source is switched OFF. Connect speed of 1200 RPM (± 75 RPM).
positive power source lead to red lead of solenoid. Governed Idle Speed Adjustment
Connect negative power source lead to solenoid 1. Make sure governed idle spring is in outer hole in
body. governor lever and hole in governed idle (outer)
4. Turn power source ON and observe pin in center of adjuster.
solenoid. Pin should retract with power ON and 2. Make sure governor spring is in inner slot of
return to its original position with power OFF. Test governor lever and hole in high speed (inner)
several times to verify operation. adjuster. Pull governor lever away from carburetor to
limit its travel and check that governor spring is
Carburetor Circuits loose and not under any tension. Turn high-speed
Float (RPM) adjustment screw counterclockwise (if
Fuel level in bowl is maintained by float and fuel inlet required) until spring is loose.
needle. Buoyant force of float stops fuel flow when 3. Hold governor lever away from carburetor so throttle
engine is at rest. When fuel is being consumed, float will lever is against idle speed (RPM) adjustment screw
drop and fuel pressure will push inlet needle away from of carburetor. Start engine and allow to warm up,
seat, allowing more fuel to enter bowl. When demand then adjust screw to set approximately 1200 RPM.
ceases, buoyant force of float will again overcome fuel Check speed using a tachometer. Turn adjustment
pressure, rising to predetermined setting and stop flow. screw (inner) clockwise (in) to increase or
Slow and Mid-Range counterclockwise (out) to decrease speed.
At low speeds engine operates only on slow circuit. 4. Release governor lever and check that throttle lever
As a metered amount of air is drawn through slow air is in idle (centered) position. Turn governed idle
bleed jets, fuel is drawn through 2 main jets and further (outer) adjustment screw to obtain equipment
metered through slow jets. Air and fuel are mixed in body manufacturer’s recommended idle speed
of slow jet and exit to transfer port. From transfer port, (1500-1800 RPM). Governed idle speed (RPM) is
air fuel mixture is delivered to idle progression chamber. typically 300 RPM (approximate) higher than low idle
From idle progression chamber, air fuel mixture is speed.
metered through idle port passages. At low idle when 5. Move throttle lever to wide-open/full throttle position
vacuum signal is weak, air/fuel mixture is controlled by and hold in this position. Turn high speed screw to
setting of idle fuel adjusting screws. This mixture is then obtain intended high speed no-load RPM. Governed
mixed with main body of air and delivered to engine. idle speed must be set before making this
As throttle plate opening increases, greater amounts of adjustment.
air/fuel mixture are drawn in through fixed and metered
idle progression holes. As throttle plate opens further, Low Idle Fuel Adjustment
vacuum signal becomes great enough so main circuit Adjust to Lean Adjust to Lean
begins to work.
Midpoint Midpoint
Main (high-speed)
At high speeds/loads engine operates on main circuit.
As a metered amount of air is drawn through 4 air jets,
fuel is drawn through main jets. Air and fuel are mixed
in main nozzles then enter main body of airflow where Rich Rich
further mixing of fuel and air occurs. This mixture is then
delivered to combustion chamber. Carburetor has a fixed
main circuit; no adjustment is possible. Left Side Right Side

24 KohlerEngines.com 62 690 02 Rev. N

 Fuel System

NOTE: Engines will have fixed low idle or limiter caps 1. Perform removal procedures for appropriate air
on idle fuel adjusting needles. Step 2 can only cleaner and carburetor outlined in Disassembly.
be performed within limits allowed by cap. Do 2. Clean exterior surfaces of dirt or foreign material
not attempt to remove limiter caps. before disassembling carburetor. Remove screws
1. Place throttle control into idle or slow position. Adjust and carefully separate fuel bowl from carburetor. Do
low idle speed to 1200 RPM. Follow Low Idle Speed not damage fuel bowl O-rings. Transfer any
(RPM) Adjustment. remaining fuel into an approved container. Save all
2. Low idle fuel needle(s) setting: place throttle into idle parts. Fuel can also be drained prior to bowl removal
or slow position. by loosening/removing bowl drain screw.
a. Turn 1 low idle fuel adjusting needle out 3. Remove screw and lift out old float, pin, and inlet
(counterclockwise) from preliminary setting until needle. Discard all of parts. Seat for inlet needle is
engine speed decreases (rich). Note position of not serviceable and should not be removed.
needle. Now turn adjusting needle in (clockwise). 4. Clean carburetor bowl and inlet seat areas as
Engine speed may increase, then it will decrease required. To reassemble fuel bowl go to step 23,
as needle is turned in (lean). Note position of otherwise go to step 5.
needle. Set adjusting needle midway between 5. Carefully remove main jets from carburetor. Note
rich and lean settings. and mark jets by location for proper reassembly.
b. Repeat procedure on other low idle adjustment Main jets may be size/side specific. After main jets
needle. are removed, main nozzles can be removed out
3. Recheck/adjust Low Idle Speed (RPM) to specified through bottom of main towers. Note orientation/
setting. direction of nozzles. End with 2 raised shoulders
should be out/down adjacent to main jets. Save
High Speed (RPM) Adjustment parts for cleaning and reuse.
1. With engine running, move throttle control to fast.
6. Remove screw securing flat washer and ground lead
2. Turn inner adjustment screw outward to decrease, or (if equipped) from top of carburetor, then carefully
inward to increase RPM speed. pull (lift) out slow jets. Slow jets may be sized/side
3. Stop when desired RPM speed is obtained. specific. Mark or tag jets for proper reassembly. Note
small O-ring on bottom of each jet. Save parts for
Carburetor Servicing cleaning and reuse unless a jet kit is also being
installed. Clean slow jets using compressed air. Do
not use wire or carburetor cleaner.
WARNING
7. Remove idle speed (RPM) adjustment screw and
Accidental Starts can cause severe injury or spring from carburetor. Discard parts.
death.
Carburetor is now disassembled for appropriate
Disconnect and ground spark plug lead(s) cleaning and installation of parts in overhaul kit.
before servicing. Further disassembly is not necessary. Throttle shaft
assembly, fuel inlet seat, idle fuel adjustment screws
Before working on engine or equipment, disable with limiter, and carburetor body, are non-serviceable
engine as follows: 1) Disconnect spark plug lead(s). 2) items and should not be removed. Choke shaft
Disconnect negative (–) battery cable from battery. assembly is serviceable, however it should not be
NOTE: Main and slow jets are fixed and side specific removed unless a choke repair kit will be installed.
and can be removed if required. Fixed jets for To install choke repair kit go to step 8, otherwise go
high altitudes are available. to step 18.
● Inspect carburetor body for cracks, holes, and other 8. Remove and discard plastic cap from end of choke
wear or damage. lever/shaft assembly.
● Inspect float for cracks, holes, and missing or 9. Note position of spring legs and choke plate for
damaged float tabs. Check float hinge and shaft for correct reassembly later. Remove screws attaching
wear or damage. choke plate to choke shaft. Pull shaft out of
● Inspect fuel inlet needle and seat for wear or damage. carburetor body, note preload of spring and discard
● Inspect spring loaded choke plate to make sure it removed parts.
moves freely on shaft.
10. Use a screw extractor (easy-out) and remove
Float Replacement/Overhaul/Choke Repair original choke shaft bushing with old choke lever
NOTE: Inlet needle center pin is spring loaded. Make from carburetor housing. Save bushing to use as a
sure float rests against fuel inlet needle without driver for installing new bushing. Discard old lever.
depressing center pin.
11. Clean I.D. of both choke shaft bores as required.
If symptoms described in Troubleshooting-Carburetor
Related Causes indicate float level problems, remove 12. Insert new bushing through new choke lever from
carburetor from engine to check and/or replace float. outside and start bushing in outer shaft bore.
Use a float kit to replace float, pin, float valve, clip, and Position choke lever so protruding boss on
screw. carburetor housing is between 2 stops formed in
choke lever.

62 690 02 Rev. N KohlerEngines.com 25

Fuel System

13. Turn old bushing upside down and use it as a driver 26. Correct float height setting is 17 mm (0.669 in.) ±
to carefully press or tap new bushing into carburetor 1.5 mm (0.059 in.), measured from float bottom to
body until it bottoms. Check that choke lever pivots body of carburetor. Replace float if height is different
freely without restriction or binding. than specified. DO NOT attempt to adjust by
14. Install new return spring onto new choke shaft, so bending float tab.
outboard leg of spring is behind formed stop on end 27. When proper float height is obtained, carefully
of choke shaft. reinstall fuel bowl onto carburetor, using new
Make sure it stays in this location during following O-rings. Secure with original screws. Torque screws
step. to 2.5 N·m (22 in. lb.) ± 0.3 N·m (3 in. lb.).
15. Slide choke shaft and spring into carburetor. Pivot 28. Set idle mixture screws at midpoint of available
(preload) shaft 3/4 turn counterclockwise with inner adjustment as a preliminary setting.
leg of spring against formed stop within choke lever 29. Use new mounting gaskets for air cleaner and
as originally assembled. Outer leg of spring must still carburetor. Reinstall carburetor and disassembled
be behind formed stop of choke shaft. components following Reassembly procedures.
16. Place a drop of Loctite® 222MS™ on threads of each 30. Reconnect spark plug leads and negative battery
new screw. Position and install new choke plate to cable. Start engine and perform Low Idle Speed
flat side of choke shaft. Start screws. Close choke Adjustment and Low Idle Fuel Needle(s) settings.
and check plate alignment within carburetor throat, HIGH ALTITUDE OPERATION
then tighten screws securely. Do not overtighten.
If this engine is operated at an altitude of 4000 ft.
17. Check for proper operation and free movement of (1219 meters) or above, a high altitude carburetor
parts. Install new cap. kit is required. To obtain high altitude carburetor kit
18. Clean carburetor body, main jets, vent ports, seats, information or to find a Kohler authorized dealer, visit
etc., using a good commercially available carburetor KohlerEngines.com or call 1-800-544-2444 (U.S. and
solvent. Keep away from plastic or rubber parts if Canada).
non-compatible. Use clean, dry compressed air to This engine should be operated in its original
blow out internal channels and ports. Do not use configuration below 4000 ft. (1219 meters).
metal tools or wire to clean orifices and jets. Inspect
and thoroughly check carburetor for cracks, wear, or Operating this engine with the wrong engine
damage. Inspect fuel inlet seat for wear or damage. configuration at a given altitude may increase its
Check spring loaded choke plate to make sure it emissions, decrease fuel efficiency and performance,
moves freely on shaft. and result in damage to the engine.
19. Install main nozzles into towers of carburetor body.
End of main nozzles with 2 raised shoulders should
be out/down (adjacent to main jets). Make sure
nozzles are completely bottomed. Carefully install
main jets into towers of carburetor body on
appropriate side, as identified when removal was
performed.
20. Make sure O-ring near bottom of each slow jet is
new, or in good condition. Align and insert slow jets
into top of carburetor.
21. Install large flat retaining washer and secure with
mounting screw, attaching ground lead if originally
secured by screw.
22. Install new idle speed (RPM) adjustment screw and
spring onto carburetor. Thread in until 3 or 4 threads
are exposed, as an initial adjustment.
23. Attach inlet needle to plastic tang of float with wire
clip. Formed 90° lip should point up, with needle
valve hanging down.
24. Install float and inlet needle down into seat and
carburetor body. Install new pivot pin through float
hinge and secure with new retaining screw.
25. 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.
Be sure to measure from casting surface, not rubber
gasket, if still attached.

26 KohlerEngines.com 62 690 02 Rev. N

 Governor System

GOVERNOR
Governed speed setting is determined by position of throttle control. It can be variable or constant, depending on
engine application.
Governor is designed to hold engine speed constant under changing load conditions. Most engines are equipped with
a centrifugal flyweight mechanical governor. Governor gear/flyweight mechanism of mechanical governor is mounted
inside crankcase and is driven off gear on camshaft.
Governor Components

J
H

H
I
A
Inside Engine

G
C
B

D F
E
A Throttle Lever B Throttle Linkage C Nut D Governor Arm
E Governor Spring F Governed Idle Spring G Cross Shaft H Flyweight
I Regulating Pin J Governor Gear

This governor design works as follows: Governor Adjustments

● Centrifugal force acting on rotating governor gear NOTE: Do not tamper with governor setting. Overspeed
assembly causes flyweights to move outward as is hazardous and could cause personal injury.
speed increases. Governor spring tension moves
them inward as speed decreases. Initial Adjustment Procedure
● As flyweights move outward, they cause regulating pin Make this adjustment whenever governor arm is
to move outward. loosened or removed from cross shaft. Adjust as follows:
● Regulating pin contacts tab on cross shaft causing 1. Make sure throttle linkage is connected to governor
shaft to rotate. arm and throttle lever on carburetor.
● One end of cross shaft protrudes through crankcase.
Rotating action of cross shaft is transmitted to throttle 2. Loosen nut holding governor lever to cross shaft.
lever of carburetor through external throttle linkage. 3. Move governor lever toward carburetor as far as it
● When engine is at rest, and throttle is in fast position, will go (wide open throttle) and hold in this position.
tension of governor spring holds throttle plate open.
When engine is operating, governor gear assembly is 4. Insert a long thin rod or tool into hole on cross shaft
rotating. Force applied by regulating pin against cross and rotate shaft clockwise (viewed from end) as far
shaft tends to close throttle plate. Governor spring as it will turn, then torque nut to 7.1 N·m (63 in. lb.).
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 allows
more fuel into engine, increasing engine speed. As
speed reaches governed setting, governor spring
tension and force applied by regulating pin will again
offset each other to hold a steady engine speed.
62 690 02 Rev. N KohlerEngines.com 27
Lubrication System

This engine uses a full pressure lubrication system which delivers oil under pressure to crankshaft, camshaft,
connecting rod bearing surfaces, and hydraulic valve lifters.
A high-efficiency gerotor oil pump maintains high oil flow and oil pressure, even at low speeds and high operating
temperatures. A pressure relief valve limits maximum pressure of system. Oil pan must be removed to service oil
pickup, pressure relief valve, and oil pump.
Lubrication Components

C
A

E H

A Oil Filter B Back Side C Oil Cooler D Cylinder Shroud E Oil Drain Plug
F Oil Fill Tube G Oil Fill/Dipstick H Pressure Switch

OIL RECOMMENDATIONS CHANGE OIL AND FILTER

Refer to Maintenance. Change oil while engine is warm.
CHECK OIL LEVEL 1. Clean area around oil fill cap/dipstick and drain plug.
NOTE: To prevent extensive engine wear or damage, Remove drain plug and oil fill cap/dipstick. Allow oil
never run engine with oil level below or above to drain completely.
operating range indicator on dipstick. 2. Clean area around oil filter; remove filter; wipe off
Ensure engine is cool. Clean oil fill/dipstick areas of any mounting surface. Reinstall drain plug and torque to
debris. 21.4 N·m (16 ft. lb.).
1. Remove dipstick; wipe oil off. 3. Place new filter in shallow pan with open end up. Fill
with new oil until oil reaches bottom of threads. Allow
2. Reinsert dipstick into tube; rest cap on tube, do not 2 minutes for oil to be absorbed by filter material.
thread cap onto tube.
4. Apply a thin film of clean oil to rubber gasket on new
3. Remove dipstick; check oil level. Level should be at filter.
top of indicator on dipstick.
5. Refer to instructions on oil filter for proper
4. If oil is low on indicator, add oil up to top of indicator installation.
mark.
6. Fill crankcase with new oil. Level should be at top of
5. Reinstall and secure dipstick. indicator on dipstick.
7. Reinstall oil fill cap/dipstick and tighten securely.
8. Start engine; check for oil leaks. Stop engine; correct
leaks. Recheck oil level.
9. Dispose of used oil and filter in accordance with
local ordinances.
28 KohlerEngines.com 62 690 02 Rev. N
 Lubrication System

OIL COOLER Installation

NOTE: Oil cooler is mounted under cylinder shroud. 1. Apply pipe sealant with Teflon® (Loctite® PST® 592™
Removal of cylinder shroud is necessary to Thread Sealant or equivalent) to threads of switch.
access oil cooler.
2. Install switch into tapped hole in oil pan.
1. Clean fins with a brush or compressed air.
3. Torque switch to 10.7 N·m (95 in. lb.).
2. Remove screws securing oil cooler and tilt to clean
back side. Testing
3. Reinstall oil cooler and torque to 2.3 N·m (21 in. lb.). Compressed air, a pressure regulator, pressure gauge,
OIL SENTRY™ (if equipped) and a continuity tester are required to test switch.
This switch is designed to prevent engine from starting 1. Connect continuity tester across blade terminal and
in a low oil or no oil condition. Oil Sentry™ may not shut metal case of switch. With 0 psi pressure applied to
down a running engine before damage occurs. In some switch, tester should indicate continuity (switch
applications this switch may activate a warning signal. closed).
Read your equipment manuals for more information. 2. Gradually increase pressure to switch. As pressure
Oil Sentry™ pressure switch is installed in oil pan increases through range of 7-11 psi tester should
pressure port. On engines not equipped with Oil Sentry™ indicate a change to no continuity (switch open).
installation hole is sealed with a 1/8-27 N.P.T.F. pipe Switch should remain open as pressure is increased
plug. to 90 psi maximum.
3. Gradually decrease pressure through range of 7-11
psi. Tester should indicate a change to continuity
(switch closed) down to 0 psi.
4. Replace switch if it does not operate as specified.

62 690 02 Rev. N KohlerEngines.com 29

Electrical System

SPARK PLUGS Inspection

CAUTION Inspect each spark plug as it is removed from cylinder
head. Deposits on tip are an indication of general
Electrical Shock can cause injury. condition of piston rings, valves, and carburetor.
Do not touch wires while engine is running. Normal and fouled plugs are shown in following photos:
Normal
Spark Plug Component and Details

A
B

Plug taken from an engine operating under normal

conditions will have light tan or gray colored deposits. If
center electrode is not worn, plug can be set to proper
gap and reused.
Worn

C D

A Wire Gauge B Spark Plug

C Ground Electrode D Gap
NOTE: Do not clean spark plug in a machine using
abrasive grit. Some grit could remain in spark
plug and enter engine causing extensive wear
and damage.
Engine misfire or starting problems are often caused On a worn plug, center electrode will be rounded and
by a spark plug that has improper gap or is in poor gap will be greater than specified gap. Replace a worn
condition. spark plug immediately.
Engine is equipped with following spark plugs: Wet Fouled
Gap 0.76 mm (0.030 in.)
Thread Size 14 mm
Reach 19.1 mm (3/4 in.)
Hex Size 15.9 mm (5/8 in.)
Refer to maintenance for Repairs/Service Parts.
Service
Clean out spark plug recess. Remove plug and replace.
1. Check gap using wire feeler gauge. Adjust gap to
0.76 mm (0.030 in.).
A wet plug is caused by excess fuel or oil in combustion
2. Install plug into cylinder head. chamber. Excess fuel could be caused by a restricted air
3. Torque plug to 27 N·m (20 ft. lb.). cleaner, a carburetor problem, or operating engine with
too much choke. Oil in combustion chamber is usually
caused by a restricted air cleaner, a breather problem,
worn piston rings, or valve guides.

30 KohlerEngines.com 62 690 02 Rev. N

 Electrical System

Carbon Fouled ELECTRONIC IGNITION SYSTEMS

Ignition System Components

A
B E

C D
Soft, sooty, black deposits indicate incomplete
combustion caused by a restricted air cleaner, over rich Kill Switch/
carburetion, weak ignition, or poor compression. A Off Position of B Air Gap
Overheated Key Switch
C Flywheel D Magnet
E Spark Plug F Ignition Modules
There are 2 different types of ignition systems used on
these engines. All systems use an ignition module which
energizes spark plug. Difference in system is in way
ignition timing is triggered.
Both ignition systems are designed to be trouble free for
life of engine. Other than periodically checking/replacing
spark plugs, no maintenance or timing adjustments
are necessary or possible. Mechanical systems do
Chalky, white deposits indicate very high combustion occasionally fail or break down. Refer to Troubleshooting
temperatures. This condition is usually accompanied to determine root of a reported problem.
by excessive gap erosion. Lean carburetor settings,
an intake air leak, or incorrect spark timing are normal Reported ignition problems are most often due to poor
causes for high combustion temperatures. connections. Before beginning test procedure, check
all external wiring. Be certain all ignition-related wires
BATTERY are connected, including spark plug leads. Be certain all
A 12-volt battery with 400 cold cranking amps (cca) is terminal connections fit snugly. Make sure ignition switch
generally recommended for starting in all conditions. A is in run position.
smaller capacity battery is often sufficient if an
application is started only in warmer temperatures. Refer
to following table for minimum capacities based on
anticipated ambient temperatures. Actual cold cranking
requirement depends on engine size, application, and
starting temperatures. Cranking requirements increase
as temperatures decrease and battery capacity shrinks.
Refer to equipment's operating instructions for specific
battery requirements.
Battery Size Recommendations
Temperature Battery Required
Above 32°F (0°C) 300 cca minimum
0°F to 32°F (-18°C to 0°C) 300 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 maintenance is necessary to prolong battery
life.
Battery Test
To test battery, follow manufacturer's instructions.

62 690 02 Rev. N KohlerEngines.com 31

Electrical System

Fixed Ignition System

This system uses a capacitive discharge (CD) coil. Ignition timing and spark remains constant regardless of engine
speed. Timing of spark is controlled by location of flywheel magnet group as referenced to engine TDC. A typical fixed
ignition system consists of:
● 1 magnet assembly which is permanently affixed to flywheel.
● 2 electronic capacitive-discharge ignition modules which mount on engine crankcase.
● 1 kill switch (or key switch) which grounds modules to stop engine.
● 2 spark plugs.
Wire Diagram-15/20/25 Amp Regulated Battery Charging System with Fixed Timing, Four Pin Connector

W
F

A E
M

I B
H Q
X S
B
G

P N O

B K O

R C

T
U
M V V

J
D

L
A Blue B Red C Green D Violet (Charging)
E White (Ignition Kill) F Connector G Battery H Battery Positive
I Battery Negative J Starter K Rectifier-Regulator L Oil Sentry™
Flywheel Stator
M Spark Plug(s) N O Ignition Module(s) P Carburetor
Assembly
Intake Manifold Rectifier-Regulator
Q R Starter Solenoid Stud S Ground T
Screw Connector
Starter Solenoid White
U V W Polarity Ribs X Solenoid Lead
Tang (AC Charging Leads)

32 KohlerEngines.com 62 690 02 Rev. N

 Electrical System

Digital Spark Advance Ignition (DSAI) System

This system uses a digital microprocessor which is located in ignition modules. Ignition timing varies depending upon
engine speed with this system. There are 2 inductive-style ignition modules that control ignition timing based on
engine RPM. A typical DSAI application consists of:
● 1 magnet assembly, which is permanently affixed to flywheel.
● 2 inductive, 12-volt ignition modules, which mount on engine crankcase.
● 1 12-volt battery, which supplies current to ignition modules.
● 1 kill switch (or key switch) which grounds spark advance module to stop engine.
● 2 spark plugs.
Wire Diagram-15/20/25 Amp Regulated Battery Charging System with DSAI Ignition and Four Pin Connector

B
G AD
H
W
AC
R

B V
A
S

E
J P U

K
T
W
I S
Q F S
L D
X
Y
R
B
M X Z AB
AA
N
C
O

A Blue B Red C Green D Violet

E White F Black G Connector H Polarity Ribs
I Battery J Battery Positive K Battery Negative L Starter Solenoid Stud
M Starter Solenoid Tang N Starter O Oil Sentry™ P Rectifier-Regulator
Q Rectifier-Regulator R Spark Plug(s) S Ignition Module(s) T Module Mounting
Connector Screw
U Flywheel Stator V Carburetor W Ground X White
Assembly (AC Charging Leads)
Y Spark Plug Lead Z Black (Ground) AA Red (B+) AB White (Shut Off)
AC Solenoid Lead AD Carburetor Mounting
Stud

62 690 02 Rev. N KohlerEngines.com 33

Electrical System

Electronic Ignition Systems Tests

Special Tools Required:
NOTE: Ignition tester must be used to test ignition on these engines. Use of any other tester can result in inaccurate
findings. Battery on unit must be fully charged and properly connected before performing tests (a battery that
is hooked up or charged backward will crank engine but it won’t have spark). Be certain drive is in neutral and
all external loads are disconnected.
● Hand tachometer.
● Ignition tester.
● Automotive timing light.
● Multi-meter (digital).
Specifications Required:
● 0.76 mm (0.03 in.).

Test Ignition Systems

NOTE: If engine starts or runs during testing, you may need to ground kill lead to shut it down. Because you have
interrupted kill circuit, it may not stop using switch.
Isolate and verify trouble is within engine.
1. Locate connectors where wiring harnesses from engine and equipment are joined. Separate connectors and
remove white kill lead from engine connector. Rejoin connectors and position or insulate kill lead terminal so it
cannot touch ground. Try to start engine to verify whether reported problem is still present.
Condition Possible Cause Conclusion
Problem goes away. Electrical System Check key switch, wires, connections,
safety interlocks, etc.
Problem persists. Ignition or Electrical System Leave kill lead isolated until all testing
is completed.
Identify white kill lead of engine
wiring harness connector. Establish
a connection to a known good
ground location. Engine should kill
completely. If not, or only one cylinder
is affected, test ignition modules and
connections but also check white kill
lead connection for affected DSAI
module (DSAI only).

34 KohlerEngines.com 62 690 02 Rev. N

 Electrical System

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 perform tests with 1 spark plug lead disconnected and not grounded, or
permanent system damage may occur.
1. With engine stopped, disconnect 1 spark plug lead. Connect spark plug lead to post terminal of spark tester and
attach tester clip to a good engine ground.
2. Crank engine over, establishing a minimum of 350-450 RPM, and observe tester(s) for spark.
3. Repeat spark test on opposite cylinder if cylinders are being tested individually.
Condition Possible Cause Conclusion
One side is not firing. Wiring and Connections Check all wiring, connections, and
terminals on that side. If wiring is
okay, replace ignition module and
retest for spark.
Tester shows spark but engine Spark Plug(s) Try new spark plug(s).
misses or won’t run on that cylinder.
Neither side is firing. Ignition Switch Recheck position of ignition switch
and check for shorted kill lead.
Both cylinders have good spark but Spark Plug(s) Install new spark plug(s) and retest
engine runs poorly or existing plug engine performance.
condition is questionable. If problem persists, check for timing
advance (DSAI only).
1 cylinder has good spark and other Ignition Test ignition modules and
cylinder has no or intermittent spark. connections (DSAI only).
Spark on both cylinders but power is Timing Advance Check for timing advance (DSAI
suspect. only).

Test Timing Advance (DSAI only)

1. Make a line near edge of flywheel screen with a marking pen, chalk, or narrow tape.
2. Connect an automotive timing light to cylinder that had good spark.
3. Run engine at idle and use timing light beam to locate line on screen. Draw a line on blower housing next to line
on screen. Accelerate to full throttle and watch for movement of line on screen relative to line on blower housing.
If both cylinders had good spark, repeat test on other cylinder.
Condition Possible Cause Conclusion
Line on screen did not move away Ignition Test ignition modules and
from line on blower housing during connections.
acceleration.
Lines made on blower housing not
90° apart.

Test Ignition Modules and Connections (DSAI only)

1. Remove blower housing from engine. Inspect wiring for any damage, cuts, bad crimps, loose terminals, or broken
wires. Check that connections are oriented properly on terminals of modules.
2. Disconnect leads from ignition module(s) and clean all of terminals (male and female) with aerosol electrical
contact cleaner to remove any old dielectric compound, dark residue, dirt, or contamination. Disconnect spark
plug leads from spark plugs.
3. Using a multi-meter, check that a proper ground is established between ground (black) lead of DSAI module
(closest to spark plug lead) and a known good ground location on engine.
4. Turn key switch to ON position and check for 12 volts at center/power (red) lead terminal of DSAI module. Use
same ground location for multi-meter as in checking for timing advance.
Condition Possible Cause Conclusion
All tests are OK but module has no Ignition Module Replace affected module.
spark or fails to advance.
Any test is BAD. Ignition Module or Connections Determine cause and fix as required;
retest.

62 690 02 Rev. N KohlerEngines.com 35

Electrical System

BATTERY CHARGING SYSTEM

NOTE: Observe following guidelines to avoid damage to electrical system and components:
● Make sure battery polarity is correct. A negative (-) ground system is used.
● Disconnect rectifier-regulator plug and/or wiring harness plug before doing any electric welding on equipment
powered by engine. Disconnect all other electrical accessories in common ground with engine.
● Prevent stator (AC) leads from touching or shorting while engine is running. This could damage stator.

NOTE: 20 amp charging systems use a 15 amp stator with a 25 amp rectifier-regulator.
Most engines are equipped with a 15, 20, or 25 amp regulated charging system.
15/20/25 Amp Regulated Charging System
Stator
Stator is mounted on crankcase behind flywheel. Follow procedures in Disassembly and Reassembly if stator
replacement is necessary.
Rectifier-Regulator
NOTE: When installing rectifier-regulator, take note of terminal positions and install plug correctly.
NOTE: Disconnect all electrical connections attached to rectifier-regulator. Testing may be performed with rectifier-
regulator mounted or loose. Repeat applicable test procedure 2 or 3 times to determine condition of part.
Rectifier-regulator is mounted on backing shroud assembly. To replace it, disconnect plug, remove mounting screws,
and ground lead.
Testing rectifier-regulator may be performed as follows, using appropriate rectifier-regulator tester.

To test 20/25 amp rectifier-regulators: To test 15 amp rectifier-regulators:

1. Connect single lead adapter in between B+ (center) 1. Connect tester ground lead (with spring clamp) to
terminal of rectifier-regulator being tested and body of rectifier-regulator being tested.
squared single end of tandem adapter lead. 2. Connect tester red lead to B+ terminal of rectifier-
2. Connect tester ground lead (with spring clamp) to regulator and 2 black tester leads to 2 AC terminals.
body of rectifier-regulator. 3. Plug tester into proper AC outlet/power for tester
3. Connect red lead and 1 black lead to terminals on being used. Turn on power switch. POWER light
open end of tandem adapter lead (connections are should be illuminated and 1 of 4 status lights may be
not location specific). on as well. This does not represent condition of part.
4. Connect remaining black lead from tester to 1 outer 4. Press TEST button until a click is heard and then
AC terminal on rectifier-regulator. release. Momentarily 1 of 4 status lights will
5. Plug tester into proper AC outlet/power for tester illuminate indicating condition of part.
being used. Turn on power switch. POWER light
should be illuminated and 1 of 4 status lights may be
on as well. This does not represent condition of part.
6. Press TEST button until a click is heard and then
release. Momentarily 1 of 4 lights will illuminate
indicating partial condition of part.

Condition Conclusion
20/25 amp 15 amp
OK (green) light comes on and stays steady. Disconnect tester black lead Part is good and may be used.
attached to 1 AC terminal and
reconnect it to other AC terminal.
Repeat test. If OK (green) light
comes on again, part is good
and may be used.
NOTE: A flashing LOW light can also occur as Rectifier-regulator is faulty and should not be used.
a result of an inadequate ground lead
connection. Make certain connection
location is clean and clamp is secure.
Other lights come on.

36 KohlerEngines.com 62 690 02 Rev. N

 Electrical System

15/20/25 Amp Battery Charging Systems

NOTE: Always zero ohmmeter on each scale before testing to ensure accurate readings. Voltage tests should be
made with engine running at 3600 RPM with no load. Battery must be good and fully charged.
When problems occur in keeping battery charged or battery charges at high rate, charging system or battery might be
causing problems.

To test charging system for no charge to battery: To test charging system for battery continuously charging
1. Insert an ammeter in B+ lead from rectifier-regulator. at high rate:
With engine running at 3600 RPM and B+ (at 1. With engine running at 3600 RPM, measure voltage
terminal on rectifier-regulator) to ground using a DC from B+ lead to ground using a DC voltmeter.
voltmeter.
If voltage is 13.8 volts or more, place a minimum Condition Conclusion
load of 5 amps (turn on lights if 60 watts or more, or Voltage is 14.7 volts or Charging system is OK.
place a 2.5 ohm, 100 watt resistor across battery less. Battery is unable to hold
terminals) on battery to reduce voltage. Observe charge; service or replace.
ammeter. Voltage is more than 14.7 Faulty rectifier-regulator;
volts. replace.
Condition Conclusion
Charge rate increases Charging system is OK
when load is applied. and battery was fully
charged.
Charge rate does not Test stator and rectifier-
increase when load is regulator (steps 2 and 3).
applied.

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 Stator is OK. Rectifier-
more. regulator is faulty; replace.
Voltage is less than 28 Stator is faulty; replace.
volts. Test stator further using an
ohmmeter (steps 3 and 4).

3. With engine stopped, measure resistance across

stator leads using an ohmmeter.
Condition Conclusion
Resistance is 0.1/0.2 Stator is OK.
ohms.
Resistance is 0 ohms. Stator is shorted; replace.
Resistance is infinity Stator is open; replace.
ohms.

4. With engine stopped, measure resistance from each

stator lead to ground using an ohmmeter.
Condition Conclusion
Resistance is infinity ohms Stator is OK (not shorted
(no continuity). to ground).
Resistance (or continuity) Stator leads are shorted to
measured. ground; replace.

62 690 02 Rev. N KohlerEngines.com 37

Starter System

NOTE: Do not crank engine continuously for more than 10 seconds. Allow a 60 second cool down period between
starting attempts. Failure to follow these guidelines can burn out starter motor.
NOTE: If starter is engaged while flywheel is rotating, starter pinion and flywheel ring gear may clash and damage
starter.
NOTE: If starter does not crank engine, shut off starter immediately. Do not make further attempts to start engine
until condition is corrected.
NOTE: Do not drop starter or strike starter frame. Doing so can damage starter.
Engines in this series use solenoid shift starters.
Troubleshooting-Starting Difficulties
Condition 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 connections.
Replace wires in poor condition and with frayed or broken
insulation.
Starter Switch By-pass switch or solenoid with a jumper wire. If starter cranks
or Solenoid normally, replace faulty components. Remove and perform
individual solenoid test procedure.
Starter energizes but turns Battery Check specific gravity of battery. If low, recharge or replace
slowly. battery as necessary.
Brushes Check for excessively dirty or worn brushes and commutator.
Clean using a coarse cloth (not emery cloth).
Replace brushes if excessively or unevenly worn.
Transmission Make sure clutch or transmission is disengaged or placed
or in neutral. This is especially important on equipment with
Engine hydrostatic drive. Transmission must be exactly in neutral to
prevent resistance which could keep engine from starting.
Check for seized engine components such as bearings,
connecting rod, and piston.

38 KohlerEngines.com 62 690 02 Rev. N

 Starter System

SOLENOID SHIFT STARTERS Starter Disassembly

When power is applied to starter electric solenoid moves NOTE: Do not reuse old retainer.
drive pinion out onto drive shaft and into mesh with
flywheel ring gear. When pinion reaches end of drive NOTE: Do not soak armature or use solvent when
shaft it rotates flywheel and cranks engine. cleaning. Wipe clean using a soft cloth, or use
compressed air.
When engine starts and start switch is released, starter
solenoid is deactivated, drive lever moves back, and 1. Remove hex nut and disconnect positive (+) brush
drive pinion moves out of mesh with ring gear into lead/bracket from solenoid terminal.
retracted position. 2. Remove head screws securing solenoid to starter.
Solenoid Shift Starter Components 3. Unhook plunger pin from drive lever. Remove gasket
from recess in housing.
H I 4. Remove thru (larger) bolts.
5. Remove commutator end plate assembly, containing
J brush holder, brushes, springs, and locking caps.
Remove thrust washer from inside commutator end.
G 6. Remove frame from armature and drive end cap.
K
F 7. Remove drive lever pivot bushing and backing plate
L (if equipped) from end cap.
E 8. Take out drive lever and pull armature out of drive
D M end cap.
N 9. Remove thrust washer from armature shaft.
C 10. Push stop collar down to expose retaining ring.
O 11. Remove retainer from armature shaft. Save stop
collar.
12. Remove drive pinion assembly from armature.
13. Clean parts as required.
P
Inspection
Drive Pinion
B Q Check and inspect following areas:
● Pinion teeth for abnormal wear or damage.
R ● Surface between pinion and clutch mechanism for
nicks or irregularities which could cause seal damage.
● Check drive clutch by holding clutch housing and
S rotating pinion. Pinion should rotate in only 1 direction.
Brushes and Springs
A T Detail

A Tube B Washer A
C Armature D Drive
E Stop F Retaining Ring
G Collar H Drive End Cap
I Screw J Plunger
K Spring L Lever
M Plate N Plug
O Solenoid P Frame and Field
Q Brush Holder R Nut A Wear Limit Length
Commutator End Screw Inspect both springs and brushes for wear, fatigue, or
S T
Plate damage. Measure length of each brush. Minimum length
U Bolt for each brush is 7.6 mm (0.300 in.). Replace brushes if
they are worn, undersize, or condition is questionable.

62 690 02 Rev. N KohlerEngines.com 39

Starter System

Armature Starter Reassembly

Components and Details
NOTE: Always use a new retainer. Do not reuse old
A retainers that have been removed.
NOTE: Correctly installed, center pivot section of drive
lever will be flush or below machined surface of
housing.
1. Apply drive lubricant to armature shaft splines. Install
drive pinion onto armature shaft.
B 2. Install and assemble stop collar/retainer assembly.
A Commutator O.D. B Mica Insulation a. Install stop collar down 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 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.
E 3. Install offset thrust (stop) washer so smaller offset of
D washer faces retainer/collar.
4. Apply a small amount of oil to bearing in drive end
cap, and install armature with drive pinion.
C Insulation Check D Armature Coil
5. Lubricate fork end and center pivot of drive lever
E Continuity Check with drive lubricant. Position fork end into space
between captured washer and rear of pinion.
1. Clean and inspect commutator (outer surface). Mica 6. Slide armature into drive end cap and at same time
insulation must be lower than commutator bars seat drive lever into housing.
(undercut) to ensure proper operation of
commutator. 7. Install rubber grommet into matching recess of drive
end cap. Molded recesses in grommet should be
2. Use an ohmmeter set to Rx1 scale. Touch probes out, matching and aligned with those in end cap.
between 2 different segments of commutator, and
check for continuity. Test all segments. Continuity 8. Install frame, with small notch forward, onto
must exist between all or armature is bad. armature and drive end cap. Align notch with
corresponding section in rubber grommet. Install
3. Check for continuity between armature coil drain tube in rear cutout, if it was removed
segments and commutator segments. There should previously.
be no continuity. If continuity exists between any 2
armature is bad. 9. Install flat thrust washer onto commutator end of
armature shaft.
4. Check armature windings/insulation for shorting.
10. Starter reassembly when replacing brushes/brush
Shift Fork holder assembly:
Check that shift fork is complete, and pivot and contact
areas are not excessively worn, cracked, or broken. a. Hold starter assembly vertically on end housing,
and carefully position assembled brush holder
Brush Replacement assembly, with supplied protective tube, against
end of commutator/armature. Mounting screw
4 brushes and springs are serviced as a set. Use a new holes in metal clips must be up/out. Slide brush
Kohler brush and spring kit if replacement is necessary. holder assembly down into place around
1. Perform steps 1-5 in Starter Disassembly. commutator, and install positive (+) brush lead
2. Remove screws securing brush holder assembly to grommet in cutout of frame. Protective tube may
end cap (plate). Note orientation for reassembly later. be saved and used for future servicing.
Discard old brush holder assembly. Starter reassembly when not replacing brushes/
3. Clean component parts as required. brush holder assembly:
New brushes and springs come preassembled in a a. Carefully unhook retaining caps from brush
brush holder with a protective sleeve that will also assemblies. Do not lose springs.
serve as an installation tool. b. Position brushes back in their slots so they are
4. Perform steps 10-13 in Starter Reassembly flush with I.D. of brush holder assembly. Insert
sequence. If starter has been disassembled, brush installation tool (with extension), or use
installation must be done after armature, drive lever, tube described above from a prior brush
and frame are installed. installation, through brush holder assembly, so
holes in metal mounting clips are up/out.

40 KohlerEngines.com 62 690 02 Rev. N

 Starter System

c. Install brush springs and snap on retainer caps.

d. Hold starter assembly vertically on end housing, and carefully place tool (with extension) and assembled
original brush holder assembly onto end of armature shaft. Slide brush holder assembly down into place
around commutator, install positive (+) brush lead grommet in cutout of frame.
11. Install end cap onto armature and frame, aligning thin raised rib in end cap with corresponding slot in grommet of
positive (+) brush lead.
12. Install thru bolts and brush holder mounting screws. Torque bolts to 5.6-9.0 N·m (49-79 in. lb.) and brush holder
mounting screws to 2.5-3.3 N·m (22-29 in. lb.).
13. Hook plunger behind upper end of drive lever and install spring into solenoid. Insert mounting screws through
holes in drive end cap. Use these to hold solenoid gasket in position, then mount solenoid. Torque screws to
4.0-6.0 N·m (35-53 in. lb.).
14. Connect positive (+) brush lead/bracket to solenoid and secure with nut. Torque nut to 8-11 N·m (71-97 in. lb.). Do
not overtighten.
Solenoid Tests
NOTE: DO NOT leave 12 volt test leads connected to solenoid for any time over what is necessary for performing
each of individual tests. Internal damage to solenoid may occur.
Disconnect 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: To test solenoid hold-in coil:
Actuation Function
1. Use a 12 volt power supply and 2 test leads. 1. Connect a 12 volt test lead to flat spade S/start
2. Connect 1 lead to flat spade S/start terminal on terminal on solenoid and other lead to body or
solenoid. Momentarily connect other lead to lower mounting surface of solenoid.
large post terminal. 2. Manually push plunger IN and check if coil holds
When connection is made solenoid should energize plunger retracted. Do not allow test leads to remain
(audible click) and plunger retract. Repeat test connected to solenoid for a prolonged period of time.
several times. Continuity
Continuity 1. Use an ohmmeter set to audible or Rx2K scale, and
1. Use an ohmmeter set to audible or Rx2K scale, and connect 2 ohmmeter leads to 2 large post terminals.
connect 2 ohmmeter leads to 2 large post terminals. 2. Perform preceding solenoid hold-in coil function test
2. Perform solenoid pull-in coil/plunger actuation test and check for continuity. Meter should indicate
and check for continuity. Ohmmeter should indicate continuity. Repeat test several times.
continuity. Repeat test several times.

Condition Conclusion
Solenoid fails to activate. Replace solenoid.
No continuity is indicated.
Plunger fails to stay retracted.

62 690 02 Rev. N KohlerEngines.com 41

Disassembly/Inspection and Service

WARNING
Accidental Starts can cause severe injury or Before working on engine or equipment, disable engine as
death. follows: 1) Disconnect spark plug lead(s). 2) Disconnect
negative (–) battery cable from battery.
Disconnect and ground spark plug lead(s)
before servicing.
External Engine Components

K
U
K
A

V
L B
W T C
U D
T
H E
R T F
N
T
S
Q
G

O P

H
I
I

A Oil Filter B Oil Filter Nipple C Oil Filter Cup D Valve Spring
E Cup Spring F Valve G Oil Filter Housing H Valley Baffle
I Outer Cylinder Baffle J Electric Starter K Cylinder Shroud L Blower Housing
M Fixed Guard N Oil Sentry™ O O-Ring P Pin
Q Fitting R Oil Cooler S Hose T Hose Clamp
U Gasket V Carburetor W Intake Manifold

42 KohlerEngines.com 62 690 02 Rev. N

 Disassembly/Inspection and Service

Clean all parts thoroughly as engine is disassembled. Remove Fuel Pump

Only clean parts can be accurately inspected
and gauged for wear or damage. There are many
commercially available cleaners that will quickly remove WARNING
grease, oil and grime from engine parts. When such a Explosive Fuel can cause fires and severe
cleaner is used, follow manufacturer’s instructions and burns.
safety precautions carefully.
Do not fill fuel tank while engine is hot or
Make sure all traces of cleaner are removed before running.
engine is reassembled and placed into operation. Even
small amounts of these cleaners can quickly break down Gasoline is extremely flammable and its vapors can
lubricating properties of engine oil. explode if ignited. Store gasoline only in approved
containers, in well ventilated, unoccupied buildings,
Disconnect Spark Plug Leads away from sparks or flames. Spilled fuel could ignite
if it comes in contact with hot parts or sparks from
NOTE: Pull on boot only, to prevent damage to spark ignition. Never use gasoline as a cleaning agent.
plug lead.
1. Disconnect leads from spark plugs. NOTE: Based on style of fuel pump used refer to
following.
2. Shut off fuel supply.
Pulse Style Fuel Pump
Drain Oil from Crankcase and Remove Oil Filter Pulse style fuel pump is mounted to side of control
bracket. It may be removed separately or with bracket.
1. Clean oil filter and housing area. Remove and
discard oil filter. To remove separately:
2. Remove dipstick and 1 oil drain plug. 1. Remove mounting screws securing fuel pump to
control bracket.
3. Allow ample time for oil to drain from crankcase.
2. Disconnect inlet, outlet, and pulse (vacuum) hoses
Remove Muffler and remove fuel pump. Properly contain any
remaining fuel.
Remove exhaust system and attaching hardware from
engine. Electric Fuel Pump
Removal will be determined based on mounted location
Remove Cylinder Shrouds and Blower Housing and application. Disconnect lead connections, fuel
line connections, and mounting hardware as required.
1. Remove top mounting screw and loosen shoulder Properly contain any remaining fuel.
screws on each side. Lift off cylinder shrouds.
2. Remove mounting screws and separate blower Remove Control Bracket, Governor Springs, and
housing from backing shroud assembly. One screw Lever
also secures oil fill/dipstick tube. Fixed guard (if 1. Unhook governed idle and governor springs from
equipped) may be removed with blower housing. controls on main bracket and governor lever. Note
3. Remove lower mounting screw and pull oil fill tube color, location, and position of each.
out of crankcase. 2. Disconnect throttle linkage and dampening spring
from governor lever at small bushing.
Remove Electric Starter Motor
3. Carefully pry off pal nut, remove washers (note
1. Disconnect leads from starter. assembly order), and disconnect choke linkage from
2. Remove screws and starter. pivot lever. Do not lose any parts. Secure remaining
pivot parts with tape to avoid losing them. Always
Remove Air Cleaner Assembly use a new pal nut during reassembly.
1. Disconnect breather hose from air cleaner and 4. If fuel pump is being removed with bracket,
formed vent hose from vent port on carburetor. disconnect pulse (vacuum) hose and outlet fuel hose
2. Remove nuts and ground lead from mounting studs. from pulse pump. Properly contain any remaining
fuel.
3. Remove screws securing air cleaner and main
control bracket to intake manifold bosses. 5. Remove lower mounting screw going into intake
manifold and remove main control bracket.
4. Remove air cleaner as an assembly from engine.
6. Loosen nut and remove governor lever from cross
shaft.

62 690 02 Rev. N KohlerEngines.com 43

Disassembly/Inspection and Service

Remove Carburetor Remove Oil Cooler

NOTE: New clamps are recommended any time
WARNING disassembly is performed, or if clamps have
Explosive Fuel can cause fires and severe been loosened (expanded) several times.
burns. 1. Remove oil cooler mounting screws. Do not lose any
Do not fill fuel tank while engine is hot or washers (if used).
running. 2. Loosen clamps and disconnect hoses from oil
cooler.
Gasoline is extremely flammable and its vapors can
explode if ignited. Store gasoline only in approved Remove Oil Filter Housing
containers, in well ventilated, unoccupied buildings,
away from sparks or flames. Spilled fuel could ignite NOTE: Further disassembly of oil filter housing
if it comes in contact with hot parts or sparks from assembly is not required unless being serviced
ignition. Never use gasoline as a cleaning agent. individually. Follow substeps a, b, and c.
1. Remove screw securing oil filter housing and
1. Disconnect fuel shut-off solenoid lead. individual O-rings to crankcase. Carefully separate
parts.
2. Remove fuel inlet hose from carburetor. Properly
contain any remaining fuel. Perform following only if oil filter housing assembly
requires individual servicing.
3. Remove carburetor and linkages as an assembly.
a. Remove nipple from cup and oil filter housing.
4. Remove carburetor gasket.
b. Remove oil filter cup and spring from housing.
5. Carburetor and linkages can be separated as
necessary. c. Remove rubber valve and spring from cup.

Remove Oil Sentry™ (if equipped)

1. Disconnect lead from Oil Sentry™ switch.
2. Remove Oil Sentry™ switch from oil pan.
Remove Baffles and Intake Manifold
1. Remove screws securing valley baffles to cylinder
heads and backing shroud assembly.
2. Remove screws securing outer cylinder baffles in
place.
3. Remove screws securing intake manifold to cylinder
heads. Cut any wire ties that secure wiring harness
or leads to intake manifold.
4. Remove intake manifold and gaskets.

44 KohlerEngines.com 62 690 02 Rev. N

 Disassembly/Inspection and Service

Flywheel/Ignition Components Remove Ignition Modules

1. Rotate flywheel so magnet is away from modules.
A
2. Remove mounting screws and disconnect kill lead
from ignition modules. Note position of ignition
modules and wiring harness clip.
B
Remove Debris Screen and Cooling Fan
Remove screws, attaching hardware, and hex studs
C securing debris screen, stiffener, and cooling fan to
D flywheel.
Remove Flywheel
E
NOTE: Always use a flywheel strap wrench or holding
tool to hold flywheel when loosening or
tightening flywheel screw. Do not use any type
F of bar or wedge to hold flywheel. Use of such
G tools could cause flywheel to become cracked or
K damaged.
NOTE: Always use a flywheel puller to remove flywheel
H from crankshaft. Do not strike crankshaft or
I flywheel, as these parts could become cracked
or damaged.
J
1. Use a flywheel strap wrench or holding tool to hold
L flywheel and loosen screw securing flywheel to
M crankshaft.
2. Remove screw and washer.
3. Use a puller to remove flywheel from crankshaft.
4. Remove woodruff key from crankshaft.
N
Inspection
Inspect flywheel for cracks and flywheel keyway for
damage. Replace flywheel if it is cracked. Replace
O 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 gear as a serviceable part. Replace flywheel
if ring gear is damaged.
Remove Stator, Rectifier-Regulator, and Wiring
Harness
1. Disconnect plug from rectifier-regulator. If B+
(center) lead must be removed from plug, use a
small flat tool to bend locking tang. Then remove
lead.
2. Remove mounting screws securing rectifier-regulator
to backing shroud assembly. Note location of ground
A Special Washer B Debris Screen lead. If rectifier-regulator is not being replaced, it
C Stiffener D Hex Stud may remain mounted to backing shroud assembly.
E Fan F Flywheel Screw 3. Remove screws securing stator to crankcase and
carefully separate stator wires from molded clips.
G Washer H Ignition Module
4. Unhook wiring harness from molded clips if it is
I Wire Harness Clamp J Flywheel being serviced separately.
K Magnet L Stator
Remove Backing Shroud Assembly
M Rectifier-Regulator N Backing Shroud Remove mounting screws securing backing shroud
O Woodruff Key assembly to crankcase.
Remove Spark Plugs
Remove spark plug from each cylinder head.

62 690 02 Rev. N KohlerEngines.com 45

Disassembly/Inspection and Service

Cylinder Head Components

Style B Style A

B D
E L
N AF AE

F U

G
H
S
I T
J
K
M

A Q
V
O W X Y
P Z
R
AA AB

AC
AD

AA

A Gasket B Valve C Cylinder Head D Pipe Plug

E Guide Plate F Spacer G Washer H Spark Plug
I Valve Stem Seal J Valve Spring K Valve Spring Retainer L Hydraulic Lifter
M Valve Spring Keeper N Push Rod O Rocker Arm P Rocker Arm Pivots
Non-adjustable
Adjustable Valve Train
Q Rocker Stud R S Valve Train (Non- T Rocker Arm Screw
(AVT) AVT)
Valve Cover Seal Valve Cover Grommet (Plastic
U Adjusting Nut V (Plastic Valve W X
(Plastic) Valve Cover)
Cover)
Valve Cover Seal
Screw (Plastic Valve Roll Pin (Aluminum Valve Cover
Y Z (Aluminum Valve AA AB
Cover) Valve Cover) (Aluminum)
Cover)
O-Ring (Aluminum Screw (Aluminum Hydraulic Lifter Hydraulic Lifter
AC AD AE AF
Valve Cover) Valve Cover) Style A (Ribbed) Style B (Smooth)

Remove Valve Covers Aluminum Valve Covers

NOTE: A new valve cover seal must be installed
Plastic Valve Covers whenever an aluminum valve cover is removed
1. Remove screw and grommet securing each valve from cylinder head.
cover.
1. Remove screw and O-ring securing each valve
2. Remove valve cover and seal from each cylinder cover.
head. Note locations of individual valve covers if
they are different. 2. Remove valve cover and seal from each cylinder
head. Note locations of individual valve covers if
they are different. Remove seal from valve cover;
discard seal.

46 KohlerEngines.com 62 690 02 Rev. N

 Disassembly/Inspection and Service

Remove Cylinder Heads and Hydraulic Lifters Disassemble Cylinder Heads

NOTE: Exhaust lifters are located on output shaft side NOTE: These engines use valve stem seals on intake
of engine while intake lifters are located on fan and exhaust valves. Use a new seal whenever
side of engine. Cylinder head number is valves are removed, or if seal is deteriorated in
embossed on outside of each cylinder head. any way. Never reuse an old seal.
1. Non-adjustable Valve Train 1. Non-adjustable Valve Train
a. Remove rocker arm screws, rocker arm pivots Remove screws, rocker arm pivots and rocker arms
and rocker arms. from cylinder head.
Adjustable Valve Train Adjustable Valve Train
Remove adjusters, rocker arm pivots and rocker
a. Loosen set screws and remove adjusting nuts on arms from cylinder head. Remove pivot studs and
rocker arm pivot studs. guide plate as required.
b. Remove rocker arm pivot and rocker arms. 2. Compress valve springs using a valve spring
2. Remove pipe plug from cylinder head to access compressor.
screw in center location. 3. Once valve spring is compressed, remove following
3. Remove screws securing each cylinder head. Note items:
locations of washers and spacer. ● Valve spring keepers.
● Valve spring retainers.
4. Mark position of push rods as either intake or ● Valve springs.
exhaust and cylinder 1 or 2. Push rods should ● Valve spring caps.
always be reinstalled in same positions. ● Intake and exhaust valves (mark position).
5. Carefully remove push rods, cylinder head, and ● Valve stem seals.
head gasket. 4. Repeat above procedure for other cylinder head. Do
6. Repeat procedure for other cylinder head. not interchange parts from 1 cylinder head to
another.
7. Remove lifters from lifter bores. Use a hydraulic lifter
tool. Do not use a magnet to remove lifters. Mark
lifters by location, as either intake or exhaust and
cylinder 1 or 2. Hydraulic lifters should always be
reinstalled in same position.
Inspection
Check base surface of hydraulic lifters for wear or
damage. If lifters need to be replaced, apply a liberal
coating of Kohler lubricant to base of each new lifter
before it is installed.
Bleeding Lifters Style A (Ribbed)
To prevent a possible bent push rod or broken rocker
arm, it is important to bleed any excess oil out of lifters
before they are installed.
1. Cut a 50-75 mm (2-3 in.) piece from end of an old
push rod and chuck it in a drill press.
2. Lay a rag or shop towel on table of drill press and
place lifter, open end up, on towel.
3. Lower chucked push rod until it contacts plunger in
lifter. Slowly pump plunger 2 or 3 times to force oil
out of feed hole in side of lifter.
Bleeding Lifters Style B (Smooth)
To prevent a possible bent push rod or broken rocker
arm, it is important to bleed any excess oil out of lifters
before they are installed.
1. Lay a rag or shop towel on table of drill press. Place
an 8 mm (5/16 in.) socket on towel with well end up,
then place open end of lifter on socket. Ensure
socket does not contact lifter ball surface.
2. Place some material, such as wood, plastic, or
aluminum on top of lifter to protect lifter finish.
3. Lower drill press chuck until it contacts material on
lifter. Slowly pump lifter 2 or 3 times to force oil out of
feed hole in side of lifter.

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Disassembly/Inspection and Service

Inspection and Service

Valve Details
EXHAUST VALVE INTAKE VALVE

F F

E E
C
G G
D
INT
B A

H H
EXH

Dimension Intake Exhaust

A Seat Angle 89° 89°
B Seat Taper 30° 30°
C Guide Depth 8.5 mm (0.334 in.) 8.5 mm (0.334 in.)
D 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 38.625/38.685 mm (1.5206/1.5230 in.) 31.625/31.825 mm (1.2450/1.2549 in.)
F Valve Face Angle 45° 45°
G Valve Margin (Min.) 1.0 mm (0.0393 in.) 1.0 mm (0.0393 in.)
H Valve Stem Diameter 6.982/7.000 mm (0.2749/0.2756 in.) 6.970/6.988 mm (0.2744/0.2751 in.)
After cleaning, check flatness of cylinder head and Valve Guides
corresponding top surface of crankcase using a surface If a valve guide is worn beyond specifications, it will not
plate or precision straight edge and feeler gauge. guide valve in a straight line. This may result in burnt
Maximum allowable out of flatness is 0.076 mm (0.003 valve faces or seats, loss of compression, and excessive
in.). oil consumption.
Carefully inspect valve mechanism parts. Inspect valve To check valve guide-to-valve stem clearance,
springs and related hardware for excessive wear or thoroughly clean valve guide and, using a split-ball
distortion. Check valves and valve seat area or inserts gauge, measure inside diameter of guide. Then, using
for evidence of deep pitting, cracks, or distortion. Check an outside micrometer, measure diameter of valve stem
clearance of valve stems in guides. at several points on stem where it moves in valve guide.
Hard starting or loss of power accompanied by high Use largest stem diameter to calculate clearance by
fuel consumption may be symptoms of faulty valves. subtracting stem diameter from guide diameter. If intake
Although these symptoms could also be attributed to clearance exceeds 0.038/0.076 mm (0.0015/0.0030 in.)
worn rings, remove and check valves first. After removal, or exhaust clearance exceeds 0.050/0.088 mm
clean valve heads, faces, and stems with a power wire (0.0020/0.0035 in.), determine if valve stem or guide is
brush. responsible for excessive clearance.
Then, carefully inspect each valve for defects such as a Maximum (I.D.) wear on intake valve guide is 7.135 mm
warped head, excessive corrosion, or a worn stem end. (0.2809 in.) and 7.159 mm (0.2819 in.) for exhaust
Replace valves found to be in bad condition. guide. Guides are not removable but can be reamed
0.25 mm (0.010 in.) oversize. Valves with 0.25 mm
oversize stems must then be used.
If guides are within limits but valve stems are worn
beyond limits, install new valves.

48 KohlerEngines.com 62 690 02 Rev. N

 Disassembly/Inspection and Service

Valve Seat Inserts

Hardened steel alloy intake and exhaust valve seat inserts are press fitted into cylinder head. Inserts are not
replaceable but 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 cutter being used. Final cut should
be made with an 89° cutter as specified for valve seat angle. Cutting proper 45° valve 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
Reground or new valves must be lapped in, to provide proper fit. Use a hand valve grinder with a suction cup for final
lapping. Lightly coat valve face with a fine grade of grinding compound, then rotate valve on its seat with grinder.
Continue grinding until a smooth surface is obtained on seat and on valve face. Thoroughly clean cylinder head in
soap and hot water to remove all traces of grinding compound. After drying cylinder head, apply a light coating of SAE
10 oil to prevent rusting.
Valve Stem Seals
These engines use valve stem seals on intake and exhaust valves. Always use new seals when valves are removed
from cylinder head. Seals should also be replaced if deteriorated or damaged in any way. Never reuse an old seal.

62 690 02 Rev. N KohlerEngines.com 49

Disassembly/Inspection and Service

Breather/Oil Pan Components

N
O

P E
K
J D
G
F
I

A C
G

H B

R I
A Oil Pan B Gerotor Gears C Oil Pump O-Ring D Oil Pump Housing
E Relief Valve Baffle F Pickup Tube G Inlet Seal H Pickup Screen
Crankshaft Bearing
I Drain Plug J K Oil Pan Gasket L Dipstick
(PTO)
M Dipstick Tube N Breather Assembly O Breather Gasket P Filter
Q Breather Hose R Oil Seal
Remove Breather Assembly Remove Oil Pan Assembly
1. Remove fasteners securing breather assembly and 1. Remove screws securing oil pan to crankcase.
gasket to crankcase. 2. Locate protruding tabs on oil pan. Carefully tap to
2. Carefully break gasket seal and remove breather break gasket seal. Do not pry on sealing surfaces as
and filter. Do not pry on sealing surfaces as it could this could cause leaks. Separate oil pan from
cause damage resulting in leaks. Note assembly crankcase. Remove old gasket.
and orientation of parts. Inspection
Inspect oil seal in oil pan and remove it if it is worn or
damaged.
Inspect crankshaft bearing surface for wear or damage.
Replace bearing or oil pan assembly if required.

50 KohlerEngines.com 62 690 02 Rev. N

 Disassembly/Inspection and Service

Oil Pump Assembly 1. Make sure recess in oil pan for oil pump gerotor
gears is clean.
Disassembly
1. Remove screws securing oil pump housing including 2. Lubricate oil pump gerotor gears with grease
relief valve baffle and screw for pickup tube. (Lubriplate® 100 or equivalent), and install into
recess.
2. Remove oil pump housing and pickup tube from oil
pan. 3. Lightly lubricate with oil and install inlet seal into oil
pump housing until it is fully seated.
3. Remove oil pump gerotor gears from oil pan recess.
4. Install O-ring in groove of oil pump housing. Use a
4. Remove oil pickup by pulling it free from oil pump small quantity of grease to hold it in place.
body.
5. Lightly lubricate I.D. of inlet seal with oil and carefully
5. Relief valve is a one-piece style, staked to oil pump insert end of pickup tube through seal into oil pump
housing; removal should not be attempted, nor is housing.
internal servicing possible. If a problem with relief
valve is encountered, oil pump should be replaced. 6. Install oil pump housing with pickup tube, over oil
pump boss and gears. Position relief valve baffle on
Inspection location 2 and location 3. Align all 3 screw locations.
Inspect oil pump housing, gerotor gears, and oil pan
recess for nicks, burrs, wear, or any visible damage. 7. Check alignment of parts and torque oil pump
Inspect inlet seal for pickup tube in housing. If any parts housing screws to 9.9 N·m (88 in. lb.) using
are worn or damaged, replace seal, oil pump or oil pan sequence below:
as required. a. Install fastener into screw location 1 and lightly
Reassembly tighten to position pump.
Torque Sequence b. Install fastener into screw location 2 and fully
torque to recommended value.
c. Install fastener into screw location 3 and fully
torque to recommended value.
d. Finish torquing fastener in screw location 1 to
recommended value.
8. Install and torque pickup screen mounting screw to
11.3 N·m (100 in. lb.) into new hole or 7.7 N·m
3 (68 in. lb.) into used hole.
Remove Camshaft
1,4 Remove camshaft and shim (if used).

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Disassembly/Inspection and Service

Crankcase Components Inspection

Check lobes of camshaft for wear or damage. Inspect
cam gear for badly worn, chipped, or missing teeth.
Replacement of camshaft will be necessary if any of
A these conditions exist.
M Remove Connecting Rods with Pistons and Rings
O NOTE: If a carbon ridge is present at top of either
L B cylinder bore, use a ridge reamer tool to remove
ridge before attempting to remove piston.
I
NOTE: Cylinders are numbered on crankcase. Use
D numbers to mark each end cap, connecting rod
and piston for reassembly. Do not mix end caps
and connecting rods.
C 1. Remove screws securing closest connecting rod end
cap. Remove end cap.
N R E 2. Carefully remove connecting rod and piston
assembly from cylinder bore.
3. Repeat above procedures for other connecting rod
G and piston assembly.
Connecting Rods
H Offset, stepped-cap connecting rods are used in these
engines.
K J Inspection and Service
Q Check bearing area (big end) for excessive wear, score
marks, running and side clearances. Replace rod and
F cap if scored or excessively worn.
Service replacement connecting rods are available in
STD crankpin size and 0.25 mm (0.010 in.) undersize.
Always refer to appropriate parts information to ensure
that correct replacements are used.

A Camshaft B Locking Tab

C Regulating Pin D Governor Gear
E Cross Shaft F Lifter Feed Cover
Gasket
G Lifter Feed Cover H Governor Yoke
Connecting Rod
I Crankshaft J End Cap
K Connecting Rod L Piston Pin
M Piston Pin Retainer N Piston (Style A)
O Piston Ring Set P Oil Seal
Crankshaft Bearing
Q R Piston (Style B)
(Flywheel)

52 KohlerEngines.com 62 690 02 Rev. N

 Disassembly/Inspection and Service

Piston and Rings Scratches on rings and pistons are caused by abrasive
material such as carbon, dirt, or pieces of hard metal.
Inspection
Detonation damage occurs when a portion of fuel charge
Piston and Rings Components and Details ignites spontaneously from heat and pressure shortly
after ignition. This creates 2 flame fronts which meet and
A explode to create extreme hammering pressures on a
specific area of piston. Detonation generally occurs from
using low octane fuels.
B J Preignition or ignition of fuel charge before timed spark
can cause damage similar to detonation. Preignition
C damage is often more severe than detonation damage.
Preignition is caused by a hot spot in combustion
chamber from sources such as glowing carbon deposits,
blocked cooling fins, an improperly seated valve, or
wrong spark plug(s).
D D Replacement pistons are available in STD bore size, and
in 0.25 mm (0.010 in.), and 0.50 mm (0.020 in.) oversize.
Replacement pistons include new piston ring sets and
E new piston pins.
E
Replacement ring sets are also available separately
F F for STD, 0.25 mm (0.010 in.), and 0.50 mm (0.020 in.)
oversize pistons. Always use new piston rings when
G installing pistons. Never reuse old rings.
G
Some important points to remember when servicing
piston rings:
H Piston Style A
I 1. Cylinder bore must be de-glazed before service ring
Style A H Style B sets are used.
A Piston Ring B End Gap 2. If cylinder bore does not need re-boring and if old
piston is within wear limits and free of score or scuff
C Identification Mark D Piston marks, old piston may be reused.
Top Compression Middle Compression 3. Remove old rings and clean up grooves. Never
E F
Ring Ring reuse old rings.
G Rails H Expander 4. Before installing new rings on piston, place top 2
rings, each in turn, in its running area in cylinder
Oil Control Ring bore and check end gap. Top and middle
I J Dye Colored Stripe
(3 Piece) compression ring end gap clearance is
Scuffing and scoring of pistons and cylinder walls occurs 0.25/0.56 mm (0.0100/0.0224 in.) for a new bore, or
when internal engine temperatures approach welding 0.94 mm (0.037 in.) for a used bore.
point of piston. Temperatures high enough to do this are 5. After installing new compression (top and middle)
created by friction, which is usually attributed to improper rings on piston, make sure top compression ring-to-
lubrication and/or overheating of engine. groove side clearance is 0.025/0.048 mm
Normally, very little wear takes place in piston boss- (0.0010/0.0019 in.) and middle compression ring-to-
piston pin area. If original piston and connecting rod can groove side clearance 0.015/0.037 mm
be reused after new rings are installed, original pin can (0.0006/0.0015 in.). If side clearance is greater than
also be reused but new piston pin retainers are required. specified, a new piston must be used.
Piston pin is included as part of piston assembly – if pin Piston Style B
boss in piston or pin are worn or damaged, a new piston 1. Cylinder bore must be de-glazed before service ring
assembly is required. sets are used.
Ring failure is usually indicated by excessive oil 2. If cylinder bore does not need re-boring and if old
consumption and blue exhaust smoke. When rings fail, piston is within wear limits and free of score or scuff
oil is allowed to enter combustion chamber where it is marks, old piston may be reused.
burned along with fuel. High oil consumption can also
occur when piston ring end gap is incorrect because 3. Remove old rings and clean up grooves. Never
ring cannot properly conform to cylinder wall under this reuse old rings.
condition. Oil control is also lost when ring gaps are not
staggered during installation.
When cylinder temperatures get too 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.

62 690 02 Rev. N KohlerEngines.com 53

Disassembly/Inspection and Service

4. Before installing new rings on piston, place top 2

rings, each in turn, in its running area in cylinder F
bore and check end gap. Top compression ring end
gap clearance is 0.125/0.304 mm (0.0049/0.0120
in.) for a new bore, or 0.515 mm (0.0203 in.) for a
used bore. Middle compression ring end cap is
0.900/1.179 mm (0.0354/0.0464 in.) for a new bore, G
or 1.432 mm (0.0564 in.) for a used bore.
E
5. After installing new compression (top and middle)
rings on piston, make sure top compression ring-to-
groove side clearance and is 0.030/0.070 mm
(0.0010/0.0026 in.) and middle compression ring-to- H
groove side clearance 0.030/0.070 mm
(0.0010/0.0026 in.). If side clearance is greater than
specified, a new piston must be used. Fillet Must Blend Smoothly with Bearing Journal
E Surface
Install New Piston Rings
NOTE: Rings must be installed correctly. Ring F High Point from Fillet Intersections
installation instructions are usually included with G 45° Minimum
new ring sets. Follow instructions carefully. Use
a piston ring expander to install rings. Install H This Fillet Area Must Be Completely Smooth
bottom (oil control) ring first and top
compression ring last. Inspect gear teeth of crankshaft. If teeth are badly worn,
To install new piston rings, proceed as follows: chipped, or some are missing, replacement of crankshaft
will be necessary.
1. Oil control ring (bottom groove): Install expander and
then rails. Make sure ends of expander are not Inspect crankshaft bearing surfaces for scoring,
overlapped. grooving, etc. Replaceable bearings are used in
crankshaft bore of oil pan and/or crankcase. Do not
2. Middle compression ring (center groove): Install replace bearings unless they show signs of damage
center ring using a piston ring installation tool. Make or are out of running clearance 0.040/0.167 mm
sure identification mark is up or colored dye stripe (if (0.0015/0.0065 in.). If crankshaft turns easily, without
contained), is to left of end gap. noise, and there is no evidence of scoring, grooving,
3. Top compression ring (top groove): Install top ring etc., on races or bearing surfaces, bearings can be
using a piston ring expander. Make sure reused.
identification mark is up or colored dye stripe (if Inspect crankshaft keyways. If they are worn or chipped,
contained), is to left of end gap. replacement of crankshaft will be necessary.
Remove Crankshaft Inspect crankpin for score marks or metallic pickup.
Slight score marks can be cleaned with crocus cloth
NOTE: If crankpin is reground, visually check to ensure soaked in oil. If wear limits, as stated in Clearance
that fillet blends smoothly with crankpin surface. Specifications, are exceeded, it will be necessary to
Carefully pull crankshaft from crankcase. Note thrust replace crankshaft or regrind crankpin to 0.25 mm
washers and shims if used. (0.010 in.) undersize. If reground, a 0.25 mm (0.010 in.)
undersize connecting rod (big end) must then be used to
Inspection and Service achieve proper running clearance. Measure crankpin for
Crankshaft Components and Details size, taper, and out-of-round.
Clearance Specifications-Connecting Rod Journal
A O.D. - New 43.982/44.000 mm
(1.731/1.732 in.)
O.D. - Max. Wear Limit 43.97 mm (1.731 in.)
B
Max. Taper 0.018 mm (0.0007 in.)
C Max. Out-of-Round 0.025 mm (0.0010 in.)
Width 53.00/53.09 mm
(2.0866/2.0901 in.)
D Connecting rod journal can be ground 1 size under.
When grinding a crankshaft, grinding stone deposits
can get caught in oil passages, which could cause
severe engine damage. Removing crankpin plug when
crankshaft is ground provides easy access for removing
any grinding deposits that may collect in oil passages.
A Self-Tapping Screw B Flat Washer
C Plug D Crankshaft

54 KohlerEngines.com 62 690 02 Rev. N

 Disassembly/Inspection and Service

Use following procedure to remove and replace plug. Crankcase

Remove Crankshaft Plug Inspection and Service
1. Drill a 3/16 in. hole through plug in crankshaft. Check all gasket surfaces to make sure they are free of
2. Thread a 3/4 in. or 1 in. long self-tapping screw with gasket fragments. Gasket surfaces must also be free of
a flat washer into drilled hole. Flat washer must be deep scratches or nicks.
large enough to seat against shoulder of plug bore. Inspect crankshaft bearing (if equipped) for wear
3. Tighten self-tapping screw until it draws plug out of or damage. Replace bearing or crankcase using a
crankshaft. miniblock or short block as required.
Install New Crankshaft Plug Check cylinder bore for scoring. In severe cases,
Use 1 single cylinder camshaft pin, as a driver and tap unburned fuel can cause scuffing and scoring of cylinder
plug into plug bore until it seats at bottom of bore. Make wall. It washes necessary lubricating oils off piston and
sure plug is tapped in evenly to prevent leakage. cylinder wall. As raw fuel seeps down cylinder wall,
piston rings make metal to metal contact with wall.
Remove Governor Gear Assembly Scoring of cylinder wall can also be caused by localized
Governor gear is held onto shaft by small molded tabs hot spots resulting from blocked cooling fins or from
in gear. When gear is removed from shaft, these tabs inadequate or contaminated lubrication.
are destroyed and gear must be replaced. Therefore, If cylinder bore is badly scored, excessively worn,
remove gear only if absolutely necessary. If governor tapered, or out-of-round, resizing is necessary. Use
cross shaft, yoke, or gear condition does not require an inside micrometer to determine amount of wear,
removal, governor gear may be left in place. If removal is then select nearest suitable oversize of either 0.25 mm
necessary, perform as follows: (0.010 in.) or 0.50 mm (0.020 in.). Resizing to these
1. Remove locking tab thrust washer and note oversizes will allow usage of available oversize piston
orientation. and ring assemblies. Initially, resize using a boring bar,
then use following procedures for honing cylinder.
2. Using a screwdriver, carefully pry upward to unseat
governor gear assembly from governor gear shaft. Honing
Remove regulating pin and governor gear assembly. Detail
3. Inspect governor gear shaft for wear or damage. A
Remove shaft only if replacement is needed.
Inspection
Governor gear is located within crankcase. Inspect
governor gear teeth. Replace gear if it is worn, chipped,
or if any teeth are missing. Inspect governor weights.
They should move freely in governor gear.
Remove Governor Yoke, Cross Shaft, and Seal
1. Remove mounting screws securing yoke to governor
cross shaft.
2. Pull governor cross shaft out of crankcase and
remove seal.
Remove Lifter Feed Chamber Cover and Gaskets
Remove screws securing lifter feed chamber cover and A 23°-33° Crosshatch
gaskets. Carefully separate parts from crankcase.
NOTE: Kohler pistons are custom-machined to exacting
Remove Flywheel and PTO End Oil Seals tolerances. When oversizing a cylinder, it should
be machined exactly 0.25 mm (0.010 in.) or
Remove oil seals from crankcase and oil pan using a 0.50 mm (0.020 in.) over new diameter.
seal puller. corresponding oversize Kohler replacement
piston will then fit correctly.
Remove Crankshaft Bearings (flywheel/PTO)
While most commercially available cylinder hones can
NOTE: Bearing should only be removed if replacement be used with either portable drills or drill presses, use
is required due to wear. If removal is performed, of a low speed drill press is preferred as it facilitates
use a press and support casting surface around more accurate alignment of bore in relation to crankshaft
bearing flange. Do not press against or support crossbore. Honing is best accomplished at a drill speed
by gasket/outer perimeter surface. of about 250 RPM and 60 strokes per minute. After
installing coarse stones in hone, proceed as follows:

62 690 02 Rev. N KohlerEngines.com 55

Disassembly/Inspection and Service

1. Lower hone into bore and after centering, adjust so Measuring Piston-to-Bore Clearance
stones are in contact with cylinder wall. Use of a Piston Detail
commercial cutting-cooling agent is recommended.
2. With lower edge of each stone positioned even with
lowest edge of bore, start drill and honing process.
Move hone up and down while resizing to prevent A
formation of cutting ridges. Check size frequently.
3. When bore is within 0.064 mm (0.0025 in.) of
desired size, remove coarse stones and replace
them with burnishing stones. Continue with
burnishing stones until bore is within 0.013 mm Style A
(0.0005 in.) of desired size and then use finish
stones (220-280 grit) and polish bore to its final size.
A crosshatch should be observed if honing is done A
correctly. Crosshatch should intersect at
approximately 23°-33° off horizontal. Too flat an
angle could cause rings to skip and wear
excessively, and too steep an angle will result in high
oil consumption.
4. After resizing, check bore for roundness, taper, and Style B
size. Use an inside micrometer, telescoping gauge,
or bore gauge to take measurements. These A 11 mm (0.4331 in.)
measurements should be taken at 3 locations in NOTE: Do not use a feeler gauge to measure piston-to-
cylinder – at top, middle, and bottom. There are 2 bore clearance; it will yield inaccurate
measurements that should be taken measurements. Always use a micrometer.
(perpendicular to each other) at all 3 locations.
Before installing piston into cylinder bore, it is necessary
Clean Cylinder Bore After Honing that clearance be accurately checked. This step is often
Proper cleaning of cylinder walls following boring and/ overlooked, and if piston clearances are not within
or honing is very critical to a successful overhaul. specifications, engine failure will usually result.
Machining grit left in cylinder bore can destroy an engine
in less than 1 hour of operation after a rebuild. Use following procedure to accurately measure piston-
to-bore clearance:
Final cleaning operation should always be a thorough
scrubbing with a brush and hot, soapy water. Use a 1. Use a micrometer and measure diameter of piston
strong detergent that is capable of breaking down above bottom of piston skirt and perpendicular to
machining oil while maintaining a good level of suds. If piston pin.
suds break down during cleaning, discard dirty water and 2. Use an inside micrometer, telescoping gauge, or
start again with more hot water and detergent. Following bore gauge and measure cylinder bore. Take
scrubbing, rinse cylinder with very hot, clear water, dry measurement approximately 63.5 mm (2.5 in.) below
it completely, and apply a light coating of engine oil to top of bore and perpendicular to piston pin.
prevent rusting.
3. Piston-to-bore clearance is difference between bore
diameter and piston diameter (step 2 minus step 1).

56 KohlerEngines.com 62 690 02 Rev. N

 Reassembly

Crankcase Components NOTE: Make sure engine is assembled using all

specified torque values, torque sequences, and
clearances. Failure to observe specifications
could cause severe engine wear or damage.
A Always use new gaskets. Apply a small amount
of oil to threads of critical fasteners before
M assembly, unless a sealant or Loctite® is
O specified or preapplied.
L B Make sure all traces of any cleaner are removed before
engine is assembled and placed into operation. Even
I small amounts of these cleaners can quickly break down
lubricating properties of engine oil.
D
Check oil pan, crankcase, cylinder heads, and valve
covers to be certain all old gasket material has been
removed. Use gasket remover, lacquer thinner, or paint
C remover to remove any remaining traces. Clean surfaces
N R with isopropyl alcohol, acetone, lacquer thinner, or
E electrical contact cleaner.
Install Flywheel End Oil Seal
G 1. Make sure seal bore of crankcase is clean and free
of any nicks or burrs.
H 2. Apply a light coat of P80 Emulsion Lubricant (refer to
Tools and Aids) to outside diameter of oil seal.
K J 3. Install oil seal into crankcase using a seal driver.
Q Make sure oil seal is installed straight and true in
bore and tool bottoms against crankcase.
F
Install Lifter Feed Chamber Gaskets and Cover
1. Install lifter feed chamber gasket, followed by lifter
feed cover over lifter feed chamber.
2. Install 3 screws. Make sure all parts are properly
aligned. Torque screws to 7.7 N·m (68 in. lb.).
Install Crankshaft Bearing (flywheel)
If bearing was removed in servicing, install a new
bearing using an arbor press and driver.
1. Make sure crankcase bore for bearing is clean, dry
and free of nicks or burrs.
2. Press flywheel side main bearing in place with notch
oriented in 12 o’clock position using an arbor press
and driver. Make sure bearing is fully seated against
flange and oil feed hole is open in crankcase.
P 3. Apply a light coat of clean engine oil to inner surface
of bearing and oil seal.
A Camshaft B Locking Tab
C Regulating Pin D Governor Gear
E Cross Shaft F Lifter Feed Cover
Gasket
G Lifter Feed Cover H Governor Yoke
Connecting Rod
I Crankshaft J End Cap
K Connecting Rod L Piston Pin
M Piston Pin Retainer N Piston (Style A)
O Piston Ring Set P Oil Seal
Crankshaft Bearing
Q R Piston (Style B)
(Flywheel)

62 690 02 Rev. N KohlerEngines.com 57

Reassembly

Install Governor Shafts, Seal, and Governor Gear Install Crankshaft

Governor Components and Details Carefully slide flywheel end of crankshaft through
bearing in crankcase.
B
Install Connecting Rods with Pistons and Rings
Piston Details
A C

C
F
D

E
A B

A Side 1 B Side 2
C Top of Piston
NOTE: Cylinders are numbered on crankcase. Make
Seal Depth sure to install piston, connecting rod and end
A Crankcase Surface B 1.5-2.0 mm cap into appropriate cylinder bore as previously
(0.059-0.078 in.) marked at disassembly. Do not mix end caps
and connecting rods.
12.66 mm
C Oil Seal D NOTE: Proper orientation of piston/connecting rod
(0.498 in.)
assemblies inside engine is extremely important.
Governor Gear Improper orientation can cause extensive wear
E Crankcase Surface F Shaft or damage. Be certain pistons and connecting
If governor shafts, seal, and/or governor gear were re- rods are assembled exactly as shown.
moved, reassemble as follows. 1. If piston rings were removed, refer to Disassembly/
1. Lightly coat outer diameter of governor cross shaft Inspection and Service procedure to install new
seal with P80 Emulsion Lubricant (refer to Tools and rings.
Aids). Install seal into crankcase to depth shown. 2. Lubricate cylinder bore, piston, and piston rings with
2. If governor gear shaft was removed, press or lightly engine oil. Compress rings of piston side 1 using a
tap replacement shaft into oil pan to depth shown. piston ring compressor.
3. Lubricate governor cross shaft bearing surfaces in 3. Lubricate crankshaft journals and connecting rod
crankcase with engine oil. Insert governor cross bearing surfaces with engine oil.
shaft end with flat cutout where governor yoke is 4. Make sure FLY stamping on piston is facing toward
secured, into crankcase and position shaft so that flywheel side of engine. Use a hammer with a rubber
flat part is visible (up). grip and gently tap piston into cylinder. Be careful oil
4. Attach governor yoke to cross shaft so curved ring rails do not spring free between bottom of ring
section is up as marked. Secure with screws. If a compressor and top of cylinder.
thread locking compound is not preapplied, apply a 5. Install inner rod cap to connecting rod using screws.
small amount of Loctite® 266™ Threadlocker or Torque screws in increments to 11.6 N·m
equivalent, to screw threads before installing. Torque (103 in. lb.). Illustrated instructions are provided in
screws to 2.2 N·m (20 in. lb.). service rod package.
5. Install first regulating pin with head down so it will Align chamfer of connecting rod with chamfer of its
contact yoke. Install governor gear with second mating end cap. When installed, flat faces of
regulating pin and flyweight assembly in/down onto connecting rods should face each other. Faces with
governor shaft until it locks into position. Apply a raised rib should be toward outside.
small amount of grease to locking tab thrust washer
and install on top of governor gear so tang is facing 6. Repeat this procedure for other connecting rod and
up in 6 o’clock position. piston assembly.

58 KohlerEngines.com 62 690 02 Rev. N

 Reassembly

Breather/Oil Pan Components

N
O

P E
K
J D
G
F
I
Breather Fastener
Torque Sequence
A C 1 3
G

H B

4 2

R I
A Oil Pan B Gerotor Gears C Oil Pump O-Ring D Oil Pump Housing
E Relief Valve Baffle F Pickup Tube G Inlet Seal H Pickup Screen
Crankshaft Bearing
I Drain Plug J K Oil Pan Gasket L Dipstick
(PTO)
M Dipstick Tube N Breather Assembly O Breather Gasket P Filter
Q Breather Hose R Oil Seal

Install Camshaft Determining Camshaft End Play

1. Liberally apply camshaft lubricant to each cam lobe. 1. Place a new oil pan gasket into position on
Lubricate camshaft bearing surfaces of crankcase crankcase.
and camshaft with engine oil. 2. Position camshaft end play checking tool over
2. Position timing mark of crankshaft gear at 12 o’clock camshaft. Use a feeler gauge to check end play
position. between camshaft and end play checking tool.
Camshaft endplay should be between 0.3/1.3 mm
3. Slide camshaft into bearing surface of crankcase, (0.011/0.051 in.).
positioning timing mark of camshaft gear at 6 o’clock
position. Make sure camshaft gear and crankshaft 3. No shim is typically used from factory. However, if
gear mesh, with both timing marks aligned. camshaft end play is not within specified range,
remove checking tool and shim as necessary.

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Reassembly

Several color coded shims are available: Install Oil Pan Assembly
White: 0.69215/0.73025 mm (0.02725/0.02875 in.) Torque Sequence
Blue: 0.74295/0.78105 mm (0.02925/0.03075 in.) 1
Red: 0.79375/0.83185 mm (0.03125/0.03275 in.)
3
Yellow: 0.84455/0.88265 mm (0.03325/0.03475 in.) 14
Green: 0.89535/0.99345 mm (0.03525/0.03675 in.)
Gray: 0.94615/0.98425 mm (0.03725/0.03875 in.) 5 12
Black: 0.99695/1.03505 mm (0.03925/0.04075 in.)

4. Reinstall end play checking tool and recheck end

play.
7 10
Install Oil Pan Seal and Crankshaft Bearing (PTO)
If bearing was removed in servicing, install a new 9 8
bearing using an arbor press and driver.
1. Make sure oil pan bore for bearing is clean, dry and 11 6
free of nicks or burrs.
2. Press crankshaft bearing (PTO) in place with notch
oriented in 12 o’clock position using an arbor press
and driver. Make sure bearing is fully seated against 13 4
flange. 2
Oil Seal 1. Make sure sealing surfaces of oil pan and crankcase
Details are clean, dry, and free of any nicks or burrs. Install
a new O-ring in oil pan.
2. Install a new oil pan gasket onto crankcase.
3. Make sure oil pump and oil pick up are installed in oil
A pan.
4. Ensure end of locking tab washer on governor gear
is positioned outward in 6 o’clock position inside
B crankcase.
5. Orient flat of oil pump gear to match position of flat
on camshaft. Install oil pan to crankcase. Carefully
seat camshaft and crankshaft into their mating
bearings. Rotate crankshaft slightly to help oil pump
and governor gears mesh.
A 3.0 mm (0.118 in.) B Oil Seal 6. Lightly oil threads and install screws securing oil pan
1. Check to make sure there are no nicks or burrs in to crankcase. Torque fasteners in sequence shown
crankshaft seal bore of oil pan. to 25.6 N·m (227 in. lb.).
2. Apply a light coat of P80 Emulsion Lubricant (refer to Check Crankshaft End Play
Tools and Aids) to outside diameter of oil seal.
Set engine on base and use a dial indicator to check
3. Install oil seal into oil pan using a seal driver. Make crankshaft end play to 0.30/1.50 mm (0.011/0.059 in.).
sure oil seal is installed straight and true in bore to
depth shown. Install Breather
4. Apply a light coat of clean engine oil to inner surface 1. Make sure sealing surfaces of crankcase and
of bearing and oil seal. breather cover are clean and free of any nicks or
burrs. Do not scrape surfaces, as this could result in
Oil Pump Assembly leakage.
Oil pump is mounted inside oil pan. If service 2. Install breather chamber gasket as shown. Assemble
was required and oil pump was removed, refer to and install breather assembly components as
Disassembly/Inspection and Service procedure. illustrated. Make sure filter does not extend above
top surface and all parts are properly aligned.
3. Install screws and torque to 12.5 N·m (110 in. lb.)
following sequence.
4. Lightly oil lower end of breather hose and install into
hole in breather assembly. Cover should be situated
between 2 raised rings of hose.

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 Reassembly

Cylinder Head Components

Style B Style A

B D
E L
N AF AE

F U

G
H
S
I T
J
K
M

A Q
V
O W X Y
P Z
R
AA AB

AC
AD

AA

A Gasket B Valve C Cylinder Head D Pipe Plug

E Guide Plate F Spacer G Washer H Spark Plug
I Valve Stem Seal J Valve Spring K Valve Spring Retainer L Hydraulic Lifter
M Valve Spring Keeper N Push Rod O Rocker Arm P Rocker Arm Pivots
Non-adjustable
Adjustable Valve Train
Q Rocker Stud R S Valve Train (Non- T Rocker Arm Screw
(AVT) AVT)
Valve Cover Seal Valve Cover Grommet (Plastic
U Adjusting Nut V (Plastic Valve W X
(Plastic) Valve Cover)
Cover)
Valve Cover Seal
Screw (Plastic Valve Roll Pin (Aluminum Valve Cover
Y Z (Aluminum Valve AA AB
Cover) Valve Cover) (Aluminum)
Cover)
O-Ring (Aluminum Screw (Aluminum Hydraulic Lifter Hydraulic Lifter
AC AD AE AF
Valve Cover) Valve Cover) Style A (Ribbed) Style B (Smooth)

Install Hydraulic Lifters

NOTE: Hydraulic lifters should always be installed in same position as they were disassembled. Exhaust lifters are
located on output shaft side of engine while intake lifters are located on fan side of engine. Cylinder numbers
are embossed on top of crankcase and each cylinder head.
1. Refer to Disassembly/Inspection and Service for lifter preparation (bleed down) procedures.
2. Apply camshaft lubricant to bottom surface of each lifter. Lubricate hydraulic lifters and lifter bores in crankcase
with engine oil. Do not prime lifters.
3. Note mark or tag identifying hydraulic lifters as either intake or exhaust and cylinder 1 or cylinder 2. Install
hydraulic lifters into their appropriate location in crankcase. Do not use a magnet.

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Reassembly

Valve Stem Seals Install Guide Plate, Pivot Studs, Push Rods and
These engines use valve stem seals on intake and Rocker Arms
exhaust valves. Always use new seals whenever valves NOTE: Install push rod guide plate so flange is down
are removed from cylinder head. Seals should also be (towards cylinder) on side 1, and up (away from
replaced if worn or damaged. Never reuse an old seal. cylinder) on side 2 (AVT only).
NOTE: Push rods should always be installed in same
Assemble Cylinder Heads position as before in disassembly.
Prior to installation, lubricate all components with engine Non-adjustable Valve Train
oil, paying particular attention to lip of valve stem seal,
valve stems, and valve guides. Install in order listed 1. Position rocker arm pivots in sockets of rocker arms.
below using a valve spring compressor. Insert screws through pivots, rocker arms, and guide
plate. Start screws into cylinder head and finger
● Intake and exhaust valves tighten only at this time.
● Valve spring retainers.
● Valve springs. 2. Note mark or tag identifying push rod as either
● Valve spring keepers. intake or exhaust and cylinder 1 or 2. Dip ends of
● Valve stem seals. push rods in engine oil and install, making sure each
● Guide plate (AVT only). push rod ball seats in its hydraulic lifter socket. Align
● Pivot studs (AVT only). rocker arms over valve stems. Hold rocker arm in
position and torque screws to the appropriate torque
for style of screw.
Install Cylinder Heads
Torque Sequence 15.5 N·m (137 in. lb.)

11.9 N·m (105 in. lb.)

2 2

Adjustable Valve Train

4 5 5 4 1. Install push rod guide plate and rocker arm pivot
studs onto cylinder heads if removed previously.
Torque studs to 11.3 N·m (100 in. lb.).
1 3 3 1 2. Note mark or tag identifying push rod as either
intake or exhaust and cylinder 1 or 2. Dip ends of
push rods in engine oil and install, making sure each
1 2 push rod ball seats in its hydraulic lifter socket.
NOTE: Match numbers embossed on cylinder heads 3. Apply grease to contact surfaces of rocker arms and
and crankcase. rocker arm pivots. Install rocker arms, rocker arm
pivots, and adjusting nut on cylinder head 1.
1. Check to make sure there are no nicks or burrs on
sealing surfaces of cylinder head or crankcase. Adjust Valve Clearance (AVT Only)
2. Check dowel pins are in place in 2 lower locations, NOTE: It takes two hands to make lash adjustment. A
and install a new cylinder head gasket, (printed side clamping device or an assistant to hold lifter
up). compressed while making adjustment will make
3. Install cylinder head. Make sure head is flat on process easier.
gasket and dowel pins. Install a flat washer on 1. Turn adjusting nut in rocker arms by hand clockwise
screws in locations 1 and 3. Install spacer followed (down), only enough to capture push rods in
by a flat washer on screw in location 5. Start 5 recesses.
screws.
2. Rotate crankshaft to establish TDC on compression
4. Torque screws in 2 stages, first to 23.7 N·m stroke for cylinder 1.
(210 in. lb.), finally to 46.9 N·m (415 in. lb.) following
sequence shown. Check for:
5. Repeat procedure for opposite cylinder. a. Compression will be felt through spark plug hole.
6. Make sure threads of pipe plugs for cylinder heads b. Keyway of crankshaft will be aligned with cylinder
are clean and dry. Install a plug into each cylinder 1.
head above screw on location 2 and torque to c. No rocker arm/push rod movement if crankshaft
28.5 N·m (252 in. lb.). is rotated slightly back and forth. If they are
moving, rotate crankshaft one full revolution.

62 KohlerEngines.com 62 690 02 Rev. N

 Reassembly

3. Pre-Bled Lifters: Install Valve Covers

a. Apply downward pressure to push rod side of Plastic Valve Covers
rocker arm to compress lifter and bottom internal 1. Make sure sealing surfaces are clean and free of
plunger. Several manual compressions may be any nicks or burrs.
necessary. Hold in this position for step 3b.
2. Install and properly seat seal onto each valve cover.
b. Insert a 0.406/0.483 mm (0.016/0.019 in.) feeler
gauge between end of one valve and rocker arm. 3. Install valve covers on same side as they were
Turn adjuster until a slight drag is felt. Hold originally installed.
adjuster in this position and tighten locking 4. Install a new grommet on each valve cover mounting
setscrew. Torque setscrew to 7.7 N·m (69 in. lb.). screw. Start each screw into hole.
After tightening recheck adjustment. Proper valve
clearance is 0.406/0.483 mm (0.016/0.019 in.). 5. Check position of each cover and seal, then torque
screws to 13.6 N·m (120 in. lb.).
c. Repeat procedure for other valve on this side.
Aluminum Valve Covers
Non-Bled Lifters (when cylinder heads and lifters are NOTE: A new valve cover seal must be installed
not removed): whenever an aluminum valve cover is removed
a. Turn 1 rocker arm adjusting nut from side 1 down from cylinder head.
until push rod is snug but can be rotated with 1. Make sure sealing surfaces are clean and free of
drag. This is 0 lash. any nicks or burrs.
b. Mark or note setting of adjustment nut, then turn 2. Install and properly seat a new seal into each valve
(tighten) adjuster nut 3 complete revolutions cover.
clockwise, plus 3/4 turn, or a total of 3-3/4 turns.
3. Apply clean engine oil under screw head and on
c. Hold adjuster nut in this position and tighten threads of each valve cover screw, O-ring, and new
locking setscrew. Torque setscrew to 7.7 N·m valve cover seal.
(69 in. lb.).
4. Install valve covers on same side as they were
d. Repeat procedure for other valve on this side. originally installed and tighten screws.
4. Viewed from PTO end, rotate crankshaft 270° (3/4 5. Check position of valve cover and seal.
turn) counterclockwise and align crankshaft keyway
with cylinder 2, which now puts that cylinder at TDC Into New Head: Torque screw to 26 N·m (230 in. lb.)
on compression stroke. to ensure seal seats in valve cover groove. Back off
screw and then torque screw again to 18.1 N·m (160
5. Repeat steps 3-5 for setting valve clearance on in. lb.).
cylinder 2.
Into Used Head: Torque screw to 16.4 N·m
6. Rotate crankshaft to check for free operation of (145 in. lb.) to ensure seal seats in valve cover
valve train. Check for clearance between valve groove. Back off screw and then torque screw again
spring coils at full lift, or bending of push rod(s) can to 16.4 N·m (145 in. lb.).
occur. Minimum allowable clearance is 0.25 mm
(0.010 in.). Install Spark Plugs
Check Assembly 1. Check gap using wire feeler gauge. Adjust gap to
Rotate crankshaft a minimum of two revolutions to check 0.76 mm (0.030 in.).
assembly and overall proper operation.
2. Install plug into cylinder head.
Check if engine can be turned over completely and
compression is noted. If it cannot (locks up at some 3. Torque plug to 27 N·m (20 ft. lb.).
point), return piston to TDC between intake and exhaust
strokes first for one cylinder and then other waiting ten
minutes to allow lifters to bleed down, then check for
compression again.

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Reassembly

Oil Cooler/Filter Components Install Oil Filter Housing Assembly

Reassemble oil filter housing if disassembled previously.
Reassembly
A 1. Install small spring onto rubber valve, and insert
small end through corresponding hole in cup until
properly seated.
2. Install larger spring into filter housing.
B 3. Insert oil filter cup, aligning cutout with
corresponding section in housing.
C 4. Install nipple in housing and torque to 17.8 N·m
(158 in. lb.).
M Installation
K D 1. Make sure all sealing surfaces are clean and all
dowel pins are in position. Install or check new
E O-rings are around all oil filter adapter dowel pins.
L 2. Install oil filter housing assembly and secure with M8
K F screw. Make sure housing is flat on crankcase and
J all O-rings remain in position. Torque screw to
23.7 N·m (210 in. lb.)
G 3. Oil filter may be installed now or upon completion of
K engine assembly.
J
Install Intake Manifold
H
I Torque Sequence

3
4
A Oil Filter B Oil Filter Nipple
C Cup D Valve Spring
1
E Cup Spring F Oil Filter Valve
2
G Oil Filter Housing H Pin
I O-Ring J Fitting 1. Install new intake manifold gaskets so notched
K Hose Clamp L Hose section is inward and points toward flywheel side.
M Oil Cooler 2. Mount intake manifold to cylinder heads. Make sure
gaskets remain in proper position. Torque screws in
2 stages using sequence shown, first to 16.9 N·m
(150 in. lb.), finally to 22.6 N·m (200 in. lb.).
3. Install carburetor mounting studs into intake manifold
if previously removed. Use nuts, locked flange to
flange, and tighten each stud until bottomed/tight.

64 KohlerEngines.com 62 690 02 Rev. N

 Reassembly

Flywheel/Ignition Components Install Backing Shroud Assembly

A NOTE: New hose clamps are recommended for
reassembly, or if clamps have been loosened
(expanded) several times to avoid leakage.
1. To aid assembly, install lower oil cooler hose onto oil
filter housing prior to installing backing shroud
assembly, and secure with a clamp.
B 2. Install backing shroud assembly and secure to
C crankcase with M6 screws. Torque screws in a
D crisscross pattern to 10.7 N·m (95 in. lb.) into new
holes, or 7.3 N·m (65 in. lb.) into used holes.

E Install Stator, Wiring Harness, and Rectifier-

Regulator
1. Apply pipe sealant with Teflon® (Loctite® PST® 592™
Thread Sealant or equivalent) to stator mounting
F G holes.
H
I 2. Position stator, aligning mounting holes so leads are
at bottom and toward rectifier-regulator mount on
cylinder 1 side.
3. Install and torque screws to 9.3 N·m (82 in. lb.).
J
K 4. Route stator wires under molded clips in backing
shroud assembly.
L 5. Check terminal on end of B+ charging lead to be
sure locking tang is angled upward. Insert terminal
M into center location of connector until it locks into
place.
6. Install wiring harness under molded clips in backing
N shroud assembly.
7. Position rectifier-regulator onto mounting posts with
cooling fins up. Attach ground lead to outer screw
and washer, then torque mounting screws to
O 2.5 N·m (22 in. lb.). Connect plug to rectifier-
regulator.

A Special Washer B Debris Screen

C Hex Stud D Stiffener
E Fan F Flywheel Screw
G Ignition Module H Washer
I Magnet J Wire Harness Clamp
K Flywheel L Stator
M Rectifier-Regulator N Backing Shroud
O Woodruff Key

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Reassembly

Install Flywheel Install Ignition Modules

1. Rotate flywheel to position magnet away from
CAUTION ignition module bosses.
Damaging Crankshaft and Flywheel can 2. Connect ground lead to single kill tab and install
cause personal injury. modules onto crankcase bosses so tab is away from
you (IN) and spark plug lead should be towards you
(OUT). Mount wiring harness clamp with loop UP, on
starter side inner module screw and route harness
through it. Attach rectifier-regulator ground lead to
Using improper procedures can lead to broken outer screw.
fragments. Broken fragments could be thrown from 3. Slide modules up as far away from flywheel as
engine. Always observe and use precautions and possible and snug screws to hold them in position.
procedures when installing flywheel.
4. Rotate flywheel to position magnet directly under 1
NOTE: Before installing flywheel make sure crankshaft ignition module.
taper and flywheel hub are clean, dry, and 5. Insert a 0.30 mm (0.012 in.) flat feeler gauge
completely free of any lubricants. Presence of between magnet and ignition module. Loosen
lubricants can cause flywheel to be over screws enough to allow magnet to pull module down
stressed and damaged when screw is torqued to against feeler gauge.
specifications. 6. Torque screws to 9.7 N·m (86 in. lb.) into new holes,
NOTE: Make sure flywheel key is installed properly in or 4.1 N·m (37 in. lb.) into used holes.
keyway. Flywheel can become cracked or 7. Repeat steps 4 through 6 for other ignition module.
damaged if key is not properly installed.
8. Rotate flywheel back and forth, checking for
1. Install woodruff key into crankshaft keyway. Make clearance between magnet and ignition modules.
sure key is properly seated and parallel with shaft Make sure magnet does not strike modules. Check
taper. gap with a feeler gauge and readjust if necessary.
2. Install flywheel onto crankshaft, being careful not to Final Air Gap: 0.280/0.330 mm (0.011/0.013 in.).
shift woodruff key. 9. Make sure leads are under molded clip on starter
3. Install screw and washer. side.
4. Use a flywheel strap wrench or holding tool to hold
flywheel. Torque screw to 69.8 N·m (51 ft. lb.).

66 KohlerEngines.com 62 690 02 Rev. N

 Reassembly

External Engine Components

K
U
K
A

V
L B
W C
T
U D
T
H E
R T F
N
T
S
Q
G

O P

H
I
I

A Oil Filter B Oil Filter Nipple C Oil Filter Cup D Valve Spring
E Cup Spring F Valve G Oil Filter Housing H Valley Baffle
I Outer Cylinder Baffle J Electric Starter K Cylinder Shroud L Blower Housing
M Fixed Guard N Oil Sentry™ O O-Ring P Pin
Q Fitting R Oil Cooler S Hose T Hose Clamp
U Gasket V Carburetor W Intake Manifold

Install Outer Cylinder Baffles 2. Torque M6 screws going into cylinder head and
crankcase to 10.7 N·m (95 in. lb.) for new holes, or
1. Install outer cylinder baffles. Make sure spark plug 7.3 N·m (65 in. lb.) for used holes.
lead is routed through corresponding opening in
each baffle. Start each screw. Torque M6 shoulder Install Oil Cooler
screws going through backing shroud assembly into
extruded holes in baffles to 2.5 N·m (22 in. lb.) into 1. Connect hoses between oil filter adapter and oil
new holes, or 2.0 N·m (18 in. lb.) into used holes. cooler. Secure with new clamps.

62 690 02 Rev. N KohlerEngines.com 67

Reassembly

2. Align oil cooler with bosses in backing shroud 3. Install stiffener followed by metal debris screen onto
assembly. Secure screws and washers to 2.3 N·m studs. Secure with special washers and mounting
(21 in. lb.). screws using Loctite® 243™ Threadlocker on
threads. Torque hex flange screws to 20.3 N·m
Install Cooling Fan and Debris Screen (180 in. lb.) and button head cap screws to 9.9 N·m
(88 in. lb.).
CAUTION
Install Electric Starter
Failure to utilize or reassemble debris screen
as designed could result in debris screen 1. Install electric starter motor using screws.
failure and serious personal injury. 2. Torque screws to 16.0 N·m (142 in. lb.).
3. Connect leads to solenoid.

1. Position cooling fan onto flywheel aligning mounting Install Valley Baffles
locations. Apply a small amount of Loctite® 243™ 1. Install valley baffles and secure with mounting
Threadlocker to threads and install long mounting screws. Lower section should fit under outer baffle.
screws. Torque screws to 10.4 N·m (92 in. lb.). Torque M6 screws going into cylinder head to
2. Apply a small amount of Loctite® 243™ Threadlocker 10.7 N·m (95 in. lb.) for new holes, or 7.3 N·m
to external threaded section, (unless new parts with (65 in. lb.) for used holes. Start upper M6 screws
preapplied locking compound are being used). only if main control bracket rear supports attach to
Thread debris screen hex studs into mounting holes these screws.
in flywheel. Torque each stud to 21.5 N·m 2. Torque M6 screw going into lower blower housing
(190 in. lb.). mounting clip to 2.5 N·m (22 in. lb.).
Control Bracket Components

M H

O I
N

K
J
L

C
G
B

E
D F

A Throttle Lever B Throttle Linkage C Nut D Governor Arm

E Governor Spring F Governed Idle Spring G Cross Shaft H Governor Lever
I Choke Cable Clamp J Control Pivot Pin K Pal Nut L Choke Linkage
M Choke Return Spring N Choke Bracket O Choke Lever

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 Reassembly

Install Carburetor Install Throttle and Choke Linkages

Cable Control Details
WARNING
Explosive Fuel can cause fires and severe A
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, B
B
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. Install a new carburetor gasket onto intake manifold

with tab up. Make sure all holes align and are open.
2. Connect throttle and choke linkages to carburetor if A Hole A B Hole B
they were previously disconnected. Install carburetor
with linkages attached as an assembly. If individual throttle/choke lever control linkages were
disconnected during disassembly, reconnect them based
Install Governor Lever on operating direction of control cables to be used.
Install governor lever onto governor shaft and connect Hole A is used for Outer Pull control cable actuation.
throttle linkage with black clip. Do not tighten governor Hole B is used for Inner Pull control cable actuation.
lever at this time. 1. Connect choke linkage to appropriate hole in choke
lever and secure with small clip.
Install Control Bracket and Air Cleaner Assembly
2. Connect throttle linkage to appropriate hole in
Torque Sequence throttle lever and secure with small clip.
Install Fuel Pump
1. Install fuel pump with hoses to control bracket, if
3, 7 1, 5 removed earlier. Torque mounting screws to 7.9 N·m
(70 in. lb.).
2. Connect outlet fuel line to carburetor inlet and
secure with a clamp.
2, 6 4, 8 3. Install pulse hose and inlet hoses in their proper
locations.
Adjusting Governor
1. Position control bracket assembly onto intake 1. Position governor lever so clamping area is inboard
manifold bosses, aligning mounting holes. but completely on knurled area of governor cross
shaft.
2. Install a new air cleaner elbow gasket onto mounting
studs. 2. Move governor lever toward carburetor as far as it
will go (wide-open throttle) and hold in position.
3. Slide air cleaner assembly onto carburetor mounting
studs, attach ground lead (with star washer if used), 3. Insert a long thin rod or tool into hole on cross shaft
and finger tighten nuts. Align forward mounting holes and rotate shaft clockwise (viewed from end) as far
in base with mounting holes/bosses of intake as it will turn, then torque nut to 7.1 N·m (63 in. lb.).
manifold and control bracket, then start screws. 4. Ensure correct color springs are used. Connect
Check positions of all parts, then torque nuts to governor spring (with long looped end), to inner hole
11.3 N·m (100 in. lb.) in sequence shown and on governor lever and control bracket.
screws to 11.3 N·m (100 in. lb.).
Connect governed idle spring to outer governor lever
4. Connect breather hose to fitting on outlet of air hole and control bracket. Long end of each spring
cleaner and connect fuel solenoid lead. must be toward governor lever. Make sure springs
5. Connect formed vent hose to air cleaner housing do not contact valley baffle.
and vent port on carburetor.
6. Connect choke link to control pivot pin. Reinstall
washer and secure with a new push-on pal nut.

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Reassembly

Governor Spring/RPM Chart Install Oil Filter and Add Oil to Crankcase
NOTE: Make sure both oil drain plugs are installed and
CV940-CV1000 torqued to 21.4 N·m (16 ft. lb.). to prevent oil
Governor Idle Spring (Color) High Speed (RPM) leakage.
Clear 1400-1625 RPM 1. Install oil drain plugs. Torque plugs to 21.4 N·m
(16 ft. lb.).
Black 1626-1800 RPM
2. Place new filter in shallow pan with open end up. Fill
with new oil until oil reaches bottom of threads. Allow
CV940, CV960, CV980 2 minutes for oil to be absorbed by filter material.
Governor Spring (Color) High Speed (RPM) 3. Apply a thin film of clean oil to rubber gasket on new
Orange 3000-3100 RPM filter.
Red 3101-3300 RPM 4. Refer to instructions on oil filter for proper
installation.
Green 3301-3750 RPM
5. Fill crankcase with new oil. Level should be at top of
Purple 3751-3900 RPM indicator on dipstick.
6. Reinstall oil fill cap/dipstick and tighten securely.
CV1000
Governor Spring (Color) High Speed (RPM) Connect Spark Plug Leads
Orange 3000-3100 RPM Connect leads to spark plugs.
Red 3101-3300 RPM Prepare Engine for Operation
Purple 3301-3900 RPM Engine is now completely reassembled. Before starting
or operating engine, follow proceeding steps.
Install Oil Sentry™ (if equipped) 1. Make sure all hardware is tightened securely.
1. Apply pipe sealant with Teflon® (Loctite® PST® 592™ 2. Make sure oil drain plugs, Oil Sentry™ pressure
Thread Sealant or equivalent) to Oil Sentry™ threads switch, and a new oil filter are installed.
switch and install it into 1/8 in. port in oil pan. Torque
switch to 10.7 N·m (95 in. lb.). 3. Adjust carburetor, idle fuel needles, or idle speed
adjusting screw as necessary.
2. Connect green wire lead to Oil Sentry™ terminal.
Testing Engine
Install Blower Housing and Cylinder Shrouds
It is recommended engine be operated on a test stand or
1. Install dipstick tube with a new lower O-Ring into bench prior to installation in equipment.
crankcase. Secure with lower mounting screw.
Torque screw to 7.7 N·m (68 in. lb.). 1. Set engine up on a test stand. Install an oil pressure
gauge. Start engine and check to be certain oil
2. Attach lift bracket (if used) onto crankcase with pressure (20 psi or more) is present. Run engine at
screws. Torque screws to 9.3 N·m (82 in. lb.) into idle for 2-3 minutes, then 5-6 minutes more between
new holes, or 7.7 N·m (68 in. lb.) into used holes. idle and midrange. Adjust carburetor mixture settings
3. Align and install blower housing. Secure with as necessary (as available).
screws. Torque screws to 2.5 N·m (22 in. lb.) into 2. Adjust governed idle and high speed (RPM) to
new holes, or 2.0 N·m (18 in. lb.) into used holes. required settings. Make sure maximum engine
4. Install cylinder shrouds and secure with screws. speed does not exceed 3900 RPM (no load).
Torque screws to 2.5 N·m (22 in. lb.) into new holes,
or 2.0 N·m (18 in. lb.) into used holes.
Install Muffler
1. Install new exhaust gaskets onto exhaust studs.
2. Install port liners (if equipped). Attach muffler and
secure with nuts onto exhaust studs. Torque nuts to
24.4 N·m (216 in. lb.).
3. Install any attaching hardware and brackets. Torque
M6 screws to 9.9 N·m (88 in. lb.), and M8 screws to
24.4 N·m (216 in. lb.).
4. Install spark arrestor (if used).

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